Why do injection molded parts tend to crack easily?
Injection molding, also known as injection molding, is a processing method in which molten plastic is injected into a mold under high pressure and then cooled and solidified in the mold to finally form the required plastic products. Injection molding is widely used in the production of plastic products of various sizes and shapes, such as daily necessities, industrial parts, automotive parts, etc.
The main steps of the injection molding process include:
Feeding: Put solid plastic granules or powders into the hopper of the injection molding machine and melt them into a flowing molten plastic through heating and stirring.
Injection: The molten plastic is pushed forward by the screw of the injection molding machine and injected into the cavity of the mold under high pressure to fill the entire mold cavity.
Cooling: The molten plastic injected into the mold is cooled and solidified in the mold to form the required product shape.
Mold opening: After the plastic is cooled and solidified, open the mold and take out the molded plastic product.
The injection molding process has many advantages, such as:
High precision: The injection molding process can produce parts and products with high precision and high consistency.
High production efficiency: The injection molding machine can produce a large number of products in a short time, which is suitable for mass production.
Stable product quality: Since the injection molding process can control every production parameter well, the quality of the product is very stable.
Strong plasticity: The injection molding process is applicable to various types of plastics and can produce products with various complex shapes.
In the injection molding process, product cracking is usually caused by the following reasons:
Material selection: Choosing materials that are not suitable for injection molding or materials with unqualified quality will lead to product cracking.
Temperature control: Injection molding requires strict control of the temperature during the heating and cooling processes. If the temperature is not controlled properly, it is easy to cause excessive internal stress in the product and cracking.
Pressure problem: Improper pressure control during the injection molding process, especially in the injection and holding pressure stages, will lead to uneven product structure or excessive internal stress and cracking.
Mold design: Unreasonable mold design or problems with manufacturing quality can also lead to product cracking.
Product design: Unreasonable product structure design, uneven wall thickness or the existence of stress concentration areas will also lead to product cracking during the injection molding process or in use.
In order to avoid product cracking, comprehensive analysis and optimization need to be carried out in aspects such as material selection, production process, mold design, and product design.
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