Honeywell CS071AE User manual

TROUBLE-SHOOTING GUIDE

Description of Problem Possible Causes Possible Corrective Action

Blisters • Excessive moisture. • Pre-dry sheet at the temperature

required for the material you are

forming.

• Heat sheet very slowly to forming

temperature.

• Protect sheet from moisture before

using.

• Heating sheet too hot. • Cut down sheet forming

temperature. You may be boiling

the stabilizers out of the material.

• Heating sheet too fast. • Lower element temperatures.

Generally speaking, element

temperatures should not exceed

950°F.

• Increase the distance between the

heating elements and the sheet.

• Uneven heating of the sheet. • Check forming oven for elements

that are overheating.

• Screen out hot spots.

• Heat sensitive material. • Check with plastic supplier on

temperature parameters for the

material involved.

Thinning • Design of the part. • The overall draw ratio of the part is

too great for the starting thickness

of the sheet.

• The part has specific areas on it

that exceed the draw ratios of the

rest of the part.

• Sheet too thin. • Increase the gauge thickness of the

plastic sheet.

• Uneven sheet temperature. • Check for air drafts in the forming

oven.

• Check for hot spots in the forming

oven. May have defective heating

elements.

• Check the sheet for a variation in

thickness.

• Forming technique. • Consider where the part is thinning

and what forming technique would

best address this problem.

• Bad plastic sheet. Melt

index of sheet may be low.

• Have physical properties of the

sheet analyzed.

TROUBLE-SHOOTING GUIDE

Description of Problem Possible Causes Possible Corrective Action

Discoloration • Forming temperature too

hot.

• Cut down on the forming

temperature of the sheet.

• Pigment loading too low. • Increase pigment loading.

• Hot spots in forming oven. • Check out heating elements.

Webbing or bridging • Poor mold design or layout. • Redesign mold.

• Use plug assist or mechanical ring

to eliminate webbing.

• Add spacing blocks to take up

excess material.

• Increase draft or radii to webbed

area.

• Slow down the vacuum speed.

• Redesign ring or plug assist.

• If it is a multiple mold, increase the

spacing between parts.

• Wrong forming technique or

bad design on present

technique.

• Select a better forming technique.

• Make mold adjustments to the

current technique. Gussets, etc.

• Incorrect sheet temperature. • In billow forming, the corners of

the sheet may be too hot.

• In snapback forming, the corners of

the sheet may be too cold.

• Screen out appropriate areas of the

sheet.

• High sheet sag. • Cut down the heat of the sheet to

be formed.

• Select a resin with a lower melt

index.

• Vacuum rate too fast. • Slow down the vacuum rate.

• • Use smaller vacuum holes

• Restrict the vacuum flow with ball

or gate valves in the main vacuum

line.

• Insufficient vacuum. • Check the vacuum system for

leaks.

• Increase the number of vacuum

holes.

• Check to see if the vacuum holes

are plugged up.

• Check to see if the vacuum holes

are in the proper area.

TROUBLE-SHOOTING GUIDE

Description of Problem Possible Causes Possible Corrective Action

• Selectively increase the size of the

vacuum holes.

• Timing the billow in the

snapback box.

• Get a more sensitive flow valve.

• Put an electric eye in the snapback

box.

Sheet pulls out of clamp

frame.

• Clamp frames warped. • Put a piece of paper in the clamp

frame and see if you can pull it out

without tearing it.

• Clamping pressure too low. • Seals leaking on clamp frames.

• Air pressure to clamp frames

adjusted to low.

• High shrinkage in plastic

sheet.

• Put double-sided adhesive foam

tape with 40-grit emery paper on

the clamp frames.

• If possible, control the orientation

in the plastic sheet.

Lumps and bumps. • Contamination in the sheet. • Cut a cross section of the lump and

examine it to see if looks different

than the plastic matrix. If so, it is

an extruder issue.

• Incompatible plastic mixed

within the sheet.

• Check incompatible lump with an

IR test.

• Compare color of lump with the

rest of the matrix.

• Water droplets on hot plastic

sheet.

• Cut a cross section of the lump and

check for compatibility.

• Bump on the mold. • Look for a depression on the side

of the sheet touching the mold.

• Loose debris on the mold. • Look at the back of the formed part

for loose debris imbedded within

the part.

Texture washout. • Draw ratio of the part too

great.

• Consider a deeper texture.

• Plastic sheet heated too hot,

especially on the texture

side.

• Turn down the texture side heaters

in the oven.

• Cut down the heater cycle time.

• Cut down the overall heat on the

sheet.

• Shade out certain areas of the sheet

to keep it cooler and less

susceptible to thinning.

TROUBLE-SHOOTING GUIDE

Description of Problem Possible Causes Possible Corrective Action

Texture separation. • Texture too deep for starting

thickness of the sheet.

• Select a different texture.

• Texture has deep furrow

lines in a pattern.

• Select a different texture.

• The material you are using may

have poor hot strength and you

may need to select a different one.

• Excessive shrinkage in the

extruded sheet.

• Draw ratio pretty large, in

excess of 3 to 1.

