Documente Academic
Documente Profesional
Documente Cultură
U KAS
QUALITY
MANAGEMENT
ISO 9001
006
Types of Moulds
CAD/CAM/CAE
BVQi
U KAS
QUALITY
MANAGEMENT
ISO 9001
006
Injection Moulds
The molds consist of two main parts: the cavity and core. The core
forms the main internal surfaces of the part. The cavity forms the
major external surfaces of the part. Typically, the core and cavity
separate as the mold opens, so that the part can be removed. This mold
separation occurs along the interface known as the parting line.
An injection mold is usually made in two halves or sections and held
together in the closed position by the molding press. The mold is
generally made out of tool steel and is provided with channels for
cooling, heating and venting, Ejector pins and other devices may be
incorporated.
CAD/CAM/CAE
BVQi
U KAS
QUALITY
MANAGEMENT
ISO 9001
006
Types of Moulds
1.Two Plate Mould
2.Three Plate Mould
3.Multi-daylight mould
4.Stack Mould
5.Runnerless Mould
6.Insulated Hot Runner Mould
7.Split Mould
CAD/CAM/CAE
BVQi
U KAS
QUALITY
MANAGEMENT
ISO 9001
006
CAD/CAM/CAE
BVQi
U KAS
QUALITY
MANAGEMENT
ISO 9001
006
CAD/CAM/CAE
BVQi
U KAS
QUALITY
MANAGEMENT
ISO 9001
006
Advantage
1.Simplicity of design
2.Utilization of standard mould parts
3.The cheapest design
Disadvantage
1.Limitations in component gate positioning when conventionally
feeding
2.Lack of available space for balanced feeding of multiple cavities
3.High material waste level(Sprues and runners).
CAD/CAM/CAE
BVQi
U KAS
QUALITY
MANAGEMENT
ISO 9001
006
CAD/CAM/CAE
BVQi
U KAS
QUALITY
MANAGEMENT
ISO 9001
006
ISO 9001
006
ISO 9001
006
Multi-daylight mould
The basic mould consist of two half, when these two half's are opened the
moldings can be extracted.The space between the mould plates is termed
as Daylight.
A mould in which more than one daylight occurs when it is opened.This
term refers to underfeed mould.
In stripper plate mould, it consists of three plates namely, fixed mould
plate, a moving mould plate and a stripper plate.When the mould is fully
opened there are two daylights.The molding and feed system are removed
from the first daylight, that is from between the striper plate and the fixed
mould plate.
CAD/CAM/CAE
BVQi
U KAS
Stack Mould
QUALITY
MANAGEMENT
ISO 9001
006
ISO 9001
006
Runnerless mould
In this process of injection molding, the runners are kept hot in order
to keep the molten plastic in a fluid state at all times. In effect this is a
"runnerless" molding process and is sometimes called the same. In
runnerless molds, the runner is contained in a plate of its own.
Hot runner molds are similar to three-plate injection molds, except
that the runner section of the mold is not opened during the molding
cycle.
The heated runner plate is insulated from the rest of the cooled mold.
Other than the heated plate for the runner, the remainder of the mold
is a standard two-plate die
CAD/CAM/CAE
BVQi
U KAS
QUALITY
MANAGEMENT
ISO 9001
006
CAD/CAM/CAE
BVQi
U KAS
QUALITY
MANAGEMENT
ISO 9001
006
Advantage
1.Reduced cycle time as a result of having a component cooling
requirement only.The runner and feed system remain molten above the
quickly frozen gate.
2.Material savings results from having no sprue or runner systems to
granulate.
3.Labor and post molding finishing costs are significantly reduced
without the need for degating of the moldings.
4.The ability to gain greater control over the mould filling and flow
characteristics of the molten polymer during the filling phase of the
molding cycle.
CAD/CAM/CAE
BVQi
U KAS
QUALITY
MANAGEMENT
ISO 9001
006
CAD/CAM/CAE
BVQi
U KAS
QUALITY
MANAGEMENT
ISO 9001
006
CAD/CAM/CAE
BVQi
U KAS
QUALITY
MANAGEMENT
ISO 9001
006
Advantages
1.The feed system can easily be stripped and cleaned,resulting in very
little material or color contamination occurring.
