Mold bases

Basic Molds are a class of molds that, while can be very basic in application, are molds that have no Action incorporated into the mold to produce a part. The parting line can be planer, non-uniform, angled, and may be complex. Basic Mold Design Before an n!ection Mold Design can be started the following criteria must be "nown, to enable a proper design. #art $i%e &unction Acceptable 'itness Mar"s for #arting (ine, Method of )!ection, and *ate Material Type, and #rocessing +haracteristics, $hrin", Draft ,e-uirements #roduction ,e-uired, Time &rame and (ife of Mold Tolerance +onsiderations ,unner &inish $pecification, Data nserts Machine Type .noc" out Bar, $i%e and spacing Tonnage #laten si%e $hot si%e (ocating ,ing hole si%e /o%%le $pherical ,adius, and 010 Dimension +oolant +onnector Type and $i%e #rocessing +apacity $tudy +ycle time /umber of +avities ,e-uired #er Mold #ossible Types of Mold bases /umber of Molds to be 1rdered, $pare +avity $teels ,e-uired *eneral 'hat is the Timing of the Design2Mold Delivery3

f the above is "nown or specified, a mold design can be started.

A GENERAL APPROACH MAY FOLLOW THE FOLLOWING STEPS: (INJECTION MOLD DESIGN REQUIRES SYNTHESIS OF MANY REQUIREMENTS AT THE SAME TIME ) $tart at the part and wor" your way out. Determine the best gate location. +A) 4&low Analysis5 is a superior tool to help determine a proper gate location. Determine the appropriate #ossible #arting (ines. The location of an acceptable parting line will provide for proper e!ection of the part from the mold. A correct parting line will ensure that the part 0$tic"s0 to the e!ection 4core5 side of the mold. Determine a ,unner (ayout that suits the number of cavities needed for the mold and incorporate +old $lug 'ells into the layout. The next three items need to be 06uggled7 at the same time. )!ection, +oolant lines, +avity steel si%es. Determine +avity steel si%es 4you should have and idea of cooling layout too, at this point5. 'ill coolant holes be needed in the cavity steels3 Determine the )!ection method, and location of the e!ector contact area. Determine +ooling (ine location per coolant line placement rules. $elect a possible Mold base 4may change later5 that suits the design re-uirements 4)!ection travel, coolant connectors counterbored, general si%e. Ma"e sure that the .noc"-out bars will actuate the e!ection system. Determine t e n!m"er #n$ %i&e '( S!))'rt Pi**#r% nee$e$ ('r t e m'*$+ E,ten$ t e E-e.t'r /#r i( Ne.e%%#r0 Se*e.t # S)r!e /!% in12 #n$ L'.#tin1 Rin1 "#%e$ '( t e M#. ine %)e.i(ie$ ('r )r'$!.in1 )#rt%+

L'.#tin1 Rin1
F!n.ti'n: The function of a (ocating ,ing is to Align the Mold Base to the $tationary #laten side of the #ress. The $prue Bushing is also located via a hole in the (ocating ,ing. The (ocating ,ing is located and fastened into the Top +lamp #late 4T+#5 via counterbored hole.

T') C*#m) P*#te (TCP)

F!n.ti'n: The function of the T+# is to provide a means to attach the (ocating ring to the mold base. The T+# also provides counterbored holes for the $8+$0s that secure the A ,etainer #late. The T+# is located on the $tationary side of the press.

A Ret#iner P*#te
F!n.ti'n: The A ,etainer #late has many functions. The four drilled and counterbored holes are machined for the *uide #ins which align the A side to the B side of the mold. A machined opening is used to insert the +avity steels. &our tapped holes are used for the $+8$0s to hold the T+# and related items to the A ,etainer #late. There is a milled slot on two sides of the plate to provide for the placement of clamps that clamp the A side of the mold to the $tationary side of the press. The hole in the center of the plate is for the $prue Bushing. There are four milled angle relief0s on the bottom called #ry $lots, this enables easy prying between the A and B plates for opening the mold during maintenance or construction. There are also holes machined into the sides for the provision of coolant.

