Problems and Solutions

Blackheads

In the Machine:

  • The weight may be very high.
  • It may have been closed for a long time.
  • The hive may not have been cleaned properly.
  • The correct nozzle may not have been used.

In the Mold:

  • Runner with angular corners

In the Raw Material:

  • It may contain mixed other materials.
  • The other material inside may burn.

Solutions in Order:

  • The machine should be cleaned with the correct material at the same temperature.
  • It should be checked whether another material has mixed in.
  • The runner entries and type should be checked.
  • The filter perforation should be checked.

Air and Gas Bubbles

In the Machine:

  • The injection pressure may be very low.
  • The backflow valve may be faulty.
  • The back pressure may be too long.
  • The melting process may be too fast.
  • Air may be trapped at the funnel inlet.
  • Poor feeding may occur.

In the Mold:

  • The mold temperature may be low.
  • The mold gas outlet may be closed.
  • The runner entry thickness of the part.
  • It may go from thin to thick.

In the Raw Material:

  • The material may not be able to withstand high temperatures.

Solutions in Order:

  • The injection pressure and extrusion pressure should be increased.
  • The back pressure should be increased.
  • The mold temperature should be increased.
  • The backflow valve should be checked.
  • The mold air channel should be checked.
  • The runner diameter should be increased.

Flow Marks

In the Machine:

  • The injection speed may be too low or too high.
  • The injection pressure may be too low.
  • The extrusion pressure may be too low.

In the Mold:

  • The mold temperature control is not good.
  • The mold temperature at the runner entry may be too high.
  • The mold may be too cold.
  • The runner diameter may be too small.
  • Incorrect runner entry.
  • Incorrect hot runner system.

In the Raw Material:

  • The material temperature may be low.

Solutions in Order:

  • The injection speed should be adjusted.
  • The possibility of unmelted material should be checked.
  • The injection cavity should be checked.

Surface Burns (Diesel Effect)

In the Machine:

  • The backflow valve may be faulty.
  • The injection speed may be too fast or too high.
  • The back pressure may be too high.

In the Mold:

  • The air outlet may be closed.
  • Burning due to sharp corners in the mold.
  • The runner entry may be narrow.

In the Raw Material:

  • The material may burn due to high temperature or may burn by friction due to low temperature.

Solutions in Order:

  • The air intake channels should be checked for blockages.
  • The injection speed should be reduced.
  • The injection pressure should be reduced.
  • Gradual injection should be tried.
  • The heaters should be checked to ensure they are working properly.
  • The screw speed should be reduced.
  • The nozzle temperature should be reduced.

Part Peeling

In the Machine:

  • The injection speed may be too high.

In the Mold:

  • The mold may be too cold.
  • There may be sharp corners in the runner.
  • High heat formation due to sharp corners.

In the Raw Material:

  • The material melt temperature may be too high.
  • The material may not be fully melted.
  • Another polymer may have been added.
  • There may be excessive scrap or mixed broken material.

Solutions in Order:

  • The melt temperature should be increased.
  • The mold temperature should be increased.
  • The injection speed should be reduced.
  • The masterbatch should be changed.
  • The amount of scrap or broken material should be reduced.
  • The material or drying should be checked.
  • The sharp corners should be given a radius.

Size Variation

In the Machine:

  • The injection pressure may be too low.
  • The extrusion time may be too short.
  • The cycle time may be too short.
  • The heaters may be faulty.
  • The backflow valve may be faulty.

In the Mold:

  • The mold temperature may be too high.
  • The runner entries may be too small.
  • The mold may be too small.

In the Raw Material:

  • The wrong material may have been chosen.

Solutions in Order:

  • The melt temperature should be increased.
  • The mold temperature should be increased.
  • The injection speed should be reduced.
  • The cycle time should be improved.
  • The runner diameter should be increased.
  • For glass-fiber reinforced materials, the runner entry should be changed.

Burr

In the Machine:

  • The clamping pressure may be too low.
  • The injection pressure may be too high.
  • The injection speed may be too high.

In the Mold:

  • The mold may be improperly connected.
  • There may be wear or damage on the mold surfaces.
  • The mold surface may be too large.

In the Raw Material:

  • The material temperature may be too high.
  • The material fluidity may be too high.

Solutions in Order:

  • The injection speed should be reduced.
  • The injection pressure should be reduced.
  • The clamping force should be increased.
  • The melt temperature should be reduced.
  • The mold temperature should be reduced.
  • The clamping force should be increased.

Flow Marks on the Part Surface

In the Machine:

  • The injection speed may be too high.

In the Mold:

  • The mold may be too cold.
  • The runner diameters may be too low.
  • Incorrect runner entry.

In the Raw Material:

  • The material may be melted.

Solutions in Order:

  • The injection pressure should be increased.
  • The nozzle heater should be checked.
  • The mold temperature should be increased.
  • The melt temperature should be increased.
  • The runner diameter should be increased.
  • The runner entry should be changed or a direct entry should be used.

Round Rings on the Part Surface

In the Machine:

  • The injection speed may be too low.
  • The injection pressure may be too low.

In the Mold:

  • The mold temperature may be too low.
  • There may be a different pattern on the mold surface.

In the Raw Material:

  • The material melt temperature may be too low.

Solutions in Order:

  • The injection speed should be increased.
  • The injection pressure should be increased.
  • The melt temperature should be increased.
  • The mold temperature should be increased.
  • The mold pattern should be checked.

Adhesion to the Mold (Female Mold)

In the Machine:

  • The injection pressure may be too high.
  • The injection speed may be too high.
  • The molding time may be too long.
  • The material intake may be too high.

In the Mold:

  • The mold temperature may be too high.
  • The mold may be too cold.
  • The mold surface pattern may be poor.

In the Raw Material:

  • The nozzle temperature may be too high.

Solutions in Order:

  • The cycle time should be checked. (Cooling)
  • The injection pressure should be reduced.
  • The molding time should be reduced.
  • The injection speed should be reduced.
  • The material intake should be adjusted for stable cushioning.
  • The mold surface should be checked.
  • The mold opening time should be increased.
  • The material temperature should be reduced.
  • The mold temperature should be reduced.
  • The correct mold separator should be used.
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