Sabtu, 07 Mei 2011

injection molding

Dari Wikipedia bahasa Indonesia, ensiklopedia bebas
Injection molding adalah metode material termoplastik dimana material yang meleleh karena pemanasan diinjeksikan oleh plunger ke dalam cetakan yang didinginkan oleh air dimana material tersebut akan menjadi dingin dan mengeras sehingga bisa dikeluarkan dari cetakan.
Meskipun banyak variasi dari proses dasar ini, 90 persen injection molding adalah memproses material termoplastik. Injection molding mengambil porsi sepertiga dari keseluruhan resin yang dikonsumsi dalam pemrosesan termoplastik. Sekarang ini bisa dipastikan bahwa setiap kantor, kendaraan, rumah, pabrik terdapat barang-barang dari plastik yang dibuat dengan cara injection molding, misalnya pesawat telepon, printer, keyboard, mouse, rumah lampu mobil ,dashboard, reflektor, roda gigi, helm, televisi, sisir, roda furnitur, telepon seluler, dan masih banyak lagi yang lain.

Daftar isi

[sembunyikan]

[sunting] Sejarah

Mesin injection molding tercatat telah dipatenkan pertama kali pada tahun 1872 di Amerika Serikat untuk memproses celluloid. Berikutnya pada tahun 1920-an di Jerman mulai dikembangkan mesin injection molding namun masih dioperasikan secara manual dimana pencekaman mold masih menggunakan tuas. Tahun 1930-an ketika berbagai macam resin tersedia dikembangkan mesin injection molding yang dioperasikan secara hidrolik. Pada era ini kebanyakan mesin injection moldingnya masih bertipe single stage plunger. Pada tahun 1946 James Hendry membuat mesin injection molding tipe single-stage reciprocating screw yang pertama. Mulai tahun 1950-an relay dan timer mulai digunakan untuk pengontrolan proses injeksi.
Mesin injection molding ukuran kecil, tampak hopper, nozzle dan clamping unit

[sunting] Proses

Termoplastik dalam bentuk butiran atau bubuk ditampung dalam sebuah hopper kemudian turun ke dalam barrel secara otomatis (karena gaya gravitasi) dimana ia dilelehkan oleh pemanas yang terdapat di dinding barrel dan oleh gesekan akibat perputaran sekrup injeksi. Plastik yang sudah meleleh diinjeksikan oleh sekrup injeksi (yang juga berfungsi sebagai plunger) melalui nozzle ke dalam cetakan yang didinginkan oleh air. Produk yang sudah dingin dan mengeras dikeluarkan dari cetakan oleh pendorong hidrolik yang tertanam dalam rumah cetakan selanjutnya diambil oleh manusia atau menggunakan robot. Pada saat proses pendinginan produk secara bersamaan di dalam barrel terjadi proses pelelehan plastik sehingga begitu produk dikeluarkan dari cetakan dan cetakan menutup, plastik leleh bisa langsung diinjeksikan.

[sunting] Jendela proses

Molding area diagram
Jendela proses atau juga disebut Molding Area Diagram adalah sebuah indikator seberapa jauh kita bisa memvariasikan proses dan masih bisa membuat produk yang memenuhi syarat. Idealnya jendela proses cukup lebar sehingga bisa mengakomodasi variasi alami yang terjadi selama proses injeksi. Jika jendela proses terlalu sempit maka ada risiko menghasilkan produk yang cacat akibat variasi proses injeksi berada di luar jendela. Jendela proses berbeda-beda untuk tiap resin karena masing-masing resin memiliki titik leleh (temperatur transisi gelas, Tg) yang berbeda-beda.
Jika temperatur proses terlalu rendah maka ada kemungkinan material tidak meleleh dan jika meleleh maka viskositasnya sangat tinggi sehingga memerlukan tekanan injeksi yang sangat tinggi. Jika tekanan injeksi terlalu tinggi maka akan menimbulkan flash atau burr pada garis pemisah cetakan akibat gaya pencekaman lebih kecili dari tekanan injeksi. Dan jika temperatur proses terlalu tinggi maka material akan mengalami kerusakan atau terbakar.