S!))'rt P*#te (SP)

F!n.ti'n: The $upport #late has many functions. The primary function of the $# to provide support to the B side +avity $teels. #roper support will reduce the possibility of flash occurring at the #arting (ine due to the B +avity steel 7bowing and flexing7 under the high pressures of n!ecting Material into the +avity. The location of the $upport #late is directly below the B +avity and ,etainer #lates, and sets on top of the )!ector ,ails 2 8ousing. There are typically several holes in this plate. They are machined for the following components9 $prue #uller #in, )!ector #ins, ,eturn #ins, $8+$, Tubular Dowel, and the end of the *uide 2 (eader #ins.

C#3it0 Stee*%
F!n.ti'n: The function of a +avity $teel is to provide the negative image of the desired part that will appear on the A side of the mold above the parting line. 'hile not always the case, the +avity $teels MA: provide coolant lines for coolant. The +avity $teels contain the *ate, and usually a small portion of the ,unner system. The +avity $teels are located in a machined hole or poc"et, or may in fact be the entire plate directly above the parting line on the A side of the mold. +avity steels typically are made from 8;< or #=> Tool $teel.

S)r!e /!% in1

F!n.ti'n: The function of the $prue Bushing is to provide a seat at the spherical radius for the /o%%le of the press. The $prue Bushing provides a 7path7 for the material from the no%%le to the runner system. The $prue Bushing is located via the (ocating ,ing, and the A ,etainer #late, and touches the B side of the mold at the #arting (ine.

S)r!e P!**er Pin

F!n.ti'n: The function of the $prue #uller #in is to 7pull7 the material from the $prue Bushing at the end of the Molding +ycle. The location of the $prue #uller #in is directly Below the $prue Bushing, it is retained via the )!ector ,etainer and )!ector #lates and passes through the $upport and B ,etainer #lates. There are three typical $prue #uller #ins9 ;. 7?7 $hape, =. Ball, <. &lat 4with a reverse taper in the puller 8ole.

G!i$e$ E-e.t'r Pin #n$ /!% in1

F!n.ti'n: The function of the *uided )!ector $ystem 4#in and Bushing5 is to ta"e the pressure off the ,eturn #ins, )!ector #ins and the $prue #uller #ins. f the mold is set to run with the )!ector system actuation in the hori%ontal position 4typical5, the e!ector sub assembly is cantilevered, and thus will put stress on the return, sprue and e!ector pins. The *uided )!ector $ystem will reduce if not eliminate these stresses. The *uide bushing is located between the )!ector and )!ector ,etainer #lates, and the *uide #in is placed either in either9 ;. The bottom of the )!ector 8ousing, or =. n the $upport #late. n either case the #in resides in the open space of the e!ector housing.

C#3it0 Stee*% (/ Si$e '( M'*$)

F!n.ti'n: The +avity $teels on the B side of the mold are identical in function to the A side cavity steels, with one additional function, they typically have holes for )!ector #ins. The B side +avity $teels are located directly below the A side cavity steels, on the B side of the #arting (ine.

G!i$e /!% in1

F!n.ti'n: The function of the *uide Bushing is to provide alignment of the two halves of the mold via the *uide #in. f the bushing is steel it is hardened and ground. The *uide Bushing is press fit into the B ,etainer #late.

E-e.t'r Pin
F!n.ti'n: The function of the )!ector #in is to e!ect the part from the mold at the end of the molding cycle. )!ector #ins always form a portion of the part and2or runner. The number of )!ector #ins in a mold varies depending on part and ,unner geometry. The #in is retained via the )!ector and )!ector ,etainer #lates and pass through the $upport and B ,etainer #lates.

G!i$e (Le#$er) Pin

F!n.ti'n: The &unction of the *uide #in is align both halves of the mold at the #arting (ine. The *uide #in aligns with the *uide Bushing. The *uide #in is hardened and ground, and is press fit into the A ,etainer #late. The Top +lamp #late provides a bac"er plate for the top of the pin.

/ Ret#iner P*#te

F!n.ti'n: The &unction of the B ,etainer #late is to retain the B side +avity $teels, and many times, has a portion of the ,unner machined into the plate. The B ,etainer #late is located directly above the $upport #late, the top of the plate is usually referred to as the #arting (ine. 8oles are machine into this plate for the following components9 *uide Bushings and ,eturn #ins.

