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Training Package: Scientific Molding Guru
Training Package: Scientific Molding Guru
 
List Price: $4,590.00
Our Price: $1,997.00
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Product Code: WBT.PKG.IM.MG

  
Description
 
With over thirty courses specifically focused on injection molding, this series is designed to make you an expert by giving access to our entire injection molding training library.

This Comprehensive Training Package Includes...

An Introduction to Injection Molding Training

This course provides participants with a general introduction to the plastics industry. The primary focus of this training program is the day-to-day operations of a typical injection molding facility.

An Introduction to Injection Molding was created for newcomers to the injection molding industry or anyone that would like to learn more about plastics. We recommend that new hires take this course before participating in our Injection Molding Basics Series.

- An overview of plastics and the industry
- A typical molding facility
- General plant safety
- An introduction to the molding process
- Molding machine components
- Material handling
- Injection mold terminology
- Common part defects


Complete Injection Molding Basics Training Series

Our Basics series provides participants with a general understanding of the three major aspects of injection molding; the injection molding machine, the molding process, and the injection mold. These programs use 3D animation to demonstrate the inner workings of the machine and mold

and to easily convey otherwise complex concepts. Important safety precautions are stressed throughout these training programs. These basic injection molding training programs are ideal for new hires, yet also serve as an excellent refresher course for any employee involved in plastics processing; from operators and technicians to management and setup personnel.

Program 1: Machine

- Cites important safety precautions for working around injection molding machines
- Gives an introduction to the injection molding process
- Introduces machine types and the different modes of operation
- Discusses the components of the injection molding machine and their respective functions
- General procedures for starting up and shutting down a molding machine

Program 2: Process

- Discusses polymers and the three criteria used to classify them
- Covers some of the more common procedures for material preparation
- Introduces the three phases of the molding process; injection, cooling and ejection
- Explains the need for maintaining an accurate process log
- Defines common injection molded part defects and explains their causes

Program 3: Mold

- Explains the specific functions that an injection mold must perform
- Introduces the various machining methods used to construct an injection mold
- Discusses the three mold configurations used in the industry
- Covers common runner shapes and gate types used in injection molds
- Gives an overview of proper injection mold maintenance


Understanding Plastics Training

This program explains how and why plastics are different and cites several different types of polymers and processing considerations. Understanding Plastics emphasizes material handling, explains regrind, and covers the effects that moisture can have on molded part properties during processing.

- The definition of plastics
- Polymer classification
- Material properties affected by processing
- Proper material handling techniques
- Processing characteristics of virgin and regrind


Understanding Processing Parameters Training

This double course details injection molding processing parameters. Processing Parameters discusses individual parameters to help molders maintain more control of their processes. Participants will learn about processing parameters as

they relate to the various phases of the injection molding process.

- Description of molding parameters
- Procedures for optimizing several different molding parameters
- The importance of machine calibration
- In-depth considerations for injection, packing, cooling and part removal


Scientific Troubleshooting of Molding Defects

This series consists of four in-depth training programs that will provide participants with the knowledge base required to identify and troubleshoot over twenty-five of the most common defects encountered with injection molding processing. Users will also come away with a better understanding of how to best process, document and maintain a reliable injection molding process.

Program 1 - Introduction

This training program focuses on the 7-step process to scientific troubleshooting. Participants are also presented with information and practices on how to best process, document and maintain a reliable injection molding process.

Step 1 – Develop a Scientific Molding Process
Step 2 – Properly Document the Process Outputs
Step 3 – Examine the Defective Part and Rule Out Obvious Causes
Step 4 – Compare the Current Process with the Documented Process
Step 5 – Return the Process to the Documented Standard
Step 6 – Verify the Part and Process
Step 7 – Document all Changes Made

Program 2 - Visual Defects

Nine of the most common visual defects encountered in injection molding processing are covered within this extensive training program. Participants will be better prepared to troubleshoot these defects as each one will be defined and their respective causes and corrections will be explained in detail. Defects include:

- Flash
- Sinks and Voids
- Short Shots
- Jetting
- Gate Blush
- Burning
- Flow Lines
- Weld and Meld Lines
- Poor Surface Finish

Program 3 - Dimensional Defects

This training program will provide participants with a better understanding of how to best troubleshoot five (5) of the most common dimensional defects encountered in injection molding. Each defect will be defined and their respective causes and corrections will be explained in detail. These dimensional defects include:

- Large Parts
- Small Parts
- Larger Parts at the Gate
- Smaller Parts at the Gate
- Warpage