[sunting] Gas Assisted Injection Molding

Gas Assisted Injection Molding
Gas Assisted Injection Molding melibatkan penggunaan gas bertekanan tinggi dalam proses injeksi. Ketika mold baru terisi sebagian material plastik leleh (1), gas bertekanan tinggi diinjeksikan. Gas ini akan mendorong plastik leleh ke arah dinding-dinding cetakan (2). Tekanan gas tetap dipertahankan untuk memberikan tekanan pemadatan sementara produk mengalami pendinginan (3). Gas yang biasa dipakai adalah gas Nitrogen karena bersifat inert.
Perbedaan tekanan di dalam mold
Keuntungan[1]:
  1. Leluasa dalam mendesain bentuk-bentuk produk berongga, berdinding tipis ataupun tebal dan berbentuk batang atau pipa
  2. Kekakuan produk lebih tinggi akibat adanya ruang kosong (momen inersia polar lebih tinggi)
  3. Memerlukan jumlah gate lebih sedikit sehingga mengurangi weldline
  4. Tidak ada cacat sinkmark pada produk-produk yang tebal
  5. Tekanan injeksi dan pemadatan yang lebih rendah
  6. Distribusi tekanan pemadatan lebih merata
  7. Siklus injeksi lebih cepat akibat waktu pendinginan yang lebih singkat.
  8. Produk yang lebih ringan

[sunting] Mesin injection molding

[sunting] Komponen utama

  1. Unit injeksi - bagian dari mesin injection molding yang berfungsi untuk melelehkan material plastik, terdiri dari hopper, barrel dan screw.
  2. Mold - bagian dari mesin injection molding dimana plastik leleh dicetak dan didinginkan
  3. Unit pencekam - bagian dari mesin injection yang berfungsi untuk mencekam mold pada saat penginjeksian material ke dalam cetakan sekaligus menyediakan mekanisme pengeluaran produk dari mold
Sebuah mold akan dipasang ke mesin injection molding

[sunting] Jenis-jenis mesin injection molding

  1. Berdasarkan metode pencekaman cetakan
    1. pencekam toggle
    2. pencekam hidrolik
  2. Berdasarkan proses pelelehan bijih plastik
    1. single-stage plunger
    2. two-stage screw-plunger
    3. single-stage reciprocating-screw
  3. Berdasarkan tonase - Mesin injection molding dibedakan berdasarkan besarnya gaya pencekaman maksimum yang bisa diberikan. Kisarannya mulai dari 5 ton untuk menghasilkan produk seberat 10 gram sampai dengan 5000 ton untuk menghasilkan produk seberat 50 kilogram.[1]
Mesin injection molding 1300 ton dengan tambahan robot di bagian atas mesin untuk pengambilan produk dari mold

[sunting] Referensi

  1. ^ a b Anonymous (2002). The Injection Molding of Quality Parts - Process Engineering Alternatives and Process Selection (edisi ke-1st). Bayer AG - Plastics Business Group, D-51368 Leverkusen.. p. 18.

[sunting] Daftar pustaka

  • (Inggris) Strong, A. Brent (2006). "Plastics: Materials and Processing". Pearson Prentice Hall ISBN 0-13-114558-4
  • (Inggris) R.J. Crawford (2002). “Plastic Engineering”. Buttenworth-Heinemann ISBN 0-7506-3764-1
  • (Inggris) Anonym (1995). “The Wordsworth Dictionary of Science & Technology”. Wordsworth Reference ISBN 1-85326-351-6
  • (Inggris) Charles A. Harper (2000). “Modern Plastic Handbook”. McGraw-Hill, ISBN 0-07-026714-6

[sunting] Pranala luar

Selasa, 03 Mei 2011

injection molding machine

From Wikipedia, the free encyclopedia

Paper clip mold opened in molding machine; the nozzle is visible at right

An Injection molding machine, also known as an injection press, is a machine for manufacturing plastic products by the injection molding process. It consists of two main parts, aninjection unit and a clamping unit.
Injection molding machines can fasten the molds in either a horizontal or vertical position. The majority of machines are horizontally oriented, but vertical machines are used in some niche applications such as insert molding, allowing the machine to take advantage of gravity. There are many ways to fasten the tools to the platens, the most common being manual clamps (both halves are bolted to the platens); however hydraulic clamps (chocks are used to hold the tool in place) and magnetic clamps are also used. The magnetic and hydraulic clamps are used where fast tool changes are required.