2.Mould start-up times are faster when compared to other hot runner
mould systems.
3.Moulds are very much cheaper to manufacture than the other hot
runner mould designs
4.Thermally unstable polymers may be processed using such a system.
CAD/CAM/CAE
BVQi
U KAS
QUALITY
MANAGEMENT
ISO 9001
006
Split Moulds
A mould in which the cavity is formed by two or more parts held
together by a chase bolster during the injection phase.
A two or more steel blocks containing the impression which can be
opened, normally at right angles to the moulds axis, to facilitate the
molding of external undercut type comments.
In Split mould, i )guiding the splits in the desired direction ii)
Actuating the splits and iii ) securely locking the splits in position
prior to the material being injected into the mold.
CAD/CAM/CAE
BVQi
U KAS
QUALITY
MANAGEMENT
ISO 9001
006
There are three main factors in the design of the guiding and
retention systems for a sliding splits type mould.
1.Side movement must be prevented to ensure that the split
halves always come together in the same place.
2.All parts of the guiding system must be of adequate strength to
support the weight of the splits and to withstand the force
applied to the splits by the operating mechanism.
3.Two split halves must have a smooth, unimpeded movement.
CAD/CAM/CAE
BVQi
U KAS
QUALITY
MANAGEMENT
ISO 9001
006
CAD/CAM/CAE
BVQi
U KAS
QUALITY
MANAGEMENT
ISO 9001
006
Undercut Moulds
A molding which has a recess or projection is termed an Undercut
molding.
External Undercut
Any recess or projection on the outside surface of the component
which prevents its removal from the cavity is termed an external
undercut.
CAD/CAM/CAE
BVQi
U KAS
QUALITY
MANAGEMENT
ISO 9001
006
CAD/CAM/CAE
BVQi
U KAS
QUALITY
MANAGEMENT
ISO 9001
006
CAD/CAM/CAE
BVQi
U KAS
QUALITY
MANAGEMENT
ISO 9001
006
Internal undercut
An internal undercut is any restriction which prevents molding from
being extracted from the core in line of draw.
The specific design adopted depends upon the shape and position of
the restriction.
A component which has a local undercut portion can be successfully
molded in the conventional mould by incorporating the undercut form
on a form pin.
A circular hardened steel pin which incorporates molding form and is
used for the molding of internal undercuts.It may have either a straight
or an angled action is termed as form pin.
CAD/CAM/CAE
BVQi
U KAS
QUALITY
MANAGEMENT
ISO 9001
006
CAD/CAM/CAE
BVQi
U KAS
QUALITY
MANAGEMENT
ISO 9001
006
Finger Cam
A hardened steel rod, fitted at an angle to the mold plate for the purpose of
operating splits and side cores.
The splits mounted in guides on the moving mould plate, have
corresponding angled circular holes to accommodate these finger cams.
CAD/CAM/CAE
BVQi
U KAS
QUALITY
MANAGEMENT
ISO 9001
006
CAD/CAM/CAE
BVQi
U KAS
QUALITY
MANAGEMENT
ISO 9001
006
CAD/CAM/CAE
BVQi
U KAS
QUALITY
MANAGEMENT
ISO 9001
006
The distance traversed by each split across the face of the mould plate is
determined by the length and angle of the finger cam.The movement can
be computer by the formula
M=(L sin) (c/cos)
As the required movement is known from the amount of component
undercut, the following rearranged formula to determine the finger cam
length is of greater use, apart from checking purposes
L=(M/sin) + (2c/sin2)
Where,
M= splits movement
= angle of finger cam
L=working length of finger cam
c =clearance
CAD/CAM/CAE
BVQi
U KAS
QUALITY
MANAGEMENT
ISO 9001
006
CAD/CAM/CAE
BVQi
U KAS
QUALITY
MANAGEMENT
ISO 9001
006
CAD/CAM/CAE
BVQi
U KAS
QUALITY
MANAGEMENT
ISO 9001
006
CAD/CAM/CAE
BVQi
U KAS
QUALITY
MANAGEMENT
ISO 9001
006
CAD/CAM/CAE
BVQi
U KAS
QUALITY
MANAGEMENT
ISO 9001
006
CAD/CAM/CAE
BVQi
U KAS
QUALITY
MANAGEMENT
ISO 9001
006
CAD/CAM/CAE
BVQi
U KAS
QUALITY
MANAGEMENT
ISO 9001
006
Spring actuation
In this design, which obviates the use of cams altogether, incorporates
compression springs to force the splits apart and utilizes the angled faces
of the chase bolster to close them.The outward splits movement must
therefore be limited so that they will re-enter the chase bolster as the
mould is closed.
