aulson "raining rograms !O! Bo' 3** +hester +" ,*. International /ales 0arry Mercugliano +ell hone1 2*,-322-33* 4ome Office hone1 2*,-5-22, &mail1 0arrym6aulson"raining!com www!paulsontraining!com
PRODUCT DETAILS CD PROGRAMS BASIC INJECTION MOLDING MACHINE OPERATIONS Basic Injection Molding Machine Operations is a two-lesson (3 hours of training) program designed for use by entry-level injection injection molding personnel new employees employees and for employment screening! "he emphasis is on safety efficiency and teamwor# Detailed Lesson Descriptions Lesson $ $ "his lesson starts with an overview of the injection molding process then covers basic material handling do%s and don%ts machine part identification and standard operator responsibilities during the molding cycle! &mphasis is given to operating operating safety protection of molds molds from damage and proper plastic part handling! Lesson ! " "his lesson e'plains molding machine machine operations! It also discusses regrinding trimming trimming flash and degating plastic parts from from runners! &mployees are taught to identify identify common part defects such as short shots flash warp surface defects and color changes!
INJECTION MOLDING #UNDAMENTALS Ne$ Trainin% Pro%ra& #or Entr' Le(el Personnel ) Goals o* t+is co,rse •
Orient new employees to the injection molding production floor and process
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"each the value of safety 7uality and teamwor#
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/how correct operating procedures
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&liminate careless and unsafe procedures
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8uic#ly identify common part defects
Reco&&ended #or- &ntry #or- &ntry 0evel ersonnel 9ll ersonnel In.ection Moldin% #,nda&entals is a new two lesson 3- hour training program that teaches your personnel the most important and fundamental aspects of the injection molding production floor and molding process! :sing state-of-the-art 3; animations participants get a firm understanding of the inside the injection molding process! "he course also uses actual in-plant scenes so that employees and prospective employees gain an understanding of typical production floor operations! / " 0 Ho,rs o* Trainin% /afety around the injection molding production floor and machinery is emphasi
undamentals! "his course serves as e'cellent refresher training for veteran employees! Lessons Incl,ded Lesson - Parts o* t+e Moldin% Mac+ine and Operator Responsi1ilities "his lesson starts with an overview of the injection molding process machine part identification and standard operator responsibilities during the molding cycle modes of operation of the machine and the important aspects of material handling &mphasis is given to operating safety protection of molds from damage and proper plastic part handling! Lesson !- Identi*'in% Part De*ects and Sa*et' "his lesson presents visual and animated 3; e'amples of all of the most common injection molded part defects such as short shots flash warp surface defects and color changes! It also discusses secondary operations such as regrinding trimming flash and de-gating plastic parts from runners! &mployees are taught to identify common part defects such as short shots flash warp surface defects and color changes!
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PRACTICAL INJECTION MOLDING ractical Injection Molding is a comprehensive 5 +;-?OM program (over , hours of training) focused on developing the s#ills and understanding your personnel need in your injection molding facility! In addition to 5 interactive lessons ractical Injection Molding features /#illBuilder which is a revolutionary new training platform for injection molders! /#illBuilder is an injection molding machine simulator combined with interactive molding labs which allows your employees to gain real hands on molding e'perience before running the molding machines on your production floor! +ombined this comprehensive interactive training series and /#illBuilder pac#age is unmatched by any training program in the plastics industry! Molders from around the world see dramatic results in productivity and profitability from this program and rely on it as the foundation of their training and troubleshooting program! ractical Injection Molding contains four core modules and is recommended for anyone involved in the injection molding process! PIM Mod,le 2 Basic In.ection Moldin% "he Basic Injection Molding module contains five +;-?OM lessons (over ., hours of training)! "his hands-on interactive pac#age is recommended for machine operators material handlers set-up personnel and production supervisors! "he Basic module focuses on the fundamentals of injection molding technology including basic #nowledge that all personnel involved in the molding process must understand to ma#e informed decisions on the production floor! Note- rice includes five +; lessons comprehensive leader%s guide and five study guides! Detailed Lesson Descriptions *or Basic In.ection Moldin% Lesson $ Inside t+e Moldin% Mac+ine $ /hows and describes all major components of the injection molding machine! Lesson ! $ Inside t+e Mold $ +onstruction and operation of two-plate three-plate and runnerless molds! Lesson / $ T+e Nat,re o* Plastics $ +haracteristics types structure si