• Select a tighter texture.

• Change the processing technique

for forming the part.

Sheet won’t fit into clamp

frame.

• Sheet not flat. • Place a weight on the bowed up

area along the clamp frame.

• Preheat sheet to remove stress.

Flow lines on part. • Nerve in the plastic sheet. • Rerun the sheet.

• Chatter due to sloppy chain

drive on the extruder.

• Run material on a good direct drive

extruder.

• Select a deeper texture.

• Melt index of resin erratic. • Blend resin more thoroughly.

• Die lines on the back of the

sheet.

• Rerun sheet.

• Run sheet from the oven at a lower

temperature.

• Select a deeper texture.

Blotchy look on the texture

side of amorphous materials.

• Excessive heat, especially

on PVC containing

materials.

• Cut down the forming temperature

heat.

• Select a better texture. Some hair

cell textures will do this in PVC

containing materials.

• High oven shrinkage. • Check shrinkage and keep within

acceptable limits.

Blotchy look on the texture

side of olefin materials.

• Poor mold contact. • Sandblast mold surface.

• Uneven cooling on the mold • Get a temperature-controlled mold.

• Check cooling lines for blockages.

TROUBLE-SHOOTING GUIDE

Description of Problem Possible Causes Possible Corrective Action

Inconsistent part. • Uneven heat on plastic

sheet.

• Check for air drafts in the heating

oven.

• Check the sheet for a variation in

gauge.

• Check for power output variations.

• Bad regrind in plastic sheet. • Do an IR or a Brabender test to

confirm compound consistency.

• Part too difficult for the

forming technique being

used.

• Change to a technique that is

suitable.

Warped parts. • Parts are cooling unevenly. • Use temperature controlled tooling.

• Check temperature controlled

tooling for water flow blockages.

• Check the material distribution on

the mold. Is the proper forming

technique being used?

• Check if the plastic sheet is being

pulled tightly against the mold.

Very important in forming the

olefins.

• Check cooling fans for proper

placement.

• Check for plugged vacuum holes.

• Mold too cold. • Preheat the mold.

• Clamp frames too cold. • Preheat the clamp frames. This is

especially important when forming

the olefins.

• Excessive gauge variation

on the finished part.

• Change forming technique to get

better material distribution.

• Insert screens in the oven to shade

out thinning areas.

• Gauge on flat sheet may be all over

the lot. Check various areas of the

sheet for gauge differences.

• Check for hot spots in the oven.

Do the thin spots occur on the

same spot consistently?

• Demolding temperature too

hot.

• Increase cooling cycle.

• Decrease mold temperature.

• Get more cooling fans cooling the

part.

• Overheated sheet. Material • Cut back on oven c

cle time or

TROUBLE-SHOOTING GUIDE

Description of Problem Possible Causes Possible Corrective Action

sagging too much. heat.

• Poor mold design. • Add a moat if you are dealing with

the olefins.

• Check for plugged vacuum holes.

• Add more vacuum holes.

• Use an alternate forming technique.

• Sandblast the mold in the case of

olefins.

• • Check mold for flexing during the

vacuum cycle.

• Poor part design. • Avoid large flat areas. Crown the

part if possible.

• Put in ribs or cosmetic designs in

the flat areas.

• Avoid severe draw ratios.

Poor detail on part. • Sheet too cold. • Increase heating time in oven.

• Increase heating element

temperature.

• Check oven for consistency.

• Check oven for drafts.

• Insufficient vacuum. • Check for leaks in the vacuum

system.

• Check to see if the system delivers

enough vacuum.

• Check to see if the mold is leaking

vacuum and/or sealing properly.

• Check to see if some vacuum holes

are clogged.

• Check to see if you have enough

vacuum holes.

• Check for the proper location of

the vacuum holes and are they the

proper size.

• Cold clamping frame. • Preheat the clamping frame to get a

better seal.

• Incorrect forming technique. • Change forming technique to best

suit the geometry of the part.

• Em

assist to

et better

TROUBLE-SHOOTING GUIDE

Description of Problem Possible Causes Possible Corrective Action

material distribution and vacuum

seal.

• Hot strength of material too

great.

• Select a material with less hot

strength.

• Use pressure-forming technique to

make the part.

• Plastic too thick in area with

poor detail.

• Use a different forming technique

to distribute the material better.

• Heat the area with the thick plastic

hotter.

Poor surface finish on part. • Mold surface too rough. • Polish mold surface to a smoother

finish.

• Sandblast the mold surface.

• Chill marks. • Get temperature controlled tool.

• Run current mold hotter.

• Change forming technique to

eliminate chill marks. Adjust

predraw depth.

• Draft angle too severe. • Add more draft to the part.

• Mold surface creates too

much drag.

• Polish mold in selected areas.

• Apply mold release sparingly in

selective areas.

• Air entrapment between the

mold and formed part.

• Add more vacuum holes to the

affected area.

• Sandblast mold surface.

• Dirty sheet. • Clean sheet with isopropyl alcohol

or deionizing airgun.

