A. Routsis Associates, Inc. - Developing Fully Skilled Workforces for the Plastics Industry

Basic Injection Molding

Program 1: Machine

• Cites important safety precautions for working around injection molding machines
• Gives an introduction to the injection molding process
• Introduces machine types and the different modes of operation
• Discusses the components of the injection molding machine and their respective functions
• General procedures for starting up and shutting down a molding machine

Program 2: Process

• Discusses polymers and the three criteria used to classify them
• Covers some of the more common procedures for material preparation
• Introduces the three phases of the molding process; injection, cooling and ejection
• Explains the need for maintaining an accurate process log
• Defines common injection molded part defects and explains their causes

Program 3: Mold

• Explains the specific functions that an injection mold must perform
• Introduces the various machining methods used to construct an injection mold
• Discusses the three mold configurations used in the industry
• Covers common runner shapes and gate types used in injection molds
• Gives an overview of proper injection mold maintenance

Advanced Injection Molding

RJG Decoupled Molding^SM

Program 1 - Introduction to DECOUPLED MOLDING^SM

• Discusses polymerization, crystallinity, additives, regrind and degradation
• Lists necessary components of a proper part design
• Describes the injection molding process in depth; from filling to cooling
• Covers molding machine components and their functions in depth

Program 2 - DECOUPLED MOLDING^SM Techniques

• Compares traditional and DECOUPLED MOLDING^SM
• Defines the three DECOUPLED MOLDING^SM techniques
• Covers transducers and proper transducer placement
• Introduces signal conditioners and display devices

Program 3 - Reading and Interpreting Data

• Provides participants with an understanding of graphs and scaling
• Explains how to identify different types of graphical curves
• Introduces the various integrals used in DECOUPLED MOLDING^SM
• Compares ideal and inconsistent pressure curves

Program 4 - Systematic Troubleshooting

• Discusses the importance of proper process documentation
• Explains the appearance and symptoms of defects
• Introduces logical steps involved in troubleshooting defects
• Describes common processing defects, their causes and actions to correct them

Processing Parameters

Understanding Processing Parameters

This double CD-ROM course details injection molding processing parameters. Processing Parameters discusses individual parameters to help molders maintain more control of their processes. Participants will learn about processing parameters as they relate to the various phases of the injection molding process

• Description of molding parameters
• Procedures for optimizing several different molding parameters
• The importance of machine calibration
• In-depth considerations for injection, packing, cooling and part removal

Process Control Systems

Process Control Systems

This two part program details process control systems and is designed to help molders make more educated choices. Process Control Systems is a must for any facility which employs (or plans to employ) closed loop process control.

• Open loop vs. closed loop process control
• How process control reduces variation
• Closed loop controllers
• Proper use of process control

Production Series

Understanding Plastics

This program explains how and why plastics are differ and cites several different types of polymers and processing considerations. Understanding Plastics emphasizes material handling, explains regrind, and covers the effects that moisture can have on molded part properties and during processing.

• The definition of plastics
• Polymer classification
• Material properties affected by processing
• Proper material handling techniques
• Processing characteristics of virgin and regrind

Troubleshooting Defects

The goal of this two part program is to reduce scrap and improve part quality. Troubleshooting Defects is packed with information about problems encountered during the injection molding process. This course will help all members of your production team identify, isolate and eliminate the root cause of molded part problems.

• Terminology and descriptions of molding defects
• Systematic corrective troubleshooting procedures
• Process documentation to ease the troubleshooting process
• Long-term and short-term effects of process changes

Establishing an Injection Molding Process

This program shows participants how to quickly and effectively establish an injection molding process. Important safety issues associated with process set-up are stressed throughout the course. This program will also help molders reduce set-up and cycle times.

• Material preparation, drying and mixing
• Screw and barrel cleaning
• Guidelines for setting each processing parameter
• Procedures for proper injection velocity profile set-up
• Proper clamp and part removal settings

Injection Mold Setup

This two part program covers the die-setting process from start to finish with an emphasis on safety. Proper procedures for mold inspection, preparation and installation are outlined. Injection Mold Setup also covers setup procedures for hydraulic, toggle and hydro-mechanical clamp systems.

• Proper mold installation procedures
• Important safety considerations
• Proper water line set-up
• Safety precautions for mold setup

Processing For Profit

Processing For Profit covers techniques used for increasing profitability while maintaining part quality. The course focuses on the relationship between the material, the mold and the molding machine. Also included is practical, up-to-date information about process documentation procedures - as well as some great tips on process optimization.

• Material handling and preparation
• Process documentation and its importance
• Process optimization
• Energy conservation

Shrinkage, Warpage & Ejection

This course is designed to familiarize production personnel with complications that may arise during processing concerning shrinkage, warpage and ejection.

• How packing affects shrinkage and warpage
• Ejection systems for simple and complex geometry
• The effects of part geometry
• Amorphous vs. semi-crystalline polymer behavior

Filling, Gating & Weld Lines

This course outlines mold filling and how different gating configurations affect filling. Also discussed are weld and meld lines and their effects on molded parts.

• Weld line occurrence and strength determination
• Gate types, location, and importance
• Fatigue and cyclic stress
• Tooling considerations

Maintenance Series

Injection Molding Hydraulics

This three disc series demonstrates the importance of hydraulics in the injection molding process. Machine operators will learn ways to reduce wear on hydraulic components, while more advanced employees concentrate on hydraulic print reading and theory.

• Basic hydraulic theory
• The role of hydraulics in injection molding
• The function and purpose of hydraulic components
• Recognition of hydraulic symbols
• Directional valves and flow controls
• Hydraulic pumps and motors
• Proportional valves and servo valves
• Hydraulic fluid management

Molding Machine Maintenance

Designed to introduce the many maintenance considerations for an injection molding machine. Participants are also shown newer technologies; such as laser leveling, ultrasonic tie bar stretch measuring, and portable machine process monitors.

• Basic machine maintenance & safety concerns
• Fluid and platen maintenance
• Screw and barrel maintenance
• Preventative maintenance & logging

Injection Mold Maintenance

This program details procedures for proper mold care before, during, and after a production run - stressing important safety considerations for mold handling. From mold storage to part removal, this course provides participants with good mold maintenance habits and aims to extend tool life & increase its productivity.

• Proper mold maintenance
• Mold storage and preparation
• Water line maintenance
• Techniques for extending tool life

Understanding 3-Phase Power

Understanding 3Ø Power covers power generation, transformation and distribution, and is designed for training all maintenance personnel that use 3Ø power applications. Proper understanding of 3Ø power will help employees balance power loads, improve power factors, and make more efficient decisions about usage and management.

• Power generation and distribution inside the plant
• WYE and Delta power systems
• The need for balanced circuits
• An introduction to Motor Control Centers (MCC)
• AC to DC power conversions
• Power Factor calculations and corrections