E-e.t'r P*#te

F!n.ti'n: The )!ector #late provides a bac"er plate for retaining the )!ector, ,eturn, and $prue #ins. The underside of the )!ector #late is where the .noc"out ,ods from the #ress touch, and ma"e the )!ector sub assembly move to e!ect the part4s5. The )!ector #late rests on the $top #ins, and has counterbored holes for the *uided )!ector Bushings, and clearance holes for the $upport #illars. The )!ector #late is fastened to the )!ector ,etainer #late via $8+$0s.

E-e.t'r H'!%in1
F!n.ti'n: The )!ector 8ousing has many functions. #roviding room for the )!ector #ins, )!ector #late, )!ector ,etainer #late and $prue #uller #in to move during the )!ection #hase of the molding cycle is the foremost function of this component. The )!ector 8ousing also provides for +lamping $lots to fasten the B side of the mold to the Movable #laten of the press. The )!ector 8ousing can come in two configurations. ;. Three steels 4Two ,ails and one Bottom +lamp #late5 fastened together, or =. n a single welded or machined casting. 8oles are machined into the )!ector 8ousing for the following components9 $8+$ for holding the B side together, $8+$ for $upport #illars, Tubular Dowel, $top Buttons, *uided )!ector 4(eader5 #ins, and .noc"out 8oles for the .noc"out ,ods on the press.

E-e.t'r Ret#iner P*#te

F!n.ti'n: The function of the )!ector ,etainer #late is to retain the )!ector #ins, $prue #uller #ins, *uided )!ector Bushing and the ,eturn #ins to the )!ector #late. There are drilled and counterbored holes for each of the components mentioned above. The )!ector ,etainer #late is fastened to the )!ector #late with $8+$0s. There are also clearance holes for the $upport #illars.

SHCS (S'.4et He#$ C#) S.re5)

F!n.ti'n: The &unction of the $8+$ in a mold are to hold the various plates in mold together. There are several $8+$0s in a typical Mold. There are $+8$0s that hold the )!ector 8ousing, $upport #late and the B ,etainer #late together, two $8+$0s pass through the Tubular Dowels. $8+$0s also hold the Top +lamp #late and the A ,etainer #lates together. $8+$0s also hold the (ocating ,ing to the Top +lamp #late.

Ret!rn Pin
F!n.ti'n: The function of a ,eturn #in is to return the entire )!ector $ub assembly to the home position. f ,eturn #ins were not utili%ed, the e!ector sub assembly would be returned via )!ector #ins, this is not acceptable, as it would damage the end of the e!ector pins and would alter the appearance the part. The ,eturn #in is retained between the )!ector and the )!ector ,etainer #lates. The ,eturn #in re-uires holes in the $upport #late and the B ,etainer plates.

T!"!*#r D'5e*
F!n.ti'n: The &unction of the Tubular Dowel is to provide proper alignment between the )!ector 8ousing, the $upport #late, and the B ,etainer #lates. There are two Tubular Dowels and they are lightly press fit into the B ,etainer and )!ector 8ousing. A $8+$ passes through the hole in the dowel.

St') /!tt'n ('r Pin)

F!n.ti'n: The function of the $top Button is to provide a minimal contact area between the )!ector 8ousing and the bottom of the )!ector #late. The space provides an area for debris in molds that are set in the vertical direction. The $top Button is press fit into either9 ;. The )!ector 8ousing or =. The bottom of the )!ector #late.

#lan view of core

#lan view of cavity

$ecction A-A

$ecction B-B

Detail of gate

B1M

Titlebloc"

,unners A ,unner is a machined groove located between the $prue Bushing and the *ate. The function of a runner is to provide a passage for the material to flow from the $prue Bushing to the *ate. There are many types of ,unner cross sectional shapes. Most common shapes are the &ull ,ound, 8alf ,ound, and the Trape%oidal. As the ,unner branches and changes direction from the $prue to the *ate the runner is reduced in its cross-sectional area 4typically about =@A5. The portion coming from the $prue is referred to as the #rimary ,unner, the next section is referred to as the $econdary ,unner, and followed by the Tertiary ,unner. The length of a runner system should be "ept to a minimum. n!ection #ressure build-up due to long runner lengths can be reduced by increasing the runner diameter. 8owever, larger runner diameters increase cycle time due to the added volume of material that needs to be chilled2solidified. R!nner t0)e% The most efficient ,unner shape is the &ull ,ound, followed by the Trape%oidal and followed by the 8alf ,ound ,unner shape. There are many modified versions of these runners. F!** R'!n$

H#*( R'!n$ The 8alf ,ound runner is simply a runner system machined with a ball nose cutter into one plate of the mold.

