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SPLIT MOULD
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SPLIT MOULD
It is required for components incorporates a recess or projection right angle to the line of draw, to relieve the undercut before the moulding is removed. A moulding which has a recess or projection is termed as undercut moulding. The undercut may be external, internal, local part of the component.
Two or more parts of the cavity closed together in a chase bolster by using locking heels during injection.
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Fig: 1.1
Fig: 1.2
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SLIDING SPLITS
The splits are positioned in guides on a flat mould plate are actuated by mechanical or hydraulic system and those are held together by locking heels which project on the other mould half.
The splits are possible to mount on either the moving or fixed mould plate.
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Fig: 1.3
Fig: 1.4
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Fig: 1.5
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Fig: 1.6
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Fig: 1.7
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Fig: 1.8
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Whether the available machines are programmed for ancillary cylinder control.
Whether molding inserts are to be incorporated.
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5. Angled-lift splits
6. Spring actuation system
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Fig: 1.9
Fig: 1.10
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Length and angle of the finger cam determine the distance traversed by each split across the face of the mould plate.
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Fig: 1.11
M = splits movement = Angle of finger cam, 10-25 L = working length of finger cam C = clearance (0.75mm)
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CALCULATION
The finger cam movement can be computed by the Formula M = (L sin ) (C / cos ) If the required movement is known, the following formula used to determine the finger cam length. L = (M / sin ) + (2C / sin 2) Where, M = splits movements, = Angle of finger cam, 10-25 L = working length of finger cam C = clearance (0.75mm) Cam diameter is usually 13 mm.
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DOG-LEG CAM
Fig: 1.12
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Fig: 1.13
Fig: 1.14
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M = movement of each split, La= angled length of cam, Ls = straight length of cam, = Cam angle, C = clearance, D = delay, e = length of straight portion of the hole.
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CALCULATION
Formula for calculating the opening movement, the length of cam, and the delay period M = La tan - C La = (M + C)/ tan D = (Ls e) + (C/tan ) Where M = movement of each split, La= angled length of cam, Ls = straight length of cam, = Cam angle, C = clearance, D = delay, e = length of straight portion of the hole.
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Due to external fitment of cam track the mold actuation system becomes simpler and mold cost is reduced.
The cam track is machined into a steel plate attached to the fixed mould half. A boss fitted to both sides of the split runs in this cam track. The movement of the splits accurately controlled by specific cam track design .
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Fig: 1.16
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Fig: 1.17
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Fig: 1.18
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Fig: 1.19
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CAM TRACK
M = movement of each split, La= angled length of cam track, = cam track angle, C = clearance, D = delay, R = radius of boss
Fig: 1.20
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CALCULATION
M = La tan - C La = (M + C) / tan D = Ls + C/ tan + r ( 1/tan - 1/sin ) M = movement of each split, La= angled length of cam track, = cam track angle, C = clearance, D = delay, R = radius of boss
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4. HYDRAULIC ACTUATION
The splits are actuated by hydraulic system. It is independently opening movement of the mould. The splits can be operated automatically at any specific time by the operating program of the machine ADVANTAGES
Cycle time less Large delay movements and large split movements can be achieved
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DISADVANTAGES
The mould is more bulky as compared with the other designs Mould setting more difficult and the hydraulic system has to be connected each time the mould is set up.
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Fig: 1.21
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ANGLED-LIFT SPLITS
In this method the splits are mounted in a chasebolster, which forms part of the moving half of the mould. The splits are moving outward with an angular motion which relieve the undercut portion of the molding and retraction of the split alignment is controlled by using spring actuation or cam track actuation
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Fig: 1.22
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Fig: 1.23
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Fig: 1.24
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The convenient angle for the guide dowel is 10 it may be increased if large opening movement is required. The actual opening movement of each split calculated by the following formula. M = E tan E = effective ejector plate movement, = Guide dowel angle.