[edit]Types of injection molding machines

Machines are classified primarily by the type of driving systems they use: hydraulic,mechanical, electric, or hybrid. Hydraulic presses have historically been the only option available to molders until Nissei Plastic Industrial Co., LTD introduced the first all-electric injection molding machine in 1983. The electric press, also known as Electric Machine Technology (EMT), reduces operation costs by cutting energy consumption and also addresses some of the environmental concerns surrounding the hydraulic press. Electric presses have been shown to be quieter, faster, and have a higher accuracy, however the machines are more expensive.Mechanical type machines use the toggle system for building up tonnage on the clamp side of the machine. Tonnage is required on all machines so that the clamp side of the machine does not open (i.e. tool half mounted on the platen) due to the injection pressure.If the tool half opens up it will create flash in the plastic product. Reliability of mechanical type of machines is more as tonnage built during each cycle is the same as compared to hydraulic machines. Hybrid injection molding machines claim to take advantage of the best features of both hydraulic and electric systems, but in actuality use almost the same amount of electricity to operate as a standard hydraulic. Hydraulic machines, although not nearly as precise, are the predominant type in most of the world, with the exception of Japan.
robotic arm is often used to remove the molded components; either by side or top entry, but it is more common for parts to drop out of the mold, through a chute and into a container.

[edit]References

Minggu, 10 April 2011

water

From Wikipedia, the free encyclopedia
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Water in three states: liquid, solid (ice), and (invisible) water vapor in the air. Clouds are accumulations of water droplets, condensed from vapor-saturated air.
Water is a chemical substance with the chemical formula H2O. Its molecule contains one oxygen and two hydrogen atoms connected by covalent bonds. Water is a liquid at ambient conditions, but it often co-exists on Earth with its solid state, ice, and gaseous state (water vapor or steam). Water also exists in a liquid crystal state near hydrophilic surfaces.[1][2]
Water covers 70.9% of the Earth's surface,[3] and is vital for all known forms of life.[4] On Earth, it is found mostly in oceans and other large water bodies, with 1.6% of water below ground in aquifers and 0.001% in the air as vapor, clouds (formed of solid and liquid water particles suspended in air), and precipitation.[5] Oceans hold 97% of surface water, glaciers and polar ice caps 2.4%, and other land surface water such as rivers, lakes and ponds 0.6%. A very small amount of the Earth's water is contained within biological bodies and manufactured products.
Water on Earth moves continually through a cycle of evaporation or transpiration (evapotranspiration), precipitation, and runoff, usually reaching the sea. Over land, evaporation and transpiration contribute to the precipitation over land.
Clean drinking water is essential to humans and other lifeforms. Access to safe drinking water has improved steadily and substantially over the last decades in almost every part of the world.[6][7] There is a clear correlation between access to safe water and GDP per capita.[8] However, some observers have estimated that by 2025 more than half of the world population will be facing water-based vulnerability.[9] A recent report (November 2009) suggests that by 2030, in some developing regions of the world, water demand will exceed supply by 50%.[10] Water plays an important role in the world economy, as it functions as a solvent for a wide variety of chemical substances and facilitates industrial cooling and transportation. Approximately 70% of freshwater is consumed by agriculture.[11]

Contents

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Chemical and physical properties