The splits are mounted on the mold plate and retained by guide strips.
Studs project from the base of the splits into a slot machined in the mould
plate.
A compression spring is fitted between the studs in a link-shaped pocket
situated in the lower mould plate.
CAD/CAM/CAE
BVQi
U KAS
QUALITY
MANAGEMENT
ISO 9001
006
CAD/CAM/CAE
BVQi
U KAS
QUALITY
MANAGEMENT
ISO 9001
006
Hydraulic actuation
In this design the splits are actuated hydraulically and it is not
dependent on the opening movement of the mould.
The splits can be operated automatically at any specific time by
including this function in the operating programme of the machine.
On machines which do not programme for auxiliary cylinder control it
is necessary to add a separate hydraulic operating circuit to the existing
system.
CAD/CAM/CAE
BVQi
U KAS
QUALITY
MANAGEMENT
ISO 9001
006
CAD/CAM/CAE
BVQi
U KAS
QUALITY
MANAGEMENT
ISO 9001
006
Split core
A steel core manufactured in two or more parts to facilitate the
molding of internal undercut components.
The split core design is used for components which have extensive
internal undercuts that cannot be incorporated on a form pin.
The split core may be moved forward either in a straight plane or an
angled plane.
CAD/CAM/CAE
BVQi
U KAS
QUALITY
MANAGEMENT
ISO 9001
006
CAD/CAM/CAE
BVQi
U KAS
QUALITY
MANAGEMENT
ISO 9001
006
CAD/CAM/CAE
BVQi
U KAS
QUALITY
MANAGEMENT
ISO 9001
006
CAD/CAM/CAE
BVQi
U KAS
QUALITY
MANAGEMENT
ISO 9001
006
CAD/CAM/CAE
BVQi
U KAS
QUALITY
MANAGEMENT
ISO 9001
006
CAD/CAM/CAE
BVQi
U KAS
QUALITY
MANAGEMENT
ISO 9001
006
Advantage
The advantage of standard mould base can be broadly grouped into
three areas, for designers, manufacturers and customers.
Designers
Risk due to drawing errors are minimized
By adopting standardization, the draughtsman does only the
essential portion of the job i.e core and cavity profiles, ejection
location, gate & cooling details only.
A wide variety of mould drawings could be drawn in minimum
time without fatigue or repetitive drafting.
Mould parts could be easily numbered so that the batch production
in manufacturing will be easy.
CAD/CAM/CAE
BVQi
U KAS
QUALITY
MANAGEMENT
ISO 9001
006
Manufacturer
*The time spent on the manufacturing mould base can be utilized for
manufacturing core and cavity details so that the efficiency of the output
can be easily increased with the availability of manpower.
Machinist replace highly skilled mould makers
Duplication will be easy if required and consumes less time.
Better control on cost can be achieved on batch production techniques.
Interchangeability of parts will be easy.
Tool maintenance is reduced.
Customers
The delivery time can be easily reduced
The quality of the product can be assured
Total cost of the tool will be reduced.