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Fig: 1.26
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CALCULATION
The opening movement of each split calculating by M = E tan E = effective ejector plate movement, = Cam track angle, usually 15
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SPRING ACTUATION
The opening movement of the split depends on the slot provided in the chase bolster and the spring effective expansion length. This ejection method is suitable for shallow undercut components. The ejector pin actuates the split, the spring exerts the a force to vertical direction, which maintains contact between the split and the angled wall of the chase-bolster and gives angled movement to the splits. Thus the splits get open.
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Fig: 1.27
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SPRING ACTUATION
Fig: 1.28
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SEQUENCE OF OPERATION
The chase bolster holds the splits during the injection phase. The compression springs exerts a force to split halves immediately when the mould starts to open.
The stud reaching the end of the slot in the mould plate stops the split movement.
Continued movement of the moving mould half operated the ejector system to release the molding . 45
CALCULATION
The formula for calculating the splits opening movement is M = H tan Where M = movement of each split, Approximately H = height of locking heel = angle of locking heel Suitable angle for the locking heel is 20 to 25.
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SIDE CORES
It is a local core mounted at an angle to the mould axis for forming a hole or recess inside the molding. This side core prevents the in-line removal of the molding hence, side core must be withdrawn prior to ejection .
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The dog-leg cam actuation method The spring-loaded system External Side Core Assembly Side cores on the parting surface
Side cores below the parting surface
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Fig: 1.29
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Fig: 1.30
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Fig: 1.31
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INTERNAL UNDERCUT
An internal undercut is the internal protrusion or recess formed in the molding by using matching core or cavity.
It is prevents a moulding from being extracted from the core in line of draw.
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Fig: 2.1
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Fig: 2.2
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FORM PIN
A component, which has a local undercut portion, can be successfully moulded in the conventional mould by incorporating the undercut form on a pin.
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Fig: 2.3
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This design is normally used for components, which incorporate an undercut on one internal wall only.
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Fig: 2.4
Fig: 2.5
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Fig: 2.6
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CALCULATION
The amount of withdrawal is calculated by the following relationship: M = E tan Where, M = the withdrawing movement E = ejection movement. = fitting angle of the form pin.
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Fig: 2.7
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Fig: 2.8
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Fig: 2.9
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Fig: 1.32
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TYPES OF THREADS
External thread.
Internal thread.
According to thread shape subdivided into continues and discontinuous thread.
Fig: 3.1
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Fig: 3.2
Fig: 3.3
Fig: 3.4
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Fig: 3.5
Fig: 3.6
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ADVAMTAGES
Mould cost is cheaper than the unscrewing mould design because of its require ejector mechanism
Maintenance cost is minimum as there are no moving parts within the mould. DISADVANTAGES This design particularly used for multi-impression moulds where the individual moldings to be unscrewed manually. Increases the moulding cycle time.
This method is suitable for a large component incorporates a local internally threaded hole or has several internally threaded holes in close proximity to each other. Prevents automatic unscrewing thereby considerably reducing the cost of the mould. Where a number of holes are closely spaced, automatic unscrewing becomes impracticable. Because it require space for gear arrangement in automatic unscrewing operation.
Fig: 3.7
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COLLAPSIBLE CORE
This design is suitable for components having internal thread and internal undercut.
The important advantage of this method over the rotating threaded core designs is that it eliminates the need for complex unscrewing mechanism.
COLLAPSIBLE CORE
Fig: 3.8
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Fig: 3.9
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UNSCREWING MOULDS
High labour costs and other modern production requirements demand the maximum use of automatic operation. In an unscrewing type mould either the cores or the cavities are rotated to automatically unscrew the moldings from the mould. To provide the required rotary motion an unscrewing unit is fitted behind the moving mould plate in place of the conventional ejector unit
POINTS CONSIDERED
In the axially fixed core design, the threaded core is merely rotated to remove the moulding. In the extractor plate design, the extractor plate is actuated at the same time as the threaded core is rotated to remove the moulding. In the withdrawing rotating core design, the threaded core is rotated by sun & planet gear mechanism and withdraws the moulding from the core plate.