Tr#)e&'i$#* Trape%oidal ,unners are very common in three plate molds. 'hile not as efficient in chilling effect of a full round runner, the ease of cutting the runner shape, and the elimination of the need to mate two runner plates together, ma"es the trape%oidal runner a good second choice of runner shape.

R!nner $i#meter% ,unner Diameter si%ing is directly related to the wall thic"ness of the part. Typically standard cutter si%es are utili%ed to machine the runner system, select the closest standard cutter si%e to "eep regrind levels below =@A. The runner that feeds material to the gate and part cavity should be ;.@ times the wall thic"ness for semi crystalline materials. &or Amorphous materials add approximately B>A. &or each branch of the runner towards the $prue add .>=@ 4 /5. The 1 dimension of the $prue should then be .>@> larger than the main runner. The no%%le D A should then be .>=@ less than the 1 Dimension.

*eneral thermoplastic materials with no fillers, and their typical runner diameters.

Material AB$, $A/ Acrylic Acrylic 4 mpact5 #henylene #olyester #olypropylene 4##5 #olyvinyl #olyurethane

Diameter .;CD@ - .<D@ .<;=@ - .<D@ .<;=@ - .@>> .=@> - .<D@ .;=@ - .<;=@ .;CD@ - .<D@ .;=@ - .<D@ .=@> - .<;=@

Material Acetate Butyrate /ylon #olycarbonate 4#+5 #olyethylene 4#)5 #olystyrene 4#$5 ,igid #F+

Diameter .;CD@ - .B<D@ .;CD@ - .<D@ .>E=@ - .<D@ .;CD@ - .<D@ .>E=@ - .<D@ .;=@ - .<D@ .=@> - .E=@

R!nner G!i$e*ine%
The ob!ective of good runner design is to provide an efficient path that will fill the cavity as -uic"ly as possible, with proper material temperature and minimal scrap. +old $lug wells must be incorporated into the runner at every branch. The cold slug well should be from. @ - ; Dia of the runner in length. A balanced runner system is highly desirable. 1n large runner systems, more than one sprue puller may be re-uired, as well as e!ector pins. The smallest runner permissible is desirable with reference to cycle time. ,unner si%es and angles 4trape%oidal5 should be e-ual to standard cutter si%es. /#*#n.e$ R!nner L#0'!t A Balanced ,unner (ayout is when the distance from the $prue to the *ate is e-ual for each and every cavity. t is important that each cavity start and end the fill process at the same time. A Balanced ,unner $ystem also provides for e-ual pressure thought the mold.

F'!r C#3it0 L#0'!t (N' C'*$ S*!1 We**)

Si, C#3it0 L#0'!t

Ei1 t C#3it0 L#0'!t

C'*$ S*!1 We** +old $lug 'ells are highly desirable in an n!ection Mold. The +old $lug 'ell provides a small reservoir 4well5 to trap air, and impurities before they enter the ,unner, *ate and +avity. A +old $lug 'ell is located above the $prue #uller #in. Typically, as the runner changes from a primary to secondary, and, secondary to tertiary there is also a cold slug well at each intersection.

R!nner Are#% 1f primary concern for an effective runner system is the Folume to $urface ratio. Minimi%ing the surface area of the runner reduces the cycle time and pressure drop. )-uivalent 8ydraulic ,unner Diameter calculations can be performed to compare various runner cross sectional shapes. 8ydraulic Diameter 48d5 is an index of the resistance of flow, The higher the 8d the lower the resistance to flow.

