Sometimes injection molding process produce molded parts with defects. It's a waste and result in decrease company's profit. We must find out the root cause and prevent a recurrence of the problem. In troubleshooting section, we learn cause and effect diagram to identify the root cause. You will realize all details of injection molding process by thinking every factors. Finally, we discuss all kinds of molding defects to understand why they can happen and how to solve them?
在射出成形的過程中，有機會產生不良品。而不良品是一種浪費，減少公司的利潤，務必要想辦法找到真因，讓問題不再重複發生。這邊會先介紹特性要因圖來幫助我們進行全面的分析來找到真因，透過這個思考的過程可以讓你更了解射出成形的每個細節。接這會針對每一個不良缺陷背後的原因，提供可能的對策。
6.1 Cause and Effect diagram
6.2 Defects Troubleshooting
2019年6月28日 星期五
2019年6月25日 星期二
1-2 Five factors of injection molding
In my early career life, I was a mold trial engineer. I arrange the schedule of new molds trial and provide the trial samples to customer for getting production approval in sample build period. After getting the customer's feedback, I will set up a mold modification meeting with mold designer, quality engineer and tooling partner to decide the modification plan.
I get a KPI (Key Performance Indicator) which is average rounds of new mold trial. I start to think about how do I provide the perfect molded parts as soon as possible?
In order to get a perfect molded parts, there are four factors that need to be considered carefully as below.
1. Material 材料
The part's drawing from customer side will be indicated the molded material.
客戶端的機構工程師通常會定義產品所使用的塑膠原料，在進行製造可行性分析時，要向原料商取得原材料的物性表與射出成形相關的製程參數。和機構工程師討論時要充分了解關鍵的功能與尺寸，確保品質特性有辦法管控。也要把相關的成形資訊提供給模具設計與現場試模人員，模具外型尺寸就可以匹配適當的射出機，現場人員在試模前可以將原材料準備烘烤完成，並且在調整射出參數時可以有建議條件可以參考。
2. Injection molding machine
在模具設計階段，首先會根據每模次塑膠材料的用量，挑選合適的塑化系統，來得到一個穩定的射出成形製程。產品若有特別的特徵或薄肉厚，對於射出系統可能會有額外的要求。
3. Molding parameters
合適的射出成形參數可以讓製程穩定，進而得到品質特性可以被控制的射出產品。
4. Mold design
要獲得完美的射出產品，模具設計扮演非常重要的角色，要考量的重點非常多。包含但是不限於以下項目：模具的強度，零件的壽命，流道系統的分布，水路設計，頂出系統等等。
After I transfer to be a mechanical engineer, I add the fifth factor "Parts design".
5. Parts design
某些特徵可能難以實現，必須與機構工程師溝通，進行適當的修改，提高製造的可能性以及未來量產的生產穩定性。
I get a KPI (Key Performance Indicator) which is average rounds of new mold trial. I start to think about how do I provide the perfect molded parts as soon as possible?
In order to get a perfect molded parts, there are four factors that need to be considered carefully as below.
1. Material 材料
The part's drawing from customer side will be indicated the molded material.
客戶端的機構工程師通常會定義產品所使用的塑膠原料，在進行製造可行性分析時，要向原料商取得原材料的物性表與射出成形相關的製程參數。和機構工程師討論時要充分了解關鍵的功能與尺寸，確保品質特性有辦法管控。也要把相關的成形資訊提供給模具設計與現場試模人員，模具外型尺寸就可以匹配適當的射出機，現場人員在試模前可以將原材料準備烘烤完成，並且在調整射出參數時可以有建議條件可以參考。
2. Injection molding machine
在模具設計階段，首先會根據每模次塑膠材料的用量，挑選合適的塑化系統，來得到一個穩定的射出成形製程。產品若有特別的特徵或薄肉厚，對於射出系統可能會有額外的要求。
3. Molding parameters
合適的射出成形參數可以讓製程穩定，進而得到品質特性可以被控制的射出產品。
4. Mold design
要獲得完美的射出產品，模具設計扮演非常重要的角色，要考量的重點非常多。包含但是不限於以下項目：模具的強度，零件的壽命，流道系統的分布，水路設計，頂出系統等等。
After I transfer to be a mechanical engineer, I add the fifth factor "Parts design".
5. Parts design
某些特徵可能難以實現，必須與機構工程師溝通，進行適當的修改，提高製造的可能性以及未來量產的生產穩定性。
1-1 What is injection molding?
In order to obtain a general understanding of injection molding, you could find the textual explanation on the Wikipedia website.