IMPRESSION LAYOUTS
1. The pitch circle diameter .
2. The In-line layout.
Fig: 3.13
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MULTIDAYLIGHT MOULD
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MULTIDAYLIGHT MOULD
It is a complex mould having more than one-daylight when the mould is opened. It consists of three main parts:
Fixed mould plate or feed plate, Floating cavity plate or stripper plate, Moving mould plate.
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These types of ejection will not leave any depression on the molding.
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The moulding and feed system are removed in the first day light between the stripper plate and the fixed mould plate from the cavity plate. Second daylight between the core plate and stripper plate for ejection.
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Fig: 4.1
Fig: 4.2
Fig: 4.3
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Fig: 4.4
Fig: 4.5
Fig: 4.6
Fig: 4.7
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Fig: 4.8
Fig: 4.9
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Fig: 4.10
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This mould is mostly prepared for multi impression circular cap components. It is the combination of stripper plate and under-feed system.
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Fig: 4.11
Fig: 4.12
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Fig: 4.13
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Fig: 4.14
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Drawback of this method: the feed system is not free to fall when the mould is opened because the secondary sprues are retained within the floating cavity plate. The feed system is removed by hand if the basic underfeed mould design is used.
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Fig: 4.15
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Fig: 4.17
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DESIGN CONSIDERATION
The float period must be sufficient to permit the floating cavity plate to clear the reverse-tapered sprues before the puller pulls the sprue. Considerable runner deflection is necessary to ensure that the secondary sprues are not pulled back into their holes when the puller is actuated. To ensure that the puller is pushed back to its moulding position when the mould is closed, the diameter of the puller must exceed the width of the runner.
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RUNNER STRIPPER PLATE The fixed secondary puller is fitted directly below each secondary sprue.
To release the feed system from this fixed secondary puller a runner stripper plate is introduced between the feed plate and the floating cavity plate.
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Fig: 4.18
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UNDERFEED MOULD
Fig: 4.19
Fig: 4.20
Fig: 4.21
Fig: 4.22
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STACK MOULD
When two injection moulds are operated in tendem in the same molding machine it is called stack mould.
Used for molding shallow, small parts in large quantities like tape cassettes. The cavities are located in two planes corresponding to two parting lines and are filled. The clamping force required is 15% higher than a standard mould. 126
It is a simplest mould design, from a runner point of view is a single-cavity, single-face mold arranged in back to back configuration of same impression or different impressions. The machine nozzle injects plastic directly into the mould cavity. The single-face mould can also be extended to a multi-cavity layout. The machine nozzle injects the melt into a runner system that feeds each individual cavity.
It is suitable of which has the thin-wall injection molding with hot runner designs.
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Fig: 4.23
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Fig: 4.24
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1. 2.
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The four-face stack mold is two stack molds placed back to back and it increases the mold shut height. It operates in the same molding machine as a conventional slack mold. Cycle limes identical to those of a conventional mold. Shot-to-shot changeover time of less than one hour required for both mechanically and air ejected parts in the stack mold. Machine shut height remains the same from one product to the next.
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The three-level stack mold uses triple valueless melt transfer system (VMTS) crossover nozzles to provide equal pressure and flow characteristics to the plastic melt to each cavity. This stack mold configuration fills in when a two-level mold cannot produce enough pans and a four-level mold is too large for the machine. Three-level stacks is used to mold both shallow draw (for example, packaging lids) and deep draw pans (such as tall containers). They can be combined with quick-change systems to give added flexibility to high-production tooling.
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The runner is cooled and ejected with the part. Every cycle, a part and a runner are produced. There are two major types of cold runner molds: Two plate and Three-plate mould.
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Mold requires less maintenance. The mold design is very simple and much cheaper than a hot runner system. Less skill to set up and operate. Color changes are also very easy, since all of the plastic in the mold is ejected with each cycle.
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The waste plastic is generated. The runners are either disposed of or reground and reprocessed with the original material. This adds a step in the manufacturing process. Regrinding increases variation in the injection molding process, and decreases the plastic's mechanical properties.