The formula9

B A 2# G 8d A G cross sectional area # G perimeter 8d G 8ydraulic Diameter

where9

C'*$ S)r!e A standard +old $prue Bushing provides a means for the material to travel from the Machine /o%%le to the ,unners. The /o%%le end of the bushing has two important dimensions. 1ne is the hole opening, it is referred to as the 717 dimension, and the other is the spherical radius that seats with the no%%le. The 010 dimension should be D2<=, 4.BB D A5 with H2;E, being used on very large molds. The spherical radius should be .D@ $#8,, with .@ $#8, being used on some machines. The hole inside the $prue Bushing should taper at .@> or .@E T#&. The taper hole diameter at the ,unner end of the bushing should be e-ual to, or be slightly larger than the runner diameter. A radius of approx. .><-.>E should be placed at the taper and runner intersection. Below the $prue Bushing should be a provision for a $prue #uller mechanism. There are three common types of $prue #ullers, and they are typically .=@ below the parting line, which functions as a cold slug well. ,everse taper well 0?0 cut on $prue #uller #in Bulb machined on the end of the $prue #uller #in. *ussets are sometimes cut into the $prue Bushing to help reduce the cycle time. H't r!nner A 8ot ,unner Mold is similar to a hot glue gun. Material is heated to a molten state, then it is dispensed at the tip to the desired area. #arts can be small single gated, or large and multigated. 8ot ,unner Molds have many uni-ue advantages over 7+old ,unner7 molds. 'hile 8ot ,unner Molds are typically more expensive than 7+old ,unner7 molds, the cost of the mold can be offset in other ways. Thermoplastic 8ot ,unner Molds can reduce costs due to9 No scraping of the runner. As the term implies, the runner in a 8ot ,unner mold stays in a molten state at all times 4no regrind5. Reducing the cycle time. n a +old ,unner mold the runner typically has the largest cross sectional area, therefore, the runner ta"es longer to solidify. )liminating the runner reduces the overall cycle time. &urthermore, in!ection time is reduced due to the shot si%e being reduced by the elimination of the runner. 8ot ,unner Molds have the ability to improve both part and mold design with flexibility of gating locations, which provides options for cavity orientation. #ressure drops are greatly

reduced due to the balanced melt flow as the temperature is consistent from the machine no%%le to the gate. #recise material temperature control is critical to successful 8ot ,unner processing. G#te% A *ate is a small area between the runner and the part cavity. The type, si%e and location of a *ate in an in!ection mold is critical to efficiently producing -uality parts. The type of gate selected depends on many factors including9 *ate witness mar"s, Material Type, &iller used 4if any5, Tooling +osts, $crap Allowance, and the Mold #lates used among others. A single gate per cavity is desired, however, part si%e and the material used may re-uire multiple gates to be used. (ocate the gate in an inconspicuous location of the part if possible. The *ate location should be at the thic"est wall of the part 4flow from thic",to thin5 and the thic"ness of the gate should be approximately two thirds the si%e of the wall. The gate location and the surrounding area is also the highest area of stress in the final part. Do not position the gate at a location that part function indicates bending or impact strength is re-uired. There are two general categories of gates9 ;. Automatic De-gating Automatic de-gating includes $ub gates and <-#late #in gates =. Manual De-gating All others generally fall into the Manual de-gating category. E$1e 1#te )dge *ates are the most commonly used of all gating options. The height of the gate should e-ual D@-;>>A of the wall thic"ness up to .;=@ in. The width should e-ual = times the depth. as it would appear in a mold.

An )dge *ate will leave a $car e-ual to the cross section of the si%e of the gate.

F#n G#te

A &an *ate will leave a $car the si%e of the cross section of the gate.

Pin G#te #in *ates are used in three-plate molds. The actual get diameter is from .><> - .;>> diameter.

A #in *ate will leave a small $car that is the si%e of the gate.

Rin1 G#te

A ,ing *ate will produce a $car around the entire part, the height is e-ual to the gate height.

S)r!e G#te The $prue gate is used when cylindrical parts need to be balanced and concentric and2or have very good weld-line strength.

A $prue *ate will leave a significant $car e-ual to the si%e of the sprue diameter at the point of contact of the part.

S!" G#te - May Also called a Tunnel *ate, +ashew or Banana The diameter at the gate is .><>-.>H> for unfilled materials and .;>>-.;=@ for filled materials. The angle is typically at <> degrees from vertical. )!ector #ins are re-uires to ensure automatic de-gating.

