Understanding the Benefits of Upgrading to a 50mm Sumitomo Free Flow Tip Assembly
- megan15067
- 1 hour ago
- 4 min read
www.completeplastics.com, sales@completeplastics.com, 770-417-6983.. Injection molding machines rely heavily on precise components to maintain efficiency, quality, and durability. One such critical component is the barrel and tip assembly. For operators using Sumitomo (SHI) Demag all-electric and hybrid injection molding machines, upgrading to a 50mm Sumitomo free flow tip assembly can bring noticeable improvements. This post explores why this upgrade matters, the technical details behind it, and how it fits into your molding operations.
Understanding the Benefits of Upgrading to a 50mm Sumitomo Free Flow Tip Assembly
The 50mm diameter barrel is a common size for mid-range Sumitomo injection molding machines, especially those in the 180 to 200+ ton range. This size strikes a balance between shot capacity and machine footprint, making it ideal for a wide range of molding applications.
Shot size compatibility: Machines like the SE180EV-A can handle shot sizes up to 10.7 ounces with this barrel diameter.
Versatility: The 50mm barrel fits several machine series, including SE-EV-A, SE-HSZ (high-speed), and legacy models like SE-D and SE-DU.
Vertical molding: The SV-M series vertical machines also use this barrel size for insert molding tasks.
Understanding the Benefits of Upgrading to a 50mm Sumitomo Free Flow Tip Assembly - The 50mm diameter is not just about size; it influences the plasticizing efficiency and the quality of the molded parts.
Key Features of the Free Flow Tip Assembly
The free flow tip assembly is designed to improve material flow at the nozzle, reducing back pressure and shear stress on the molten plastic. This leads to several benefits:
Improved melt stability: The 30-degree tip angle helps maintain consistent flow, reducing the risk of burn marks or degradation.
Reduced shear heat: By minimizing resistance, the assembly lowers shear-generated heat, preserving material properties.
Better shot-to-shot consistency: Consistent flow means more uniform parts, reducing scrap rates.
The length of the tip assembly, at 6.92 inches, complements the 49.86-inch barrel length to maintain the proper L/D ratio and ensure smooth plasticizing.
Compatible Machine Series and Their Applications
Understanding which machines use the 50mm barrel and free flow tip assembly helps in selecting the right replacement or upgrade part.
SE-EV-A Series: These all-electric machines, such as the SE180EV-A, are known for energy efficiency and precision. The 50mm barrel supports larger shot sizes and high-performance molding.
SE-HSZ Series: High-speed machines in this series, with tonnages from 242 to 385, benefit from the free flow tip to handle demanding injection speeds and pressures.
Legacy Models (SE-D, SE-DU, SE-S): Older machines still widely used in many plants often feature this barrel size, making the free flow tip assembly a direct replacement part.
SV-M Series (Vertical): Vertical machines designed for insert molding use the 50mm barrel to maintain consistent flow and reduce cycle times.
Knowing your machine’s model number, such as SE180 or SE220, is essential for confirming compatibility before ordering.
Technical Context: L/D Ratio and Plasticizing System
The length-to-diameter (L/D) ratio is a critical factor in injection molding performance. For a 50mm diameter barrel with a length of approximately 49.86 inches (about 1270mm), the L/D ratio typically falls between 20:1 and 25:1. This ratio is standard for Sumitomo’s high-performance plasticizing units.
Why L/D ratio matters: A higher L/D ratio allows better melting and mixing of the plastic material, improving part quality.
Plasticizing system: Sumitomo’s SL (Spiral Logic) screw assembly often pairs with these barrels. The SL screw reduces shear heat and improves melt homogeneity, which complements the free flow tip’s function.
Together, these features ensure that the machine can handle a wide range of materials and maintain consistent output.
Practical Benefits of Upgrading
Upgrading to a 50mm Sumitomo free flow tip assembly offers several practical advantages for injection molding operations:
Extended barrel life: The free flow design reduces wear caused by high shear and pressure.
Energy savings: Lower back pressure means the machine uses less energy during injection.
Improved part quality: Consistent melt flow reduces defects like short shots, burn marks, and warping.
Reduced maintenance downtime: Better flow reduces the risk of clogging and barrel damage, minimizing machine downtime.
Compatibility with existing machines: The assembly fits a wide range of Sumitomo models, making it a straightforward upgrade.
For example, a molding plant running SE180EV-A machines reported a 15% reduction in scrap rates after switching to the free flow tip assembly, thanks to improved melt consistency.
How to Choose the Right Assembly
Before upgrading, verify your machine’s model and specifications:
Check the machine ID plate for model numbers like SE180, SE220, or others.
Confirm the barrel diameter and length match the 50mm and approximately 50-inch length.
Contact suppliers such as Complete Plastics (sales@completeplastics.com, 770-417-6983) for part confirmation and ordering.
Knowing these details ensures you get the correct assembly that fits your machine and meets your production needs.
Installation and Maintenance Tips
Proper installation and maintenance maximize the benefits of the free flow tip assembly:
Installation: Follow Sumitomo’s guidelines or consult with a qualified technician to ensure correct alignment and torque settings.
Regular inspection: Check for wear or damage on the tip and barrel surfaces during scheduled maintenance.
Cleaning: Use recommended cleaning agents and avoid abrasive tools that can damage the assembly.
Monitor performance: Track shot consistency and cycle times to detect early signs of wear or flow issues.
Routine care extends the life of the assembly and maintains molding quality.
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