Program 4 - Material and Cycle-Related Defects

This training program provides participants with a better understanding of how to best identify and troubleshoot many of the most common Material and Cycle-Related defects encountered in injection molding. Each defect will be defined and their respective causes and corrections will be explained in detail. The material and cycle-related defects discussed in this course include:

- Splay, Bubbles, and Blisters
- Brittleness, Cracking, and Crazing
- Delamination
- Contamination
- Poor Color Distribution
- Part Sticking and Ejector Pin Marks
- Occasional Part Hang-Up


Injection Mold Setup Training

This program covers the die-setting process from start to finish with an emphasis on safety. Proper procedures for mold inspection, preparation and installation are outlined. Injection Mold Setup also covers setup procedures for hydraulic, toggle and hydro-mechanical clamp systems.

Proper mold installation procedures
Important safety considerations
Proper water line set-up
Safety precautions for mold setup


Establishing a Scientific Molding Process Training

This program shows participants how to quickly and effectively establish an injection molding process. Important safety issues associated with process set-up are stressed throughout the course. This program will also help molders reduce set-up and cycle times.

- Material preparation, drying and mixing
- Screw and barrel cleaning
- Guidelines for setting each processing parameter
- Procedures for proper injection velocity profile set-up
- Proper clamp and part removal settings


Processing For Profit Training

Processing For Profit covers techniques used for increasing profitability while maintaining part quality. The course focuses on the relationship between the material, the mold and the molding machine. Also included is practical, up-to-date information about process documentation procedures - as well as some great tips on process optimization.

- Material handling and preparation
- Process documentation and its importance
- Process optimization
- Energy conservation


Understanding Process Control Systems Training

This training program details process control systems and is designed to help molders make more educated choices. Process Control Systems is a must for any facility which employs (or plans to employ) closed loop process control.

- Open loop vs. closed loop process control
- How process control reduces variation
- Closed loop controllers
- Proper use of process control


The Effects of Mold Filling, Gating & Weld Lines Training

This course outlines mold filling and how different gating configurations affect filling. Also discussed are weld and meld lines and their effects on molded parts.

- Weld line occurrence and strength determination
- Gate types, location, and importance
- Fatigue and cyclic stress
- Tooling considerations


The Effects of Shrinkage, Warpage & Part Ejection Training

This course is designed to familiarize production personnel with complications that may arise during processing concerning shrinkage, warpage and ejection.

- How packing affects shrinkage and warpage
- Ejection systems for simple and complex geometry
- The effects of part geometry
- Amorphous vs. semi-crystalline polymer behavior


Complete DECOUPLED MOLDING (SM) Training Series

These courses convey many of the concepts and theories covered within the RJG DECOUPLED MOLDING (SM) training seminars. This four course series starts with the major components of the molding process, and progresses to systematic troubleshooting.

The DECOUPLED MOLDING system is an ideal processing method intended for anyone interested in optimizing an injection molding process.

Program 1 - Introduction to DECOUPLED MOLDING (SM)

Discusses polymerization, crystallinity, additives, regrind and degradation
Lists necessary components of a proper part design
Describes the injection molding process in depth; from filling to cooling
Covers molding machine components and their functions in depth

Program 2 - DECOUPLED MOLDING SM Techniques

Compares traditional and DECOUPLED MOLDING (SM)
Defines the three DECOUPLED MOLDING (SM) techniques
Covers transducers and proper transducer placement
Introduces signal conditioners and display devices

Program 3 - Reading and Interpreting Data

Provides participants with an understanding of graphs and scaling
Explains how to identify different types of graphical curves
Introduces the various integrals used in DECOUPLED MOLDING (SM)
Compares ideal and inconsistent pressure curves

Program 4 - Systematic Troubleshooting

Discusses the importance of proper process documentation
Explains the appearance and symptoms of defects
Introduces logical steps involved in troubleshooting defects
Describes common processing defects, their causes and actions to correct them


Math for Molders

This two-part training program was created for all personnel within the injection molding industry who would like to expand or fine tune their math skills.

These courses will greatly benefit any participant of RJG’s classroom-based, Master Molder SM Certification Series either as a primer or as follow-up training.

Program 1:

- Whole Numbers, Negative Numbers and Decimals
- Using a Calculator
- Addition, Subtraction, Multiplication and Division
- Rounding Numbers and Significant Figures
- Formulas, Equations and Order of Operations


Program 2:

- Metric and Imperial Units
- Length and Distance
- Area, Volume & Flow
- Weight, Mass and Force
- Conversions
- Understanding Percentages
- Calculating Plastic Pressure and Part Shrinkage
- Calculating Tolerances


Complete Intelligent Molder Training Series

These courses were produced for technicians and process engineers that want to thoroughly evaluate both the capability and repeatability of a given injection molding machine, injection mold, or injection molding process.