A $ub *ate will leave a #in si%ed $car on the part.

T#" G#te A Tab or &ilm gate typically is used where part re-uirements are for flat and2or very minimal warpage. The Tab re-uires post processing to remove the scar.

C''*in1
+onsidered the third phase of the n!ection Molding +ycle, the +ooling #hase consumes the greatest amount of time. Therefore, it is a serious area for designers and mold ma"ers to ma"e sure that all +oolant schemes have been thoroughly investigated for their suitability. +orrect cooling of an n!ection Mold is re-uired to produce good -uality parts at an optimum rate. All n!ection Molds have some sort of cooling provision to ensure efficient part production. +hilled water 4C>-;B> degrees &5 is perhaps the most common medium to extract heat energy from the the mold. +oolant lines are drilled into various plates at specific locations to provide even uniform cooling of the mold cavity steels. Many standard cooling components are available to provide the Mold Designer with many options to achieve the uniform cooling patterns needed for ensure -uality part production. The most common coolant line diameter is D2;E, while @2;E and H2;E are used less fre-uently.

+ooling rules

+oolant lines will be9 .B<D@ in Diameter unless otherwise approved.

C'm)'nent%
W#ter Line C'nne.t'r

P*!1% #n$ r'$% #ressure #lugs are used to 7plug7 the water line hole with a water tight seal at the edges of various plates. Diverting #lugs provide a means to bloc" the water flow and thus 7Diverts7 the direction of the water flow. Brass ,ods connect to and position Diverting #lugs. The rods usually touch the #ressure #lugs for proper positioning.

/#((*e%

C'))er A**'0 Pin%

T erm#* Pin%

/!""*er T!"e%

C#%.#$e 5#ter -!n.ti'n

W#ter m#ni('*$

E-e.ti'n +onsidered the fourth phase of the n!ection Molding #rocess, )!ection is the process of removing the solidified part from the mold. +ommon e!ection methods include9 )!ector #ins, )!ector $leeves, )!ector Blades and $tripper #late. )!ector #ins and Blades and to a lesser extent the $tripper #late and )!ector $leeves, all leave a 7witness mar"7 on the finished part. &urthermore, the e!ector pin and blade will either ;5 leave an impression or =5 a protrusion, where the pin or blade is located on the part. (ocating e!ectors is important. Balanced pressure on the part by all e!ectors is important. Accurate location of e!ectors on part walls, ribs, and bosses is highly desirable. #art appearance and function must be ta"en into consideration when designing the e!ection system. $tripper #late e!ection is highly preferred due to the even pressure and minimal witness mar"s on the part. The number and si%e of e!ectors used is dependant on the si%e and shape of the part. Draw #olishing is recommended for thin walls, ribs, or minimal draft areas.

)!ector #ins are sometimes used to help e!ect the runner system from the mold. f a $ub*ate is used in the mold, an )!ector #in is used near the beginning of the drop of the gate to help brea" the part from the runner2sub-gate. Accelerated e!ector systems are sometimes needed to e!ect the part from a tall core. t is also possible to 7Tip7 a part to get the part to fall from the mold in a certain direction. T0)e% '( e-e.t'r% )!ector #ins are available in a wide variety of si%es and materials. E-e.t'r S*ee3e An )!ector $leeve is basically an )!ector #in with a hole thru the center. The hole is used for a +ore #in to form a portion of the desired part. The +ore #in touches the part, the other end of the +ore #in runs thru the )!ector 8ousing and terminate near the bottom of the moldbase. The actuation of an )!ector $leeve is li"e an )!ector #in. E-e.t'r /*#$e% )!ector Blades are available in a wide variety of si%es and material types. )!ector Blades can be used in area that have a 0$lot0 for the blade whereas an e!ector pin would only be able to touch a smaller portion of the part. Ji((e06Je.t'r A 6iffey-6ector is a standard part that aids in the e!ection using. Stri))er P*#te% $tripper #lates are used to strip the part off the +ore $teel. The $tripper #late is actuated via $tripper Bolts from the A side of the mold, or by the )!ector Mechanisms in a variety of ways. Air P'))et% Air #oppets are standard components that aid the e!ection of a part by using compressed air within the mold. The timing of the actuation of the air is controlled by the controller of the press, the amount and the pressure is predetermined during mold tryout. A.ti'n m'*$% Action molds are molds that have some sort of mechanical 0Action0 incorporated into the design to enable molding of complex part geometry. Any significant hole, slot, undercut, or thread that is not perpendicular to the #arting (ine re-uires Action to enable the mold to produce the part. S*i$e A.ti'n $lide Action re-uires several mechanical components to enable the molding of complex part geometry.