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La1 Lesson 5 " T+e Ma6i&,& In.ection Press,re Settin%s $ ;iscusses how to set the ma'imum injection pressure setting so the fill rate control never lac#s the pressure it needs to fill the cavity according to the fill rate profile! La1 Lesson 7 $ Settin% t+e Holdin% Ti&er $ &'amines how the holding timer determines the length of time the holding (second stage) pressure stays on! 0esson also e'amines the effects of the holding time on gate sealing and molded part weight and dimensions! La1 Lesson 8 $ Settin% t+e Holdin% Press,re $ >ocuses on how to set various holding pressures to determine the effect on the molded part weight and length! La1 Lesson 9 $ Mold Closed Ti&e and Mold Open Ti&e (s: Melt Te&perat,re $ 0earn the effects of mold closed and open time on the melt temperature! /et the mold-closed time to the minimum re7uired to ma#e a good part! La1 Lesson ; $ T+e E**ects o* Barrel
PIM Mod,le ! " E6pert Series Co,rse and Lesson Descriptions
ractical Injection Molding $ &'pert /eries is a 5-+; (appro'imately 5 hours of training) program that builds on the #nowledge gained from the IM $ Basic module! &mphasis of this course is on building an in-depth understanding of the molding process for those wanting to be at the e'pert molding level! Lesson DescriptionsLesson - Inside t+e In.ection Molded Part "his lesson describes the structure of plastic molecules and the different internal structures than can develop in molded parts - crystalline amorphous and oriented! 9 parts internal structure affects finished part properties! Lesson !- Plastic #lo$- Understandin% Ho$ #lo$ A**ects t+e Moldin% Process "his lesson e'plains how the various types of plastics flow orient and change their viscosity! Molecular orientation is discussed including its effects on part directional properties and frictional heat generation! Lesson /- T+e E**ects o* Te&perat,re= Press,re= #lo$ > Coolin% on t+e Molded Part "his lesson shows that although a typical molding machine has from 5 to 3, separate controls the plastic #nows only the four primary plastic processing conditions -- pressure temperature flow rate and cooling rate! Lesson 0- T+e Re?,ire&ents to Control Molded Part @,alit' "his lesson continues our discussion of the four primary plastic processing conditions! 4ere we e'amine the effects of cavity pressure on molded part properties! "he internal part stresses caused by pressure and cooling are e'plained! Lesson 3- T+e E6pert Use o* Moldin% Mac+ine Controls "his lesson teaches the practical application of the information presented in the previous lessons! "he effects of machine controls on p lastic behavior is analy
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PIM Mod,le / " Opti&iin% Mac+ine Control Settin%s Optimi
Detailed Lesson Descriptions *or Opti&iin% Mac+ine Control Settin%s Lesson $ Settin% Up *or an E**icient Moldin% R,n - "his lesson teaches methods to optimi Sol(in% Process Pro1le&s - "his lesson discusses how to maintain pea#-molding efficiency by monitoring specified controls and operating parameters! "he lesson also describes how to correct the most common processing problems encountered during routine production!
S4ill1,ilder *or PIM Opti&iin% Mac+ine Control Settin%s "he /#illBuilder lessons designed to a ccompany aulson%s +; Optimizing Molding Machine Controls Settings course are designed to simulate the molding floor environment! :sers operate a virtual molding machine control panel that allows them to ma#e machine adjustments and cycle the machine just li#e on the molding floor! "he combination Of /#illbuilder with IM Optimi! "he available molding machine controls are the barrel heaters screw rpm and the bac#pressure! Lesson ! - Opti&iin% Melt Te&perat,re Moldin% a Cr'stalline Material: Molding a cell phone cover in polypropylene a crystalline material the goal of this lesson is to create and maintain a melt temperature of ,,F>! "he available molding machine controls are the barrel heaters screw rpm and the bac#pressure! Lesson / - Opti&iin% #ill Ti&e to ac+ie(e t+e #astest #ill Possi1le: "he goal in this lesson is to fill the mold as fast as possible while still molding a good part! In general good molding practice dictates
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that the mold should be filled as fast as is practical! "he plastic type is 9B/ and the available machine controls are the clamp tonnage the fill rates and the holding pressure! Lesson 0 - Opti&iin% Part Di&ensions Moldin% an A&orp+o,s Material: art dimensions are often critical in injection molding! "his lesson teaches some techni7ues for tightly controlling part dimensions while molding an amorphous plastic li#e polycarbonate! 9vailable machine controls are the mold temperatureA fill rates and the holding pressure! Lesson 3 - Opti&iin% Part Di&ensions Moldin% a Cr'stalline Material: +rystalline materials li#e polypropylene can be more difficult to #eep to tight dimensions! "his lesson teaches some techni7ues for tightly controlling part dimensions while molding a crystalline li#e polypropylene! 9vailable machine controls are the mold temperatureA fill rates and the holding pressure! Lesson 5 - Opti&iin% Part ei%+t to Ac+ie(e Mini&,& Plastic Usa%e: ?educing part weight to the minimum that ma#es a good part saves money by using less ma#e a good part! Molding a brac#et in polystyrene the student will have the holding material! In this lesson molding techni7ues are e'plored that reduce plastic usage but still pressure and the mold temperature as available machine controls! Lesson 7 - Opti&iin% Mold and Melt Te&perat,re to ac+ie(e t+e &ost E**icient C'cle Ti&e ! 9chieving the lowest possible cycle time can often be the difference between ma#ing and losing money on a molding job! :nderstanding energy balance is important! "he less heat you put in the plastic the less you have to ta#e out! Molding a cover in po lyethylene the student has the barrel heaters screw rpm bac#pressure mold temperature and cooling time controls available!
