This thesis deals with the optimization of the production technology of the cap tube made by injection molding. Series production is set at 5 000 000 units per year; the minimum time of the production is 5 years. A literary study is developed, focusing on the technology of injection molding in molds including the possibilities of the optimization of the production by changing the structure of the mold. The practical part of the thesis is devoted to the optimization of existing mold with cold runner system for the production of the cap tube, using the hot runner system supplied by Synventive. The change of the structure of the mold involves changing the three plate mold to a two plate mold. It is about changing the fixed part of the mold in which the hot runner system is placed; it is composed of standards parts of the company HASCO. Based on the technological parameters the injection machine Krauss Maffei KM 80-380 CX is chosen. There is a technical-economical evaluation of the optimization of the production by using the hot runner system at the end of the thesis.

L'objectif de cette thèse fut de comprendre les mécanismes de dégradation des SAN et des ABS à partir de déchets de rebuts de production bruts et/ou chargés de la société Albéa (anciennement connue sous le nom d'Alcan Packaging). Ce projet devrait permettre de répondre à des exigences en termes de diminution de volume de déchets, d'amélioration de propriétés et de diminution de coûts. Ce travail permettra également d'améliorer notre compréhension sur des aspects fondamentaux de recyclabilité physique des polymères lors de différents cycles en injection moulage. L'étude au mélangeur interne a permis de mettre en évidence les phénomènes de dégradation sous l'influence des conditions de mise en œuvre (vitesse, température et temps de mélange). Ainsi, dans le cas du SAN, les mécanismes de la dégradation thermo-mécanique sont générés à la fois par la thermo-oxydation et par la dégradation mécanique impliquant des coupures de chaînes. Dans le cas des ABS, les mécanismes de dégradation thermo-mécanique mis en jeu impliquent, outre les sites chromophores, plusieurs réactions en compétition comme la réticulation et les coupures de chaîne. L'originalité de cette étude réside dans la mise en évidence expérimentale, à travers des techniques originales (TMDSC, RMN du solide, AFM), d'un mécanisme théorique de dégradation des SAN et des ABS en se plaçant dans les conditions réelles de mise en œuvre. Nous avons alors pu mettre en évidence la réelle contribution de l'effet thermique et de l'effet du cisaillement qui jusqu'alors, dans la littérature, semblait non étudié. Finalement, les effets de dégradation du SAN n'ont pas affecté les propriétés mécaniques bien qu'une décoloration et une diminution de la viscosité aient été observées. En revanche, dans le cas de l'ABS recyclé, les propriétés en traction et la résistance au choc ont considérablement été affectées, notamment par la présence de vernis qui interfère sur le transfert de contraintes entre les nodules de PB et la matrice SAN. / The aim of this PhD thesis was to understand the mechanisms of degradation of SAN and ABS from waste sprues and undelivered packages from Albea Group (formerly known as Alcan Packaging). The results of this project should allow the reduction of waste volume, the improvement of material properties and a costs reduction. The present workshould also improve the understanding of the fundamental aspects of physical recyclability of polymers during different cycles in injection molding.The first part of the study performed using an internal mixer showed how degradation was influenced by processing parameters such as the rotor speed, the temperature and the mixing time. Thus, considering the SAN, the mechanisms of the thermo-mechanical degradation are both generated by the thermo-mechanical degradation and by the oxidation that involves chain scissions. In the case of ABS, its mechanisms of thermo-mechanical degradation imply further chromophores sites, several competition reactions such as crosslinking and chain scissions.The innovative feature of our work was to establish a theoretical mechanism of degradation of ABS and SAN under processing conditions used in industry thanks to our experimental approach with original investigation procedure (TMDSC, solid state NMR, AFM). Afterwards, we were then able to identify the real contribution on the one hand of the shearing effect, which seemed still unstudied in the literature, and of the other hand of the thermal effect.Finally, it was found that degradation was not affecting SAN mechanical properties whereas discoloration and a reduction of viscosity were observed. On the opposite, the recycling of ABS resulted in a significant reduction of tensile properties and the impact strength due to the presence of varnish which interfered in stress transfer between PB nodules and the SAN matrix.

This thesis contains of theoretical part which deals with injection molding, properties of some polymer materials are included also. Design of plastic injection mold for cover of electronic device is presented in practical part. Manufacturing parameters and injection machine selection are specified with mold structure consideration. Production costs and the final price of the plastic part are calculated in economical evaluation.

This thesis deals with the plastic parts design for VW Scirocco R front bumper. Plastic parts were designed for an injection molding mass production. Besides of designing a shape of the parts based on package, assembly concept, functional and aesthetic requirements, great deal of attention is applied to proper part molding with regard to technological and economic aspects.

This master´s thesis addresses the design of technology manufacturing plastic parts. The first part deals with the study of theoretical properties of plastics and processing applicable to a given problem. In the second part is designed double injection mold with hot runners. The following authentication function by analyzing the injection solution and the work concludes technical and economic assessment of the project.

Eine stetig gleichbleibende hohe Qualität zu fertigen, ist erklärtes Ziel des Spritzgießgewer-bes. Aus technischen oder wirtschaftlichen Gründen ist es jedoch nicht möglich, für konstan-te Produktionsrahmenbedingungen zu sorgen. Die effizienteste Methode ist , die Schwan-kungen über die Wahl der richtigen Prozessführungsmethode auszugleichen. Im ersten Teil der Arbeit konnte herausgefunden werden, welche praxisrelevanten Störgrö-ßen einen Einfluss auf den Spritzgießprozess haben und wie sie sich auswirken. Bei den Materialparametern sind Änderungen der Viskosität (15 %) und der Einfriertemperatur des Materials (4 °C) am Einzug festzustellen. Zusätzlich veränderte sich das Messverhalten der Drucksensoren, wodurch ein Drift von 5 bar entstand. Störgrößenbedingt änderten sich auch die Prozesstemperaturen um 1 °C. Im zweiten Teil der Arbeit werden diverse, während der Arbeit entwickelte, Prozessfüh-rungsmethoden miteinander verglichen. Aufgabe war es, die im ersten Teil gefundenen rea-len störgrößenbedingten Einflüsse zu kompensieren. Es stellte sich heraus, dass sich ledig-lich die materialbedingten Schwankungen nicht ausgleichen lassen. Zumindest können de-ren Auswirkungen durch eine Regelung der werkstoffnahen Parameter abschwächt werden. / To produce a steady consistent high quality is the declared goal of the injection moulding industry. For technical or economic reasons, it is not possible to ensure constant production framework conditions. The proper method is to compensate the variable influences with the choice of the correct process control method. The first part of the thesis focuses on the analysis of the different disturbances factors. The investigation showed that the material property, melt viscosity, varies about 15% and the recrystallisation temperature arises a deviation of 4°C. Another changes could be measured in the offset of the pressure sensor (5 bar) and the process temperatures (1°C). The next goal was to find a suitable control method to balance these intermittencies. The test series showed clearly that changes in the material properties could not be compensated. But there impact toward the quality could be extenuated with a constant course of the process parameter in the cavity.