Injection Molding Machine Screw Barrel Issues: A Troubleshooting Guide

October 29, 2024

Addressing Common Issues in Injection Molding Machines

Injection molding machines are essential in the manufacturing process, yet they frequently face minor issues that can disrupt production efficiency and impact overall profitability. To assist manufacturers in troubleshooting these challenges, a comprehensive overview of common problems related to the screw mechanism has been compiled, along with relevant solutions.

Common Symptoms and Solutions

Symptom	Cause	Solution
No Cutting	Screw break	Replace with a new screw
	Hopper rack "bridge" formation	Remove the "bridge" blockage
	Excessively high feed section temperature	Adjust the feed section temperature for optimal flow
	Oversized crushed material	Re-crush the material and modify the feed inlet design
Product Yellowing with Black Spots	Worn screw tube	Replace the screw or tube based on wear assessment
	Dead angle in screw assembly	Replace with a specialized screw or additional components
	Carbonization of the screw from raw material	Use a screw made from more corrosion-resistant material
	Small nozzle hole	Redrill the nozzle to a larger size
	Excessive screw compression ratio	Change to a screw with an appropriate compression ratio
	High screw temperature	Implement cooling measures for the screw core
Poor Plasticization	Incomplete melting of raw material	Increase the temperature of the barrel and use a different screw
Uneven Color Mixing	Ineffective mixing by the screw	Use a high-efficiency mixing screw
Unstable Glue End	Large gap between left and right aprons	Replace with aprons that have smaller clearances
	Poor matching of rubber ring and meson	Ensure proper dimensions and alignment of components
	Excessive gap between apron and tube	Replace worn parts as necessary
Leakage at Feed Pipe and Flange	Loose connection between tube and flange	Adjust the length of the stops for a tighter fit
	Non-vertical end face of flange	Rework to ensure vertical alignment
	Insufficient strength of screw or tube	Use stronger screws and adjustable material tubes
Screw Backlash Issues	High feed section temperature; oversized crushed material; excessive shell pressure; improper feed section setup; small screw barrel gap	Optimize parameters, re-crush materials, replace screws, and redesign feed port
Bubbles in Products	Low back pressure; small compression ratio; slow injection speed; low mold temperature	Adjust process parameters and select a screw with a larger compression ratio
Abnormal Noise from Screw	Improper assembly of the material pipe; incorrect barrel material size; small screw diameter; poor screw straightness; inadequate screw discharge design; foreign debris in the barrel	Verify assembly, remove foreign objects, and ensure smooth structure of raw materials

Conclusion

While the issues faced by injection molding machines may seem minor, they can significantly affect production efficiency and economic outcomes. By understanding the symptoms, causes, and effective solutions, manufacturers can proactively address these challenges, ensuring smoother operations and improved product quality. Regular maintenance and prompt troubleshooting are key to maintaining optimal performance in injection molding processes.

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Mr. Kenny Ye

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