If you want to see videos about injection molding, you can type "injection molding" on the YouTube. I think that Paulson Training do a great job on this. You could refer this YouTube link to get a brief understanding although there is no voice over.
If you want to see videos about injection molding, you can type "injection molding" on the YouTube. I think that Paulson Training do a great job on this. You could refer this YouTube link to get a brief understanding although there is no voice over.
1. Introduction
在我們的生活中隨處可見各式各樣的塑膠製品，因為它低成本、容易生產和多樣化的功能特性，也就讓它被應用到各個領域之中。生產塑膠製品的製程有很多種，本部落格僅針對最常用的射出成形來做討論。
1-1 What is injection molding?
什麼是射出成形?
1-2 Five factors of injection molding
射出成形的五個重點
1-1 What is injection molding?
什麼是射出成形?
1-2 Five factors of injection molding
射出成形的五個重點
2019年6月20日 星期四
7-1 English-Chinese vocabulary list
There are some technical terms in the articles.
In order to better understanding them, I make a English-Chinese vocabulary list for Chinese reader.
Injection Molding 射出成形、注塑成形
Mold Mould 模具
In order to better understanding them, I make a English-Chinese vocabulary list for Chinese reader.
Injection Molding 射出成形、注塑成形
Mold Mould 模具
2019年6月14日 星期五
Contents of basic injection molding
以下是預計要寫的射出成形基礎的內容，未來會有變更的可能。
The expected contents of basic injection molding are as below.
In the interest of continuous development and improvement, I will change these on this blog at any time.
1. Introduction
1-1 What is injection molding?
2. Plastics Materials
3. Injection molding equipment
3-1 Injection molding machine
3-2 Material feed system
3-3 Temperature control system
4. Mold
4-1 Mold base type
4-2 Gate & Runner system
4-3 Ejector
5. Molding parameters
6. Trouble shooting
7. English-Chinese vocabulary list
The expected contents of basic injection molding are as below.
In the interest of continuous development and improvement, I will change these on this blog at any time.
1. Introduction
1-1 What is injection molding?
2. Plastics Materials
3. Injection molding equipment
3-1 Injection molding machine
3-2 Material feed system
3-3 Temperature control system
4. Mold
4-1 Mold base type
4-2 Gate & Runner system
4-3 Ejector
5. Molding parameters
6. Trouble shooting
7. English-Chinese vocabulary list
2019年6月10日 星期一
Original aspiration
Remain true to original aspiration and keep mission firmly in mind. 不忘初心，方得始終。
Why do I decide to write this blogger ?
1. Share my knowledge and experience (story?).
I studied mechanical engineering and majored in injection molding and tooling process. After I graduated, I have 10+ years of relevant experience. Sometimes my friends ask me the problems what they happened in the trial mold. They would like to know why the issue result from and how to solve it.
In order to share my knowledge, I will write down some basic knowledge about the injection molding and attached some reference links or explanation. I think this also challenge me to internalize something I’ve learned or experienced.
Moreover, there are many interesting things happened in my career life. I may tell my story and some case study in the future.
2. Improve my presentation and communication skills
Actually my English is not fluent enough. In my career life, all my customer are really friendly. when we are discuss about engineer issues, they always use simple words and sentences to avoid misunderstanding. I also do my best to illustrate opinions by making many slides and photos.
When I write a blog post, I have to organize my thought and articulate it by writing. I expect that will enhance my English presentation skills.
Why do I decide to write this blogger ?
1. Share my knowledge and experience (story?).
I studied mechanical engineering and majored in injection molding and tooling process. After I graduated, I have 10+ years of relevant experience. Sometimes my friends ask me the problems what they happened in the trial mold. They would like to know why the issue result from and how to solve it.
In order to share my knowledge, I will write down some basic knowledge about the injection molding and attached some reference links or explanation. I think this also challenge me to internalize something I’ve learned or experienced.
Moreover, there are many interesting things happened in my career life. I may tell my story and some case study in the future.
2. Improve my presentation and communication skills
Actually my English is not fluent enough. In my career life, all my customer are really friendly. when we are discuss about engineer issues, they always use simple words and sentences to avoid misunderstanding. I also do my best to illustrate opinions by making many slides and photos.
When I write a blog post, I have to organize my thought and articulate it by writing. I expect that will enhance my English presentation skills.
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6.1 Cause and Effect diagram
To understand cause and effect diagram, you could refer the links as below. 了解特性要因圖可以參考底下的連接。 Cause and Effect diagram on the Wikiped...