• Dirty mold. • Clean mold off with airgun or

mechanical means.

• Dirt and debris in the

atmosphere.

• Put in filtering system.

• Clean up the thermoforming area

thoroughly.

• Isolate the thermoforming area.

• Contaminated sheet. • Wipe sheet off before putting it in

the thermoformer.

• Separate sheet out that has

contaminates imbedded into it.

• Voids. • Cull out affected sheets where

possible.

• Scratched surface on sheet. • Interleaf sheet. Handle sheet

carefully.

TROUBLE-SHOOTING GUIDE

Description of Problem Possible Causes Possible Corrective Action

• Avoid dragging the corner of the

sheet across the surface of the

textured side.

• Streaks. • Examine what you are cleaning the

sheet with before putting it into the

thermoformer.

• Undispersed pigment in the sheet.

• Poor mixing during extrusion.

Rerun the material.

• Dirty embossing roll during the

extrusion process. Clean the

texture roll.

• Dust and dirt in the

atmosphere.

• Keep the thermoforming area

clean. Put in a filter system if

necessary.

Chill marks. • Mold temperature too low.

Material freezes onto the

mold when it touches it.

• Increase the mold temperature.

• The radius on the part is too

small.

• Redesign the part to accommodate

a larger radius.

• Wrong forming technique is

being used.

• Change the forming technique to

an appropriate one.

• Insufficient draft angle on

the part.

• Increase the draft angle.

• Plug temperature too low. • Increase the plug temperature.

• Cover the plug with an insulative

material.

• Use an insulating material to make

the plug.

• Sheet too hot. • Cut down the oven temperature.

• Reduce the heating cycle.

Dimples on mold side of parts. • Vacuum holes too large. • Decrease vacuum-hole size.

• Sheet too hot. • Reduce the heating cycle or cut

down the oven temperature.

• Dirt or debris on the mold

surfaces.

• Clean the mold frequently during

the forming operation.

• Vacuum rate is too high. • Cut down the vacuum volume.

Color loss or stress whitening

or blushing.

• Sheet too cold. • Heat sheet to a higher temperature

before forming.

• Sheet too hot. • Cut back on heating cycle to

prevent discoloration.

TROUBLE-SHOOTING GUIDE

Description of Problem Possible Causes Possible Corrective Action

• Reduce the temperature of the

heaters to prevent surface

scorching.

• Reduce the distance the heaters are

in relation to the sheet being

heated.

• Part too thin. • Increase the thickness of the sheet.

• Change the forming technique to

improve the part thickness.

• Shade the oven or turn down the

element temperatures in the area

the part is thinning.

• Mold too cold. • Increase mold temperature.

• Poor mold design. • Change draft angles.

• Increase radii.

• Change mold geometry to reduce

the draw ratio.

Poor material distribution

and/or excessive thinning in

specific areas.

• Uneven heating of the sheet. • Check the heaters to see if they are

set properly.

• Check for faulty heaters.

• Check for drafts or air currents in

the oven.

• Shade oven if element zoning is

not possible.

• Check to see if the elements are too

close to the plastic.

• Excessive gauge variation in

the sheet.

• Check the gauge of the sheet.

• Cold mold. • Increase the mold temperature.

• Check the mold for plugged water

lines.

• Excessive sag. • Cut down sheet temperature.

• Use zone heating to cut down

temperature in the center of the

sheet.

TROUBLE-SHOOTING GUIDE

Description of Problem Possible Causes Possible Corrective Action

Shiny streaks on part. • Sheet too hot in certain

spots.

• Control the heat in the hot zone of

the sheet by cutting down the

element temperature in the specific

area.

• Increase the distance between the

heater and the sheet.

• Screen the entire oven to dissipate

the heat more evenly.

• Check the unformed plastic sheet

for shiny spots.

Thin corners on the formed

part.

• Sheet too thin. • Use heavier gauged sheet.

• Poor material distribution. • Reduce sheet forming temperature.

• Change forming technique to get

better sheet distribution.

• Change from female to male mold.

• Sheet temperature too high

at the corners.

• Use screening or control the

temperature of the heating zones.

Excessive shrinkage after part

is removed from the mold.

• Inadequate cooling. • Increase cooling cycle time.

• Reduce the mold temperature.

• Employ better cooling fans.

• Place cooling fans in more logistic

places.

• Use cooling fixtures.

Shrink marks on formed part. • Poor seal edge on the mold. • Repair or improve the seal edge.

• Put in a moat on the mold.

• Mold surface too smooth. • Put as sandblast finish on the mold.

• Inadequate vacuum. • Check mold and vacuum system

for leaks.

• Increase vacuum capacity.

• Check for plugged vacuum holes.

• Add vacuum holes or increase the

size as appropriate.

Difficult to remove part off

the mold.

• Insufficient draft on a male

mold.

• Increase draft.

• Remove the part from the mold as

hot as possible without warping it.

• Male mold temperature too

cold.

• Increase the mold temperature to

keep the part from cooling too

much.

• Mold surface too rough for

the draft angle.

• Smooth out the mold in the areas

that are locking on.

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