Model of hydrogen bonds between molecules of water
Impact from a water drop causes an upward "rebound" jet surrounded by circular capillary waves.
Dew drops adhering to a spider web
Capillary action of water compared to mercury
Water is the chemical substance with chemical formula H2O: one molecule of water has two hydrogen atoms covalently bonded to a single oxygen atom.
Water appears in nature in all three common states of matter and may take many different forms on Earth: water vapor and clouds in the sky; seawater and icebergs in the polar oceans; glaciers and rivers in the mountains; and the liquid in aquifers in the ground.
At high temperatures and pressures, such as in the interior of giant planets, it is argued that water exists as ionic water in which the molecules break down into a soup of hydrogen and oxygen ions, and at even higher pressures as superionic water in which the oxygen crystallises but the hydrogen ions float around freely within the oxygen lattice.[12]
The major chemical and physical properties of water are:
  • Since the water molecule is not linear and the oxygen atom has a higher electronegativity than hydrogen atoms, it carries a slight negative charge, whereas the hydrogen atoms are slightly positive. As a result, water is a polar molecule with an electrical dipole moment. Water also can form an unusually large number of intermolecular hydrogen bonds (four) for a molecule of its size. These factors lead to strong attractive forces between molecules of water, giving rise to water's high surface tension[14] and capillary forces. The capillary action refers to the tendency of water to move up a narrow tube against the force of gravity. This property is relied upon by all vascular plants, such as trees.[citation needed]
  • The boiling point of water (and all other liquids) is dependent on the barometric pressure. For example, on the top of Mt. Everest water boils at 68 °C (154 °F), compared to 100 °C (212 °F) at sea level. Conversely, water deep in the ocean near geothermal vents can reach temperatures of hundreds of degrees and remain liquid.
  • Water has the second highest molar specific heat capacity of any known substance, after ammonia, as well as a high heat of vaporization (40.65 kJ·mol−1), both of which are a result of the extensive hydrogen bonding between its molecules. These two unusual properties allow water to moderate Earth's climate by buffering large fluctuations in temperature.
  • The maximum density of water occurs at 3.98 °C (39.16 °F).[15] It has the anomalous property of becoming less dense, not more, when it is cooled down to its solid form, ice. It expands to occupy 9% greater volume in this solid state, which accounts for the fact of ice floating on liquid water.
  • Its Density is 1,000 kg/m3 liquid (4 °C), and weighs 62.4 lb/ft.3 (917 kg/m3, solid). It weighs 8.3454 lb/gal. (US, liquid) [16]
ADR label for transporting goods dangerously reactive with water
  • Water is miscible with many liquids, such as ethanol, in all proportions, forming a single homogeneous liquid. On the other hand, water and most oils are immiscible usually forming layers according to increasing density from the top. As a gas, water vapor is completely miscible with air.
  • Water forms an azeotrope with many other solvents.
  • As an oxide of hydrogen, water is formed when hydrogen or hydrogen-containing compounds burn or react with oxygen or oxygen-containing compounds. Water is not a fuel, it is an end-product of the combustion of hydrogen. The energy required to split water into hydrogen and oxygen by electrolysis or any other means is greater than the energy that can be collected when the hydrogen and oxygen recombine.[17]

Taste and odor

Water can dissolve many different substances, giving it varying tastes and odors. Humans and other animals have developed senses which enable them to evaluate the potability of water by avoiding water that is too salty or putrid. The taste of spring water and mineral water, often advertised in marketing of consumer products, derives from the minerals dissolved in it. However, pure H2O is tasteless and odorless. The advertised purity of spring and mineral water refers to absence of toxins, pollutants and microbes.

Distribution in nature

In the universe

Much of the universe's water is produced as a byproduct of star formation. When stars are born, their birth is accompanied by a strong outward wind of gas and dust. When this outflow of material eventually impacts the surrounding gas, the shock waves that are created compress and heat the gas. The water observed is quickly produced in this warm dense gas.[18]
Water has been detected in interstellar clouds within our galaxy, the Milky Way. Water probably exists in abundance in other galaxies, too, because its components, hydrogen and oxygen, are among the most abundant elements in the universe. Interstellar clouds eventually condense into solar nebulae and solar systems such as ours.
Water vapor is present in
Liquid water is present on
  • Earth: 71% of surface
Strong evidence suggests that liquid water is present just under the surface of Saturn's moon Enceladus. Jupiter's moon Europa may have liquid water in the form as a 100 km deep subsurface ocean, which would amount to more water than is in all the Earth's oceans.
Water ice is present on
Water ice may be present on Ceres and Tethys. Water and other volatiles probably comprise much of the internal structures of Uranus and Neptune and the water in the deeper layers may be in the form of ionic water in which the molecules break down into a soup of hydrogen and oxygen ions, and deeper down as superionic water in which the oxygen crystallises but the hydrogen ions float around freely within the oxygen lattice.[12]
Some of the Moon's minerals contain water molecules. For instance, in 2008 a laboratory device which ejects and identifies particles found small amounts of the compound in the inside of volcanic pearls brought from Moon to Earth by the Apollo 15 crew in 1971.[23] NASA reported the detection of water molecules by NASA's Moon Mineralogy Mapper aboard the Indian Space Research Organization's Chandrayaan-1 spacecraft in September 2009.[24]