CAD/CAM/CAE
BVQi
U KAS
QUALITY
MANAGEMENT
a)Rectangular cavity
The maximum deflection commonly allowed is 0.13-0.25mm depending upon
the size of the tool.Of this 0.1-0.2mm may be due to clearances between the
blocks of the built-up mould and elongation of the bolster or register faces.For
stress design purposes, therefore, a maximum deflection of 0.025-0.05mm is
usually take.The approximate thickness of the side wall required may be
calculated from the following formula:
t = 3( c.p.d4 / E. )
- Maximum deflection of side walls(cm)
c- Constant , t thickness of cavity wall (cm)
p- Maximum cavity pressure(say 630 Kg/cm2)
d- Total depth of cavity wall(cm)
E- Modulus of elasticity for steel(0.1 x106 kgf/cm2)
CAD/CAM/CAE
BVQi
U KAS
QUALITY
MANAGEMENT
ISO 9001
006
b) Cylindrical cavities:
Increase in radius due to the internal pressure of injected material can
be determined from
CAD/CAM/CAE
BVQi
U KAS
QUALITY
MANAGEMENT
ISO 9001
006
CAD/CAM/CAE
BVQi
U KAS
QUALITY
MANAGEMENT
ISO 9001
006
Q= a.h.pf
a= Maximum side of core(cm)
h= Height of core(cm)
pf= say 300 kg/cm2
Working diameter(d) of guide pillar
d(4Q/N fs )
Q= Side thrust (kg)
N= Number of pillars
fs= shear stress, say 16 Tons/sq.inch=158 x 16 kg/cm 2
CAD/CAM/CAE
BVQi
U KAS
QUALITY
MANAGEMENT
ISO 9001
006
ISO 9001
006
CAD/CAM/CAE
BVQi
U KAS
QUALITY
MANAGEMENT
ISO 9001
006
CAD/CAM/CAE
BVQi
U KAS
QUALITY
MANAGEMENT
ISO 9001
006
Molding:
1.Is the flash at the tool parting line position visually acceptable on the molding?
2.Are the positions of any print lines arising from tool blocks, cores, ejectors, etc.,
visually acceptable on the molding.?
3.Is the gate position visually acceptable on the molding?
4.Will the position of any flow or knit lines that may occur be acceptable in
appearance?
5.Will any knit lines cause weakness in a critical area?
6.Will any heavy section in the molding cause unacceptable sink marks?
7.Is the design free of any undercut areas that will prevent ejection?
CAD/CAM/CAE
BVQi
U KAS
QUALITY
MANAGEMENT
ISO 9001
006
Mould
1.Is the mould parting line chosen the most efficient for mould operation and
tool construction?
2.Have the Core and cavity been designed in the easiest manner for
machining on the available equipment?
3.Will any slender blades or pins deform under cavity pressure or flow?
4.Is the cavity of adequate strength to resist internal cavity pressure?
5.Area all tool components exposed to side thrust from cavity pressure?
6.Is the tool construction free from any chance of horizontal flash?
7.Does the ejector packing provides sufficient support to the die plate to
prevent distortion under cavity pressure?
8.Can all parts of the tool be dismantled and separated in the event of tool
breakdown or modification?
9.Are all necessary parts hardened?
10.Have all allowances for molding shrinkage been provided?
CAD/CAM/CAE
BVQi
U KAS
QUALITY
MANAGEMENT
ISO 9001
006
11.Has sufficient molding taper been allowed on all parts forming molding
surfaces?
12.Will the tool dimensions produce moldings within component tolerances?
13.Will the molding remain on the ejection side when the mold opens?
14.Is the ejection stroke sufficient to clear the molding?
15.Have sufficient ejectors been provided to prevent sticking, cracking or
distortion of the molding?
16.Are the ejector and ejector bars sufficiently strong?
17.Is the ejector mechanism suitable for the particular machine ejector systems?
18.Has the ejector return mechanism been provided?
19.Have adequate guide pins been provided between the tool halves?
20.On split tools or moving cores in the opening movement provided by cams,
cylinders, etc., sufficient to clear the undercuts on the component?
21.Are all inserts positively located for position and prevented from displacing
themselves during tool closing or under plastic flow in the cavity?
CAD/CAM/CAE
BVQi
U KAS
QUALITY
MANAGEMENT
ISO 9001
22.On split tools or moving cores, is the mechanism sufficiently fool proof to 006
ISO 9001
006
34.On split tools can be in the forward position without interfering with the
closing of the splits?If not-is mechanism provided to ensure ejectors are returned
before the splits close?
35.Is the sufficient clearance provided between ejector chains or links to
withdraw the component through them without difficulty?
36.Have tool lifting eye bolts been provided?
CAD/CAM/CAE
BVQi
U KAS
QUALITY
MANAGEMENT
ISO 9001
006
END
CAD/CAM/CAE