ELECTRIC INJECTION MOLDING COURSE &lectric molding machines now account for over 5 ,G of new machine sales! "here are several reasons for their popularityA more precise control lower electricity consumption and potentially faster cycles are among the reasons! But along with these and other advantages are potential problems! "hese machines re7uire an understanding of this new technology by the operating personnel to gain the benefits and avoid very e'pensive mista#es! In short they re7uire more #nowledgeable personnel at all levels! How available aulson offers a new three-lesson &lectric Injection Molding Machine course! "his new course integrates into the aulson 5 lesson ractical Injection Molding training course! Molders who already have the 5 lesson course and are interested in &lectric molding machines will want to integrate this new course into their training program! Others may just want to start out with just the 9ll-&lectric course! "he 9ll-&lectric Molding Machine +ourse 0esson 11
&lectric Machine ;esign +ycle D arts
"he parts of the &lectric molding machine 4ow &lectric molding machines wor# +omparing the operation of the &lectric and the 4ydraulic molding machine Operation of the ball screw drive "he molding cycle Instruments and controls used on these machines "ypical operating conditions 0esson . 11
"he &ffects of &ach +ontrol
/afety around these machines Machine modes of operation1 manual semi-automatic and automatic &'planation and effects of the injection controls1 injection rates and pressures vpt settings bac# pressure shot si
Optimi
+lamp settings1 control of clamp distance and speed clamp force safety concerns! &jector control Optimi
9s always every aulson course includes student wor#boo#s so that the student has a permanent record of what has been learned and to add or ma#e notes as he or she is ta#ing the course!
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Si&Tec+ In.ection Moldin% Mac+ine Si&,lator Bac4%ro,nd " "he aulson Injection Molding /imulator the world%s first software program that simulates the complete injection molding process from hopper to finished part! Over ,,, programming and research hours were spent on its development! "he result is a complete mathematical representation of the effect of each molding machine control the subse7uent effects on the plastic as it flows the shear heating the pac#ing process and the cooling of the part! /im"ech .,,3 is the forefront of applied molding process simulation! "he simulator can evaluate changes in the molding process that would ta#e hours or even days to do on an actual molding machine! Molders resin suppliers machine builders researchers can 7uic#ly evaluate ideas that will lead to improved personnel capability higher productivity and better mold and machine performance! Si&Tec+ !;;/ Calc,lates1 cavity pressures melt temperatures screw run time cavity fill time fill pressure loss pac#ing pressure loss cycle time percent full at @" cushion si
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+o S+o,ld Use Si&Tec+ !;;/ Process En%ineers and Moldin% Tec+nicians $ Molders can simulate the molding of production parts to find optimum cycles and determine the effects of any control change! Part and Mold Desi%ners $ ;esigners can change any machine control part si
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#eat,res and Bene*its o* Si&Tec+ #eat,res"he program has the capability to simulate all types of machines1 >ill rate controlled decoupled II molding and two-injection stage molding machines! (presently only fill rate controlled machines are used) "he program includes all the machine and mold operating controls found on both older and modern molding machines! :ser can mold the geometric representation of his part and change the runner gate and gate location! :ser can select the number of cavities! :ser can change machine barrel screw and clamp specifications or add a new molding machine :ser can change plastics or add a new plastic Outputs shows shot si
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Bene*its/im"ech .,,3 Optimi
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Molding production improvement $ find the best machine settings for improved cycle times! Increase the number of molding e'perts through simulation training! Improve mold and part design personnel by giving them molding e'perience! +onduct resin evaluations under realistic molding simulation conditions! ?educe tech service time by improving the capabilities of employees and customers!