Water and habitable zone

The existence of liquid water, and to a lesser extent its gaseous and solid forms, on Earth are vital to the existence of life on Earth as we know it. The Earth is located in the habitable zone of the solar system; if it were slightly closer to or farther from the Sun (about 5%, or about 8 million kilometers), the conditions which allow the three forms to be present simultaneously would be far less likely to exist.[25][26]
Earth's gravity allows it to hold an atmosphere. Water vapor and carbon dioxide in the atmosphere provide a temperature buffer (greenhouse effect) which helps maintain a relatively steady surface temperature. If Earth were smaller, a thinner atmosphere would allow temperature extremes, thus preventing the accumulation of water except in polar ice caps (as on Mars).
The surface temperature of Earth has been relatively constant through geologic time despite varying levels of incoming solar radiation (insolation), indicating that a dynamic process governs Earth's temperature via a combination of greenhouse gases and surface or atmospheric albedo. This proposal is known as the Gaia hypothesis.
The state of water on a planet depends on ambient pressure, which is determined by the planet's gravity. If a planet is sufficiently massive, the water on it may be solid even at high temperatures, because of the high pressure caused by gravity, as it was observed on exoplanets Gliese 436 b[27] and GJ 1214 b.[28]
There are various theories about origin of water on Earth.

On Earth

A graphical distribution of the locations of water on Earth.
Water covers 71% of the Earth's surface; the oceans contain 97.2% of the Earth's water. The Antarctic ice sheet, which contains 61% of all fresh water on Earth, is visible at the bottom. Condensed atmospheric water can be seen as clouds, contributing to the Earth's albedo.
Hydrology is the study of the movement, distribution, and quality of water throughout the Earth. The study of the distribution of water is hydrography. The study of the distribution and movement of groundwater is hydrogeology, of glaciers is glaciology, of inland waters is limnology and distribution of oceans is oceanography. Ecological processes with hydrology are in focus of ecohydrology.
The collective mass of water found on, under, and over the surface of a planet is called the hydrosphere. Earth's approximate water volume (the total water supply of the world) is 1,360,000,000 km3 (326,000,000 mi3).
Groundwater and fresh water are useful or potentially useful to humans as water resources.
Liquid water is found in bodies of water, such as an ocean, sea, lake, river, stream, canal, pond, or puddle. The majority of water on Earth is sea water. Water is also present in the atmosphere in solid, liquid, and vapor states. It also exists as groundwater in aquifers.
Water is important in many geological processes. Groundwater is present in most rocks, and the pressure of this groundwater affects patterns of faulting. Water in the mantle is responsible for the melt that produces volcanoes at subduction zones. On the surface of the Earth, water is important in both chemical and physical weathering processes. Water and, to a lesser but still significant extent, ice, are also responsible for a large amount of sediment transport that occurs on the surface of the earth. Deposition of transported sediment forms many types of sedimentary rocks, which make up the geologic record of Earth history.

