Moulding+i.e+sprue,+flash,+parison,+die,+draft,+angle+and+injection+moulding+e.g+blow+moulding,+vaccum+forming

Type =Moulding=

11.2.1 Define sprue, flash, parison, die, draft angle and injection moulding.
Sprue //This is the passage through which a liquid material flows into a die, where it solidifies to form parts.//Flash //Excess material on a moulded part, forming a thin fan where two parts of the mould meet.//Parison //A short length of extruded pipe for use in blow moulding.//Die //A tool used in the manufacture of parts by moulding, forging, swaging or stamping processes.//Draft angle //The angle of taper, expressed in degrees (usually 5° to 7°), given to the sides of the forging and the side walls of the die impression.//Injection moulding //The direct introduction of molten plastic under pressure into a die, which then cools rapidly, allowing the formed object to be released from the mould.//

11.2.2 Explain how an injection-moulded product is made.
//Diagrams must include the hopper, hydraulics, heaters, screw, sprue and mould.//
 * [[image:http://alexpb.com/notes/wp-content/uploads/2007/12/injectionmold.gif height="250" link="@http://alexpb.com/notes/wp-content/uploads/2007/12/injectionmold.gif"]] || [[image:http://www.machinerylubrication.com/Backup/200305/IndFoc-Fig1.jpg height="250" link="@http://www.machinerylubrication.com/Backup/200305/IndFoc-Fig1.jpg"]] ||


 * OpenLearning on injection moulding.

11.2.3 Outline the advantages of injection moulding.
//Consider initial capital investment, tooling, accuracy, quality control and quantity of product.// NB can be considered a clean technology
 * High initial capital investment
 * Quick re-tooling
 * Highly accurate
 * High Quality control - few errors
 * Can be volume produced 24/7

11.2.4 Discuss how standardised bottle caps have constrained bottle design, but have cut costs for manufacturers.
//Bottle caps can be classed as standardised parts. Bottle tops are injection moulded, while bottles are normally made by blow moulding. It is financially beneficial for a blow moulding company to use off-the-shelf bottle tops instead of purchasing an injection moulding machine and new tooling.//

11.2.5 Describe how a blow-moulded product is made.
//Diagrams must include the extruder, parison, the mould and air inlet.//

11.2.6 Explain how a rotational-moulded product is made.
//Diagrams must include the mould, filling the mould, heater chamber, rotation and cooling chamber.//
 * [[image:http://images.machinedesign.com/images/archive/501226700200jpg_00000046623.jpg link="@http://images.machinedesign.com/images/archive/501226700200jpg_00000046623.jpg"]] || [[image:http://polidon.com/up_files/rotomolding/ROTOmolding_big.gif height="350" link="@http://polidon.com/up_files/rotomolding/ROTOmolding_big.gif"]] ||

11.2.7 Explain how a compression-moulded product is made.
//Diagrams must include the mould, pre-form, hydraulic press, finished part and flash material.//
 * [[image:http://hsc.csu.edu.au/engineering_studies/transport/3059/images/figure3.gif width="250" link="@http://hsc.csu.edu.au/engineering_studies/transport/3059/images/figure3.gif"]] || [[image:http://www.coronet.eu.com/Uploads/UserImages/2004030816424compression2.jpg width="250" link="@http://www.coronet.eu.com/Uploads/UserImages/2004030816424compression2.jpg"]] ||

11.2.8 Discuss why some products have to be made using compression moulding.
//Consider the heat the product must withstand, quantity and type of product to be made. Refer to thermosets.// The plate needs rigidity and resist heat

11.2.9 Describe how a vacuum-formed product is made.
//Diagrams must include the vacuum chamber, former, platen, heater, air in and out.//
 * [[image:http://alexpb.com/notes/wp-content/uploads/2007/12/vacuum_forming.gif height="300" link="@http://alexpb.com/notes/wp-content/uploads/2007/12/vacuum_forming.gif"]] || [[image:http://i.treehugger.com/files/EggCarton2.jpg width="250" link="@http://i.treehugger.com/files/EggCarton2.jpg"]] ||

11.2.10 Identify manufacturing methods suitable for thermoplastics and thermosets.
//Thermoplastics: vacuum forming, blow moulding, injection moulding and rotational moulding. Thermosetting plastic: compression moulding.//in the content of your page here.