#re?,entl' As4ed @,estions +at sie co&p,ter do I need to r,n t+is si&,lation pro%ra& "he program si
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ersonnel can learn a7nd practice molding away from the production floor! "hey can ma#e any change to the machine mold or plastic and test the results! Molding problems can be shown and solved using /im"ech! "he results is to give molders the realistic e'perience they need to become e'perts! "he greatest difference between the top molding companies and all the rest is the capability and number of e'perts they ha ve available! +at are ot+er ,ses *or Si&Tec+ 1esides trainin% /im"ech can simulate your molding jobs! It can be used to find setup conditions that are then transferred to the production machines! Molders can simulate molding conditions on production molds that reduce cycle times or solve molding problems! "he user can evaluate conditions that might be harmful of actual machines! Can I si&,late &,lti2ca(it' &olds on t+e si&,lator Nes Can I c+an%e %ate locations Nes you can center gate or edge gate any mold you put in! Can I si&,late a +ot r,nner &old as $ell as a con(entional &old Nes I& in Plastic Tec+nical Ser(ice= +o$ co,ld I ,se a si&,lation pro%ra& Nou can simulate and troubleshoot a customer%s mold in your tech service office! "hen you can recommend molding conditions base on your results using the simulator! Can I %et printo,ts o* t+e res,lts o* &' &oldin% si&,lation Nes a complete printout is available using the JprintK button! Can I r,n a se?,ence o* &oldin% c'cles to co&pare t+e e**ects o* c+an%es in control settin%s= ca(it' desi%n= or t+e plastic Nes! :p to cycles can be run consecutively! Can I load &' e6act part desi%n s,c+ as an STL *ile in t+is pro%ra&: Nes! "he part will be shown on the simulator screen! 4owever the program will run a geometric representation of the part to allow a fast calculation! Can I si&,late &,lti2ca(it' &olds Nes Are all t+e &oldin% &ac+ine control settin%s acti(e incl,din% *ill rates and *ill to press,re FPT trans*er Nes! 9ll of them are included in the software! Can I ,se t+e si&,lator to do researc+ on t+e e **ects o* &ac+ine controls= ca(it' c+an%es= or plastic c+an%es Nes the most important benefit of this software program in the ability to 7uic#ly change any variable to determine its effects without the problem of machine conditions changing between cycles or changing over time ! +at i&pro(e&ents and ,pdates $ill 1e a(aila1le to ,sers aulson is establishing a user group in addition to its own internal development group! Hew features and improvements will be continuously added and released yearly to customers!
In.ection Molded Part Pro1le&s and Sol,tions Injection Molded art roblems and /olutions is an eleven program that discusses eleven common molding problems and solutions to solve those problems! "opics covered include @oids /in# Mar#s
/hort /hots >lash Celd lines /play etting Burn Mar#s Carp +rac#ing and ;imensional +ontrol! "his program is recommended for set-up personnel foremen process engineers production supervisors and molding managers!
