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Stage 2
The Injection Moulding machine consists of a hollow steel barrel, containing a rotating screw (Archemidial Screw). The screw carries the plastic along the barrel to the mould. Heaters surround the barrel melt the plastic as it travels along the barrel
Stage 3
The screw is forced back as the melted plastic collects at the end of the barrel. Once enough plastic has collected a hydraulic ram pushes the screw forward injecting the plastic through a sprue into a mould cavity.The mould is warmed before injecting and the plastic is injected quickly to prevent it from hardening before the mould is full.
Stage 4
Pressure is maintained for a short time (dwell time) to prevent the material creeping back during setting (hardening). This prevents shrinkage and hollows, therefore giving a better quality product.The moulding is left to cool before removing (ejected) from the mould. The moulding takes on the shape of the mould cavity.
Depending on material to be injected 1.Termoplastic injection molds 2.Elastomer molds 3.Thermoset molds 4.Structural foam molds Polyethylene Low Density (LDPE, LLDPE), Polypropylene (PP), Polyethylene Terephthalate (PET), Polyvinyl chloride (PVC),Polyethylene High Density (HDPE)
Split Mould
Stacked Mould
PLASTIC PRODUCT
The Factors to be considered for the Design of a Plastic Product are: Properties of the Plastic Material. Proposed function of the Product Method of Manufacture Factors to decide the type of Moulding operation are: Type of Plastic Material Shape and Size of the Product The Moulding Processes are classified as: Operation involves : Physical changes only Chemical changes only Injection Moulding Casting of Monomers Blow Moulding Both Physical and Chemical change Compression or Transfer Moulding
Production Volume (requirement in time) Estimated Moulding Cycle (Cycle time) Is the Drawing clear ? Projection 1st angle, 3rd angle Tolerances Notes on Drawing Draft angle, etc. End use requirement Moulding Material Shrinkage
Locating Ring
Sprue Bush
Mould Temperature
Density of the Material Bulk Factor of the Material
Shot Capacity
Plasticizing Capacity
Layout of Cavities:
For efficient and Economical Layout the following points to be considered during Layout of the Cavities.
Fill all the cavities with required pressure and temperature. Balanced Layout
Attain uniform clamping Prevent local flashing of the mould.
LAYOUT OF CAVITIES
A> B =
(a2 + 2b ) 2
a2 + 1.656ab
(a)Runner Design
The designer should keep in mind the following points during design of runner. Shape and Cross section of the runner
Size of the runner Layout of the runner
Hexagonal
Square Rectangular
b) Trapezoidal
c) Modified Trapezoidal
d) Hexagonal
Runner layout
GATE DESIGN Gate is a small channel that connects the cavity with the runner. A small gate is desired so that :
The gate freezes soon after the cavity filled The injection plunger can be withdrawn immediately without forming voids due to suck-back. It is easy for degating Small witness mark remains on the product Better filling of cavities in multi-impression mould. More packing of material due to shrinkage effect is minimised.
Types of gate
Direct sprue gate
Pin point gate Rectangular Edge gate
Fan gate
Diaphragm gate Ring gate Film gate Sub-surface or submarine or Tunnel gate.
problems in the product such as: Axial and Radial Eccentricity Angular deviation Warpage
O Ring
Flow pattern used on a deep cavity block with the channels running length wise
Baffle Cooling
Ejection System
The ejection system in a mould should be:
Positive in action No ejection mark will be seen on the product No defects on the product (i.e distortion, flash, witness mark)
Types of ejection :
Pin ejection ( Round Pin, D-Pin ) Blade ejection Stripper ejection ( Stripper plate, Stripper Ring ) Sleeve ejection Air ejection ( Valve ejection )
VENTING OF RUNNER
Parting Surface
The parting surfaces are that part of the surface where surface of the core and cavity of a mould are matched perfectly to remove the chance of flash. Parting Line: It is the line which can be seen in the component due to the matching of core and cavity. Types of Parting surface a) Flat Parting Surface b) Non Flat Parting Surface
a)
Surface,the parting lines lies in one plane as per the selection of the parting surface
b)
In this case the parting lines lies on curved surface and is not in a plane.
Types:
Stepped Parting Surface: This type of parting surface is generally in the shape of a step.
Irregular or Profile Parting Surface: In this type the surface is irregular profile in shape. Angled Parting Surface: The parting surface is selected for easy ejection of the component. Complex Edge Parting Surface: It is a spoon type of component in which there is no constant edge. In this type of surface, the parting line is also not in the same plane.
STEPPED SURFACE
PROFILE SURFACE
ANGLED SURFACE
Mould Alignment
Locating Ring: It is circular member fitted at the top of
the mould to locate the mould with the machine. This part is used for the alignment of mould to machine. Locating ring is used in the injection mould to maintain the mould axes and the axes of machine in one line.
Types
Constant Diameter type: In this type of locating ring, the diameter of ring is constant throughout the depth which is fixed with front face of the mould by using socket headed screw. 2. Reduced Diameter Type: In this type the platen hole diameter is less compared to mould recess diameter. 3. Increased Diameter Type :In this type the platen hole diameter is more when compared to mould recess diameter. 4. Increased Depth type: It is identical to increased depth type expect the depth of the mould fitting diameter which is increased to accommodate insulated metal sheet adjacent too the front plate.
1.