Each course references three in-depth tests and will greatly benefit any participant of RJG’s classroom-based, Master Molder SM Certification Series – either as a primer or as follow-up training.

Program 1 - Machine Evaluation

- Dynamic Check Ring Repeatability Test
- Load Sensitivity Test
- Platen Deflection Test

Program 2 - Mold Evaluation

- Dynamic Cavity Imbalance Test
- Mold Deflection Test
- Tonnage Calculation Worksheet

Program 3 - Process Evaluation

- In-Mold Rheology Test
- Gate Seal Worksheet
- DECOUPLED II Process Sheet


RJG’s eDART™ Training

This course was created for production personnel that monitor and optimize injection molding processes equipped with RJG’s eDART™ process controllers. This course will greatly benefit setup personnel, process engineers, machine operators, and managers that use, or plan on using, an eDART™ system.

Participants will be better prepared to establish the following:

- Improved processing methods
- Increased operation efficiency
- Machine and process analysis
- Automated quality control
- Improved process stability


Material Drying Technology, Course 1

These programs identify drying as a critical step when processing any plastic – and teach participants that proper preparation, handling, monitoring and controlling moisture levels results in higher quality parts, higher production yields and consistent processing. Material Drying Technology course two focuses on the operation and utilization of Hot Air Dryers, Compressed Air Dryers, Desiccant Dryers, and Vacuum Dyers in today’s production environments. Course two also teaches the participants how to Calculate Material Consumption, Residence Time, and Dryer Capacity.

- Polymer Basics
- Hygroscopic vs. Non-Hygroscopic Polymers
- Hydrolysis
- Purposes of Drying
- Dewpoint
- Dewpoint Measurement
- Dewpoint Sensors
- Drying Procedures


Material Drying Technology, Course 2

- Hot Air Dryers
- Compressed Air Dryers
- Desiccant Dryers
- Vacuum Dyers
- Calculating Material Consumption
- Calculating Residence Time
- Calculating Dryer Capacity


Injection Mold Maintenance Training

This program details procedures for proper mold care before, during, and after a production run - stressing important safety considerations for mold handling. From mold storage to part removal, this course provides participants with good mold maintenance habits and aims to extend tool life & increase its productivity.

- Proper mold maintenance
- Mold storage and preparation
- Water line maintenance
- Techniques for extending tool life


Understanding Electric Injection Molding Machines

This training program will provide participants with a better understanding of how electric injection molding machines function – as well as the many benefits and capabilities associated with electric molding machines.

- General Injection Molding Safety
- Electric Molding Machine Safety
- Machine Guarding
- Comparing Hydraulic and Electric Machines
- Basic Molding Machine Functions
- Efficiency, Accuracy and Repeatability
- Alternative Machine Designs
- Typical Uses for Electric Injection Molding Machines


Processing with Electric Injection Molding Machines

Packed with in-depth processing information, this course will undoubtedly prepare processors for making more appropriate and cost-effective decisions. Participants will also learn how to optimize any process that's running on an electric injection molding machine.

- Closed-Loop Process Controls
- Hydraulic vs. Electric Molding Machine Controls
- Process Optimization Strategies:
  · 1st Stage Filling
  · 1st Stage to 2nd Stage Transfer
  · 2nd Stage Pack
  · Screw Delay
  · Screw Recovery
  · Screw Decompression
  · Cooling Time
  · Mold Opening
  · Part Ejection
  · Mold Closing
  · Clamping


Injection Molding Hydraulics Training Series

This course demonstrates the importance of hydraulics in the injection molding process. Machine operators will learn ways to reduce wear on hydraulic components, while more advanced employees concentrate on hydraulic print reading and theory.

- Basic hydraulic theory
- The role of hydraulics in injection molding
- The function and purpose of hydraulic components
- Recognition of hydraulic symbols
- Directional valves and flow controls
- Hydraulic pumps and motors
- Proportional valves and servo valves
- Hydraulic fluid management


Injection Molding Machine Maintenance Training

Designed to introduce the many maintenance considerations for an injection molding machine. Participants are also shown newer technologies; such as laser leveling, ultrasonic tie bar stretch measuring, and portable machine process monitors.

- Basic machine maintenance & safety concerns
- Fluid and platen maintenance
- Screw and barrel maintenance
- Preventative maintenance & logging


40-60 hours of Professional Multimedia Training with Study Guides


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