Detailed Lesson Descriptions *or In.ection Molded Part Pro1le&s and Sol,tions oids $ /mall holes in thic# sections caused by plastic shrin#age! Sin4 Mar4s $ /mall depressions in molded part surfaces opposite thic# sections caused b y internal stresses as the plastic cools! S+ort S+ots $ :ndersi
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Lesson /: Controllin% #las+ on a Molded Part: Chen flash occurs it means that the plastic pressure in the cavity e'ceeded the clamp force forcing open the mold parting line enough to allow plastic to flow into the parting line! >lash can be eliminated by several different molding techni7ues! "his /#illBuilder lesson e'plores all the possible solutions for eliminating flash on a molded part including high or low melt and mold temperatures high pac#ing and holding pressures unbalanced pressure distribution in the mold parting line damage or too deep of a vent channel! Lesson 0 2 Sol(in% Sin4 &ar4s on a Molded Part: /in# mar#s in a molded product are caused by plastic shrin#age! "he pac#ing and holding phases of the molding cycle are designed to reduce and control the amount of shrin#age by putting more molecules in the cavity! In thic# sections li#e where walls and ribs and bosses meet the plastic shrin#s more! "his is where you often see sin# mar#s occur! "his /#illBuilder lesson challenges the student to solve this problem in a variety of different ways! Both mold temperature and injection pressures are e'perimented with to demonstrate to the user more than one possible solution to the problem! Lesson 3 2 Identi*'in% and Sol(in% oids in Molded Parts: @oids in a molded product are caused by the plastic shrin#age! @oids and sin# mar#s are often interchangeable! In thic# sections if the wall of the part is fro
I&ple&entin% Deco,pled Moldin% Implementing ;ecoupled Molding is a new 3-lesson (5 hours of training) training program on interactive +;%s with full motion digital video and photo-realistic 3-; animation that details the molding process li#e you have never seen it before! "his training course perfectly combines the decoupled molding e'pertise of ?= with the proven 7uality of aulson! ;ecoupled molding is a system of molding techni7ues designed to achieve a high level of accuracy and repeatability in the molding process even as molding conditions li#e viscosity naturally vary! 0earn how to establish a methodology for setting up a decoupled molding process and the basics of pressure chart reading to identify problem areas! Detailed lesson descriptions Lesson 2 Introd,ction to Deco,pled Moldin% ! &'plains the goals of the course and defines the necessary terminology! ;efines decoupled molding and decoupled molding techni7ues! ;iscusses the effect of normal viscosity variations on pea# cavity pressure types of transducers and their best applications! Lesson ! " Deco,pled Moldin% Tec+ni?,es ! ;iscusses decoupled . and 3 in greater depth highlighting when to use each type the objective fill pac# and hold techni7ues! "eaches importance of plastic flow and viscosity variations to the molding p rocess! &'plains difference between process monitoring and process control and the best techni7ues for each! Lesson / $ &stablishing a ;ecoupled Molding rocess! ;iscusses processing strategies that utili
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Hot R,nner Moldin% Sol,tions ;eveloped in conjunction with leading manufacturers of 4ot ?unner /ystems this fully interactive 5lesson course (*-2 hours of training) uses full motion digital video and detailed 3-; animation and graphics! "his technology ta#es the employee inside the hot runner system to e'amine the many hot runner components including the manifold no< Co&&on Hot R,nner Applications : "his lesson discusses no<
pareto method of problem evaluation and the Ishi#owa method of problem analysis are described to aid in identifying the causes of problems! Plastic Dr'in% Tec+nolo%' FPDT lastic ;rying "echnology is a two-lesson program (3 hours of training) intended for material handlers set-up personnel foremen process engineers production supervisors molding managers and 7uality assurance personnel! "his is a comprehensive training program that teaches the important but often neglected topic of plastic drying! "hree common drying systems are taught1 hot air desiccant and refrigerant-dehumidifying systems! &ach are e'plained from their operational control and maintenance characteristics! Detailed Lesson Descriptions *or Plastic Dr'in% Tec+nolo%' Lesson $ Principles o* Dr'in% $ "his lesson establishes the bac#ground and basics of drying from the effects of moisture on molded parts to the theories of dryer operation! ;efined terms include hygroscopic relative humidity dew point weight percent vapor pressure differential closed loop and open loop! Lesson ! " Dr'er Operation= Control and Maintenance $ "his lesson deals with the functional characteristics of three common drying approaches1 hot air desiccant and refrigerant dehumidifying systems! "he purpose of this instruction is to help personnel set up operate and maintain their drying e7uipment to avoid production problems caused b y incomplete moisture removal!
Desi%n o* E6peri&ents *or In.ection Molders FDOE ;esign of &'periments for Injection Molders (;O&) is a three-lesson program (3 to hours of training) which provides an overview of how to design and e'periment in an injection molding facility! "his program is recommended for 7uality assurance personnel supervisors lead persons and molding managers! "his comprehensive pac#age allows you to train your employees on the importance of ;O& practices and easy and efficiently data can be collected and used to troubleshoot an injection molding process! Detailed Lesson Descriptions *or Desi%n o* E6peri&ents *or In.ection Moldin% Lesson " Learnin% t+e Basics: "his lesson introduces the basics of e'perimental design for the injection molding process! It also discusses ways to organiaced and ;-Optimal designs!