Water cycle

The water cycle (known scientifically as the hydrologic cycle) refers to the continuous exchange of water within the hydrosphere, between the atmosphere, soil water, surface water, groundwater, and plants.
Water moves perpetually through each of these regions in the water cycle consisting of following transfer processes:
  • evaporation from oceans and other water bodies into the air and transpiration from land plants and animals into air.
  • precipitation, from water vapor condensing from the air and falling to earth or ocean.
  • runoff from the land usually reaching the sea.
Most water vapor over the oceans returns to the oceans, but winds carry water vapor over land at the same rate as runoff into the sea, about 36 Tt per year. Over land, evaporation and transpiration contribute another 71 Tt per year. Precipitation, at a rate of 107 Tt per year over land, has several forms: most commonly rain, snow, and hail, with some contribution from fog and dew. Condensed water in the air may also refract sunlight to produce rainbows.
Water runoff often collects over watersheds flowing into rivers. A mathematical model used to simulate river or stream flow and calculate water quality parameters is hydrological transport model. Some of water is diverted to irrigation for agriculture. Rivers and seas offer opportunity for travel and commerce. Through erosion, runoff shapes the environment creating river valleys and deltas which provide rich soil and level ground for the establishment of population centers. A flood occurs when an area of land, usually low-lying, is covered with water. It is when a river overflows its banks or flood from the sea. A drought is an extended period of months or years when a region notes a deficiency in its water supply. This occurs when a region receives consistently below average precipitation.

Fresh water storage

Bay of Fundy High Tide.jpgBay of Fundy Low Tide.jpg
High tide (left) and low tide (right)
Some runoff water is trapped for periods of time, for example in lakes. At high altitude, during winter, and in the far north and south, snow collects in ice caps, snow pack and glaciers. Water also infiltrates the ground and goes into aquifers. This groundwater later flows back to the surface in springs, or more spectacularly in hot springs and geysers. Groundwater is also extracted artificially in wells. This water storage is important, since clean, fresh water is essential to human and other land-based life. In many parts of the world, it is in short supply.

Sea water

Sea water contains about 3.5% salt on average, plus smaller amounts of other substances. The physical properties of sea water differ from fresh water in some important respects. It freezes at a lower temperature (about −1.9 °C) and its density increases with decreasing temperature to the freezing point, instead of reaching maximum density at a temperature above freezing. The salinity of water in major seas varies from about 0.7% in the Baltic Sea to 4.0% in the Red Sea.

Tides

Tides are the cyclic rising and falling of local sea levels caused by the tidal forces of the Moon and the Sun acting on the oceans. Tides cause changes in the depth of the marine and estuarine water bodies and produce oscillating currents known as tidal streams. The changing tide produced at a given location is the result of the changing positions of the Moon and Sun relative to the Earth coupled with the effects of Earth rotation and the local bathymetry. The strip of seashore that is submerged at high tide and exposed at low tide, the intertidal zone, is an important ecological product of ocean tides.

Effects on life

An oasis is an isolated water source with vegetation in desert
Overview of photosynthesis and respiration. Water (at right), together with carbon dioxide (CO2), form oxygen and organic compounds (at left), which can be respired to water and (CO2).
From a biological standpoint, water has many distinct properties that are critical for the proliferation of life that set it apart from other substances. It carries out this role by allowing organic compounds to react in ways that ultimately allow replication. All known forms of life depend on water. Water is vital both as a solvent in which many of the body's solutes dissolve and as an essential part of many metabolic processes within the body. Metabolism is the sum total of anabolism and catabolism. In anabolism, water is removed from molecules (through energy requiring enzymatic chemical reactions) in order to grow larger molecules (e.g. starches, triglycerides and proteins for storage of fuels and information). In catabolism, water is used to break bonds in order to generate smaller molecules (e.g. glucose, fatty acids and amino acids to be used for fuels for energy use or other purposes). Without water, these particular metabolic processes could not exist.
Water is fundamental to photosynthesis and respiration. Photosynthetic cells use the sun's energy to split off water's hydrogen from oxygen. Hydrogen is combined with CO2 (absorbed from air or water) to form glucose and release oxygen. All living cells use such fuels and oxidize the hydrogen and carbon to capture the sun's energy and reform water and CO2 in the process (cellular respiration).
Water is also central to acid-base neutrality and enzyme function. An acid, a hydrogen ion (H+, that is, a proton) donor, can be neutralized by a base, a proton acceptor such as hydroxide ion (OH) to form water. Water is considered to be neutral, with a pH (the negative log of the hydrogen ion concentration) of 7. Acids have pH values less than 7 while bases have values greater than 7.
Some of the biodiversity of a coral reef

Aquatic life forms

Some marine diatoms – a key