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The hot runner mould contains a heated runner manifold block, insulated from the rest of the mould keeps the runner permanently melt. The hot runner mould replaces the conventional sprue bushing with a hot sprue bushing or a heated nozzle.
The polymer material directed to the mould cavities without heat loss and pressure loss. Large moulding like automotive dash board, bumpers, computer housing, multi colour moulding etc. are produced in this process.
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Hot runner mould section view TRAINING Fig: 5.2 CORPORATE AND
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Fig: 5.4
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. Sufficient heat energy must be supplied to the hotrunner unit it replaces conduction, convection and radiation heat losses. To ensure that the temperature of the melt in the flowway is maintained without either hot or cold regions, careful location of the heating elements is essential. Considerable production time may be lost if a heater fails. Thought must be given therefore to choice of heating element; its location and the facilities for. removing it.
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The layout of the wiring system should be neat and easily traceable.
Heating element wires, which are subject to, heat or abrasion attack should be protected.
Use manufacturers recommended clearances when fitting heating elements of the cartridge type. Flat-type heating elements and induction heating elements should be completely enclosed within the unit for maximum efficiency.
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The hot-runner unit must be insulated from the rest of the mould structure. For many materials, close control of the temperature of the melt is vital. Hence Careful consideration to be made for the location of thermocouples. To minimize degradation, color-changing and material-changing problems the melt flow-way must be as streamlined as possible, without sharp corners, ledges or other stagnation points which tend to hold back the polymer melt for extended periods.
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Fig:5.5
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Fig:5.6
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Fig:5.7 Fig:5.8
Fig:5.8
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Fig:5.9
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THE MELT-FLOW-WAY
Fig: 5.10
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RUNNER PLUG
It is made from stainless steel for plugs in the flow path of hot runner system to direct the plasticized materials. It has larger thermal expansion than the manifold material. As the manifold is heated to operating temperature, the stainless plugs will expand at a greater rate making the possibility of leakage impossible.
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TYPES OF NOZZLES
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1.EXTENDED NOZZLE
On the extended nozzle a resistance type band heater is provided which is controlled by means of thermocouple. To minimize the transfer of heat from the heated nozzle to the mould, a circumferential clearance of at least 7mm must be provided between the two parts. The main advantage of this nozzle is to minimize the length of the sprue gate as short as possible.
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Fig:5.11
EXTENDED NOZZLE
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2.BARB NOZZLE
This type of nozzle is used to minimize the blemish on the component at the gate point. The plastic material flows through to the nozzle, sprue and gate. After solidification, the sprue is pulled from the sprue bush by the barb of the nozzle.
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3.ANTECHAMBER NOZZLE
It is termed as hot well design, a small mass of plastic material is retained in the antechamber which insulates the central core of plastic material. The plastic material remains fluid to allow it to pass intermittently through the antechamber into the impression.
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INSERT
ANTECHAMBER
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In this type of mould the melt flows from standard or extended nozzle into a large diameter runner via the reverse taper sprue and gate. The outer layer of the melt solidifies against the cold runner wall which forms an insulating shell, while the centre core of the material retain in the molten state.
The outer layer of runner acts as an insulating media and avoids heat loss from the polymer melt to the mould.
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EXPANSION PROBLEMS
The hot-runner unit mould is that metals expand when heated. The manifold block increases in all three dimensions when the temperature is increased. The distance between the centers of the secondary nozzles increases with respect to the fixed distance between the centers of the impressions machined in the cavity plate. When designing the hot-runner mould, allowance must be made for this expansion to ensure that the centerlines are in line during production
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EXPANSION PROBLEMS
Fig:5.15
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NOZZLE LENGTH 48 mm 68 mm
The equation for calculating expansion is as follows: e=L X X T Where e = expansion (mm or in) L = length dimension (mm or in) = Coefficient of thermal expansion (mm/mm C or in / inC) T = increase in temperature ( C)
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