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In.ection Moldin% Mac+ine Maintenance F! Lessons Co,rse S,&&ar'"his .-+; course is a hands-on instructional program demonstrating the proper machine maintenance procedures for all hydraulic injection molding machines! "his 3 to hour interactive training course demonstrates and teaches the hands-on maintenance techni7ues that provide increased reliability and uptime for your molding machines! "he importance of establishing a regular maintenance schedule including tools and techni7ues is reinforced! 9ll machine systems hydraulic electrical and mechanical are covered in this course 9lso highlighted is the importance of safety in the wor#place and performing on-going safety system chec#s! Topics Co(ered/afety Injection :nit Maintenance /crew D Barrel Maintenance +lamping :nit Maintenance 4ydraulic /ystem Maintenance &lectrical /ystem Maintenance Lesson "his lesson describes the importance of safety when performing routine maintenance on your injection molding machine and includes demonstrations of safety practices such as loc#outtagout procedures and wor#ing with various types of safety systems on an injection molding machine! "his lesson also e'amines the maintenance schedules and recommended p rocedures for the injection unit and screw D barrel as well as corrective maintenance procedures for the clamping unit! Lesson !"his lesson continues to e'plore the general maintenance re7uirements for injection molding machines! "he lesson also describes recommended maintenance procedures and schedules for the hydraulic and electrical systems of the injection molding machine! T+is co,rse is desi%ned *or- Machine Maintenance Machine Operator /hift >oreman Mold /etter and rocess /et-up personnel! E**icient Mold Settin% FEMS &fficient Mold /etting is a two-lesson program (3- hours of training) recommended for setup mold maintenance and machine operating personnel! "his course is specifically designed to teach your employees valuable s#ills for the mold setting and removal stages of the injection molding process! &fficient Mold /etting is an e'cellent course for new employees as well as a great refresher course for veteran molders! Detailed Lesson Descriptions *or E**icient Mold Settin% Lesson " Mold Installation and Set2Up Proced,res $ &'plains procedures for transporting installing and setting up injection molds! "his lesson also describes in detail the safety procedures involved when wor#ing with molds moving the mold from the storage area to the injection machine the installation of the mold between the platens and basic mold start-up and operating procedures! Lesson ! " Mold Tro,1les+ootin%= Re&o(al and Stora%e $ ;iscusses potential mold problems that may occur during operation as well as the procedures for machine shutdown mold removal and mold maintenance and proper storage! In.ection Moldin% Operatin% Met+ods and Econo&ics Injection Molding Operating Methods and &conomics is a +;-?OM program ( to . hours of training) that focuses on how to ma'imi
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PLASTIC PART DESIGN #OR INJECTION MOLDING ;eveloped in conjunction with =lenn Beall the leading e'pert on plastic part design this interactive video training course ta#es the designer through a coordinated step-by-step procedure that reduces the comple' subject of plastic part design for injection molding to a simple easy to understand techni7ue! 8 Lessons- ;2! Ho,rs lastic art ;esign for Injection Molding1 •
;emonstrates proven parts designing techni7ues
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rovides industry accepted plastic part design rules and details!
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;elivers important part design #nowledge to improve part 7uality eliminate mold revisions and reduce costs!
Many injection molded parts suffer throughout their e'istence due to minor design defects! "he use of this course and the guidelines e'plained will allow the designer to spot design defects in the drawing stage and save tens of thousands of dollars in molding problems and tooling revisions! "his course is recommended for1 art ;esign ersonnel roduction /upervisors rocess &ngineers 8uality +ontrol ersonnel Molding Managers! Lessons Incl,dedPlastic Part Desi%n *or In.ection Moldin% Lessons •
0esson $ ;esigning the Hominal Call
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0esson . $ ;esigning "hree ;imensional /hapes
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0esson 3 $ ;esigning rojections off the Hominal Call
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0esson $ ;esigning ;epressions in the Hominal Call
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0esson 5 $ ;esigning 4ollow Bosses
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0esson * $ ;esigning Molded "hreads
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0esson $ ;esigning arts with :ndercuts
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0esson 2 $ /ummary
Understandin% Materials *or Pro*ita1le Moldin% :nderstanding Materials for rofitable Molding is a series of individual lessons (each providing to hours of training) which provide an overview of the properties and characteristics of an individual raw material type! &ach lesson describes the properties and molding characteristics that will improve the processing of that material! Our series of materials will include the most common commodity and engineering grade plastics! 9 thorough understanding of these principles means less material waste and a significant cost savings!
