Welcome to the Plastic411 Processing Assessment. Upon completion, this test is designed to identify plastic injection skill level. Skill range is from material handler to process engineer.
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#1 If a material ratio is identified at 25:1, or 4%.. the correct mixture would be:
#2 The orifice of a nozzle tip should be ________________ the sprue bushing orifice
#3 Color swirls can be caused by:
#4 What steps are taken to develop a decoupled molding process?
#5 A gate seal study is performed to:
#6 A dryer that is working properly, should:
#7 A material that is hydroscopic is prone to drawing in moisture and must be dried at the temperature and time determined by the material manufacturer
#8 Which of the following shows an example of a submarine gate?
#9 The purpose of Process Monitoring is:
#10 The glass transition temperature (Tg) is:
#11 Peak pressure is:
#12 Melt temperature is measured by:
#13 Shear heat from the screw rotation and back pressure supplies 70-90% of the total heat in the screw. Heater bands supply the rest and help prevent fluctuations.
#14 When venting a mold, what percentage of the cavity parameter should be vented and at what spacing?
#15 A press uses 85 pounds of material per hour, producing 170 parts. How much material will be used in 5 hours, and how many parts will be produced? How much does 1 part weigh?
#16 The flash pictured needs to be corrected using process changes. Choose answers below to correct condition.
#17 Gassing is common with many materials, such as nylon. How often should a mold be cleaned and checked for proper greasing?
#18 A burn at the flow front’s end of fill can be a sign of:
#19 What reasons below might lead to an erratic and inconsistent cushion?
#20 A press keeps alarming because the metering zone temperature is higher than normal. The monitoring is set at 25 degrees above the setpoint. What reasons below could be causing it
#21 Runner size should be ____________ the wall thickness dimension of a part.
#22 When is it important to close a mold in set-up mode?
#23 This part has signs of heavy splay at end of fill. Which of the following changes may improve the condition, or identify the cause?
#24 Based on this gate seal chart, Hold time for this process should be:
#25 This burn defect is on every shot. The burn is occurring half way through the injection. If the part has a 10″ inch shot size, how should the injection be profiled?
#26 If this part was pulled from the mold with the side marked “warp” being the stationary half, what adjustment would you make to get rid of the warp (after you checked to make sure mold set up was correct)?
#27 Where in the screw does the majority of plastic melting occur?
#28 If bar x is moved to the right, what direction will the gears move the bottom bar?
#29 When installing clamps, the bolts should be torqued to:
#30 T or F: When changing a hot runner mold, hot runner can be heated to temperature 30 minutes prior to changing mold to reduce mold change time.
#31 When making a change to back pressure, how long does it take for barrel temperature to stabilize?
#32 After confirming that melt temperature is in the middle of the melt window, what happens to material viscosity and fill time when heats are raised?
#33 What is the normal drying time and temperature for unfilled nylon?
#34 What conditions lead to bubble (void) defects in a part?
#35 What is the purpose of a nylon tip?
#36 The typical peak pressure for nylon is:
#37 When changing from nylon to polypropylene during a mold change:
#38 True or false: Size and shape of material from grinder does not affect how it mixes with virgin material or the production process.
#39 The material manufacturer recommends a melt window of 500-550 F, and the melt temperature checks at 546. What result might you get if you increase back pressure?
#40 Parts you are producing are too small according to print. What changes might you make to increase their dimensions?
#41 T or F: A part that is short (not completely filled) and has flash should be checked for signs of tool damage or wear at the parting line.
#42 What is the drying time and temperature for Polypropylene?
#43 True or False: A pressure drop study is best utilized when injection pressures are close to or at maximum pressure at middle to end of fill within the molding process
#44 When making a change from injection to hold pressure (cut-off), how long does it take for the change to take effect in the process?
#45 Which is the best method of ejector set up?
#46 When setting a mold, clamps should be attached:
#47 When making changes to back pressure, how long does it take for those changes to take effect?
#48 Flash that is feather-like in appearance:
#49 Splay at end of fill happens when:
#50 A mold that has details the flow front must pass around at 50 % fill might require:
#51 When a parting line is being checked for damage:
#52 Valve gate delay timers:
#53 Nylon regrind can be used over and over, with little effect on process control
#54 Polypropylene regrind can be used over and over, with little effect on process control.
#55 Molds that have valve gates set up properly require a gate seal study once a process has been established.
#56 Material with a high relative viscosity:
#57 Best practice for shutting down a clear Polycarbonate hot runner tool would be:
#58 Dispersion discs can be used for:
#59 Measuring the flex of a tool within the platen configuration can identify:
#60 Which Screw/ Barrel measurements best identify cause for inconsistent cushion?
#61 Which material used for purging doesn’t belong?
#62 You are trying to acheive 95-98% fill with no hold pressure. You are currently at 80%. What adjustments can be made to achieve 95-98%?
#63 When having issues with color swirl, you should:
#64 T or F: When picking a nozzle tip, it should have the same size orifice as the sprue bushing
#65 T or F: Low Pressure close should be set to the minimum pressure required to achieve lock up pressure.
#66 When having problems with contamination with a hot runner tool, you may need to:
#67 Glass transition temperature refures to:
#68 When making temperature changes to a hot runner, manifold temperatures:
#69 If the actual temperature of a thermolator reads much lower than the set point, it is likely that:
#70 When having problems removing a part from a mold with a robot, you should:
#71 T or F: Material that is hot to the touch has been dried and is ready for use
#72 Support pillars in a mold:
#73 Vented Pins:
#74 When changing material from Nylon to clear polycarbonate, you should:
#75 When changing materials during a mold change, nylon to polypropylene should be:
#76 When setting Decompression after rotate, you should:
#77 Poor knits that lead to cracking weaknesses or visual defects are generally signs of:
#78 If part color is light, but color set point and equipment operation is correct:
#79 When shutting a press down for the weekend:
#80 The correct pressure to torque bolts into a platen is:
#81 Splay is caused by:
#82 You are running a 4 cavity hot runner tool. One part has a burn at end of fill, and higher part weight than another that is short and has a low part weight. You should:
#83 A tool you are running has a valve gate that isn’t firing. You should:
#84 When mold temperature is causing warp, you should:
#85 A mold you are running has a shine appearance that is occuring on a textured surface. You should:
#86 Lamination (flaking) is caused by:
#87 Water pressure measured going into a mold measures at 14 GPM, The pressure coming out is at 11 GPM. This condition should be:
#88 At start up, there is a problem at the feed throat that is causing a Polycarbonate material to load poorly. Potential fixes to the problem might be:
#89 When setting process monitoring for fill time, the +/- set point should be:
#90 A process has been validated when:
#91 T or F: If adding back pressure to a process does not result in a temperature increase, the result may lead to material degradation and poor material properties,
#92 During mold changes, if a material change requires changing from PCABS to polypropylene, you should:
#93 If a thin-walled part tends to stick on the stationary side of the mold, you may need to:
#94 Jetting (Worming) is caused by:
#95 If the size of a gate is to small, it could lead to the following defects:
#96 If an ejection pin is too small, it can cause the following conditions:
#97 The following conditions can cause problems that can affect process control consistency:
#98 T or F: When heating a press from cold state, a front, metered or feed zone temperature that rises at a different rate could be a sign of bad heater bands,
#99 T or F: Hot runner temperatures are generally used as an extension of nozzle temperature into the hot runner manifold. As such, nozzle temperature and manifold temperatures are usually the same.
#100 T or F: Raising barrel and mold temperatures leads to increased peak pressure and viscosity.
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