Lessons Description *or Understandin% Materials *or Pro*ita1le Moldin%
;iscussed in these lessons are the chemical and physical properties of the specific material under discussion in each lesson the recommended processing windows startup and shutdown tips and how to solve typical molding problems on each of these materials! 9ll material training programs released follow the same format by discussing the chemical and physical properties the recommended processing windows start up and showdown topics and how to solve typical molding problems! Materials pro%ra&s a(aila1le olycarbonate (+) olypropylene () olyethylene (& 0;& 4;& 00;& :4MC&) Hylon (9) 9B/ olystyrene (/) 9crylic (MM9) 9cetyl (OM) olyester (B") "hermoplastic &lastomers ("&)
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ETRUSION E6tr,der Operation and Control " Sin%le Scre$ &'truder Operation and +ontrol $ /ingle /crew is a nine-lesson program ( hours of training) recommended for e'truder operators material handlers set-up personnel and production supervisors! "his program begins with the fundamentals of single screw technology and ta#es your employees through the entire single screw process! 9lso included in this program is in-depth troubleshooting information allowing your employees to become e'pert at troubleshooting your e'truders! Detailed Lesson Descriptions *or E6tr,der Operation and Control " Sin%le Scre$ Lesson $ T+e Sin%le Scre$ E6tr,der- Parts and Operation - "eaches e'truder applications the raw material forms used in e'trusion how p lastic travels through the e'truder the parts of the e'truder and how they operate! Lesson ! $ T+e Str,ct,re o* Plastic Ra$ Materials - &'plains how a plastic is made (polymeri
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Da(is Standard Plasticatin% Sin%le Scre$ E6tr,der F! lessons
;avis /tandard +ondensed @ersion1 In this . lesson (. hour) course we will discuss the individual components of the single screw e'truder what they loo# li#e and how they operate! Ce will also ta#e a loo# at how plastic travels through this type of single screw e'truder! In the second half of the course we will discuss the control of plastic melting flow and pressure in the e'truder! Ce will also e'amine the effects of temperature pressure and e7uipment design on the material and e'plore ways to optimi
Pa,lsons #,ll ersion"o learn more about e'truder operation and optimi
"he program includes an overview of the structure of plastic raw materials how plastics flow and their behavior in the single screw e'truder! "he course also e'plores ways of optimi
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Co&po,ndin% $it+ t+e T$in Scre$ E6tr,der +ompounding with the "win /crew &'truder is an eight-lesson training program (, hours of training) intended for twin-screw e'truder operators material handlers set-up personnel and production supervisors! ;iscussed are the components and operation of the twin-screw e'truder used for compounding reactive e'trusion and devolatili Properties o* Plastic Ra$ Materials - e'plores the structure and characteristics of plastics! Lesson / 2 T+e E**ects o* Press,re= Te&perat,re and #lo$ - ta#es a closer loo# at the characteristics of plastics and e'amines plastic flow behavior in detail! Lesson 0 - Plastic Be+a(ior In T+e T$in Scre$ E6tr,der - discusses screw design elements and the plastic behavior in the twin e'truder! 0esson also loo#s at how plastic flows through the counterrotating and co-rotating twin screw e'truder and the counter-rotating tangential twin-screw e'truder! Lesson 3 - Opti&iin% T$in Scre$ E6tr,der Controls - e'plores twin-screw e'trusion operating conditions and variations e'truder and die head controls and post-e'trusion conditions! 9lso e'amined in greater detail the impact screw speed has on temperature in the intermeshing and tangential (non-intermeshing) types of twin-screw e'truders! Lesson 5 - Sa*et'= Pre2Start > Start2,p Proced,res - discusses twin-screw e'truder safety pre-start and start-up procedures! Lesson 7 - Stead'2State Operation= S+,tdo$n > Maintenance Proced,res ! ;iscusses twin-screw e'truder steady-state operation shutdown and maintenance procedures! Lesson 8 - T$in Scre$ E6tr,der Tro,1les+ootin% ?eviews basic troubleshooting procedures for compounding twin-screw e'truders!
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S+eet E6tr,sion Tec+nolo%' /heet &'trusion "echnology is a seven-lesson training program (L- hours of training) designed specifically for the training needs of the sheet e'trusion plant! Intended for set-up personnel machine operators production supervisors process engineers and e'trusion technicians this program is designed to be used in conjunction with our nine-lesson single screw e'trusion program! ersonnel from e'truder operators through process engineers will find valuable information to help ma#e their wor# and the sheet e'trusion process more efficient!
Detailed Lesson Descriptions *or S+eet E6tr,sion Tec+nolo%' Lesson - Parts and Operation o* t+e S+eet E6tr,sion Line - 9n overview of the machinery that ma#es up the sheet line and how it operates! ;iscussion includes roll stand designs and operation design and operation of the chill rolls types of gauging systems static discharge systems design and operation of trimmers pull rolls winders and cutters! Lesson ! - Parts o* t+e S+eet Die - "he first part of this lesson discusses sheet die construction and the parts of the sheet die including the manifold heaters restrictor bar dec#le bars and types of die lips including fi'ed lip adjustable lip and fle'ible lip! "he second part of the lesson discusses plastic flow behavior through the sheet die! Lesson / 2 Controllin% Plastic #lo$ in t+e Die - "his lesson discusses the design and operation of the "-type the +oat hanger and the +urved Manifold sheet die designs as well as how the restrictor bar and the die gap adjustment are used to control plastic flow through the sheet die! >eed bloc# and co-e'trusion dies are also discussed! Lesson 0 2 Plastic #lo$ Be+a(ior in t+e S+eet E6tr,sion Line and Process Control - ;iscusses what happens to the plastic once it leaves the sheet die and travels through the downstream sheet line! Orientation die swell the effects of roll speed and roll cooling how cooling affects semi-crystalline plastics unia'ial and bia'ial orientation and annealing are all discussed! "he lesson also discusses the fundamentals of process control of the sheet line! Lesson 3 2 Prestart= Start,p and Operation o* t+e S+eet Line - "his lesson discusses how to plan and startup the sheet e'trusion line safely and efficiently! roper steady state operations such as monitoring the e7uipment and sheet product are also discussed! Lesson 5 - S+,tdo$n o* t+e S+eet Line - "his lesson discusses how to safely shut down the sheet line! &mergency shutdown procedures are also discussed! "he lesson finishes with a discussion on safety in the sheet e'trusion plant! Lesson 7 2 Tro,1les+ootin% *or t+e S+eet E6tr,der ! "his lesson discusses common sheet defects such as surface lines and warp and their possible causes and solutions!
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E6tr,sion Blo$ Moldin% aulson%s &'trusion Blow Molding "echnology program is a seven-lesson program (L- hours of training) that teaches your personnel to understand the basics of blow molding technology plastic behavior and resolve common problem situations! &'trusion Blow Molding is intended for machine operators material handlers set-up personnel and production supervisors! "his seven lesson program will also help your personnel recogni
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Lesson 5 - Pro1le&s and Sol,tions - Part - In this session the problem solving analysis methods shown in session 5 are used to analy
IT<= General H'dra,lics= Pne,&atics= Electric and Mec+anical Trainin% "his series provides trainees a wor#ing understanding of electric hydraulic mechanical and pneumatic systems! &ach of the four programs has provisions for on line testing trac#ing and certification! Nou learn by seeing then actually doing! "rainees create hydraulic electric etc! circuits and then test their performance in a simulated run mode! "he insertion of these interactive real world e'periences #eep the trainee interested in the learning process! In this way the student builds e'perience in creating circuits and mechanical designs chec#ing them understanding applications and trouble shooting problems! ?ealistic 3; graphics ma#e hard to understand materials easy to comprehend! "he series provides both maintenance and production the information needed to #eep machines running productivity and efficiency levels up maintenance costs down and downtime at a minimum! A11re(iated content description 9ll programs address reading schematics and mechanical drawings including a basic understanding of symbols and their meanings!
9ll programs address building basic circuits or mechanical devices then running and trouble shooting them!
"he electric program addresses basic physics how to wor# with varying types of power both two and three phase as well as some low voltage circuits! /ome of the topics covered include understanding energy conversions and re7uirements polarity grounding power connections solenoids designing power circuits brea#ers fuses switches etc! "his program provides a basis for creating designing and maintaining electric systems!
Mechanical training includes an understanding of basic physics linear actuators clutches bra#es clutch-bra#e combinations bearings drives and couplings! "his program provides a basis for creating designing and maintaining mechanical devices!
4ydraulics training covers fluid power physics pumps actuators pressure control valves directional control valves flow controls fluid conditioning chec# valves accessory components fluid conductors understanding schematic and basic system design! "his program provides a basis for creating designing and maintaining hydraulic systems!
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neumatics addresses an understanding of basic physics compressors operations and types air dryers air preparation air distribution direct control valves actuators miscellaneous valves accessories air line conductors vacuum and a understanding of schematics! "his program provides a basis for creating designing and maintaining pneumatic systems .
>or assistance call or email1 0arry Mercugliano aulson "raining rograms International /ales &mail1 0arrym6aulson"raining!com 4ome Office hone1 2*,-322-33* Last Update 9-12-07
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