$lide Action molds typically contain the following components9 Angle2+am28orn #in $lide (-*ibs 'ear #late $lide ,etainer $lide (oc" /ote9 The (-*ib should /1T move with the slide. S*i$e #n$ Li(ter The image below is a section thru a $lide and (ifter Action Mold.

Li(ter m'*$ (ifter Action in an in!ection mold provides for the molding of undercuts, lips and other similar geometry on parts, and also aids the e!ection process. Typical components in a lifter mold include9 (ifter T-+oupling I-+oupling The Animation of the (ifter Mold below can be repeated by refreshing this page. E#r*0 ret!rn %0%tem 'hen a slide cavity steel occupies the same space of an eventual e!ector pin, there is a need for an early return system in the mold.

f an early return system is not designed into a mold with the circumstances above, the slide will attempt to return to the closed position, before the e!ector pin is returned, and will cause a collision. H0$r#!*i. A.ti'n 8ydraulic Action in an n!ection Mold, usually means that a hydraulic cylinder has been incorporated into the design to enable a component 4core pin, cavity steel, etc5 to be moved at some phase during the in!ection molding cycle. Typical components for 8ydraulic Action are9 The 8ydraulic +ylinder Mounting Brac"et, and relater connectors The timing control of the actuation of the 8ydraulic cylinder is typically done via )lectrical2Mechanical switches attached to the mold base, or, more commonly directly attached to the controller of the press. C'**#)%i"*e C're +ollapsible +ore molds provide a method to produce under cut 0(ips or Threads7 in an in!ection molded part. $tandard collapsible cores can be purchased with altering of the portion that forms a portion of the part. f a standard collapsible core will not wor" in a particular design it is usually possible to design one to meet the design re-uirement. Ge#rin1 *earing with an in!ection mold to produce full threads is common. There are many considerations 4#art, #ress, $i%e of Mold base, /umber of cavities, etcJ5 that have to be considered to produce the pasts to specification. H't R!nner M'*$ A 8ot ,unner Mold is similar to a hot glue gun. Material heated to a molten state, then it is dispensed at the tip to the desired area. 8ot ,unner Molds have many uni-ue advantages over 7+old ,unner7 molds. 'hile 8ot ,unner Molds are typically more expensive than a 7+old ,unner7 molds, the cost of the mold can be offset in other ways. Thermoplastic 8ot ,unner Molds can reduce costs by the following9 No scraping of the runner. As the term implies, the runner in a 8ot ,unner mold stays in a molten state at all times. Reducing the cycle time. n a +old ,unner mold the runner typically has the largest cross sectional area, therefore, the runner ta"es longer to solidify. )liminating the runner reduces the overall cycle time. &urthermore, in!ection time is reduced due to the shot si%e being reduced by the elimination of the runner.

8ot ,unner Molds have the ability to improve both part and mold design with flexibility of gating locations, which provides options for cavity orientation. #ressure drops are greatly reduced due to the balanced melt flow as the temperature is consistent from the no%%le to the gate. 7ie5 '( .#3it0

7ie5 '( e-e.t'r

Se.ti'n /6/

Se.ti'n A6A

In-e.ti'n M'*$in1 Pr'.e%% The n!ection Molding #rocess in its simplest form is9 The process of ta"ing plastic at room temperature, heating it to a fluid state, forcing the material into a cavity that is the negative shape of the desired product, allowing the material to solidify, then remove the part from the mold. A more technical description of the n!ection Molding #rocess is9 #lacing material in the hopper of the n!ection Molding press, 8eating the material in the barrel via band heaters and friction to a fluid state, forcing the material through the /o%%le, entering the $prue Bushing, then entering the ,unner system and *ate, the material then enters the +avity which is a negative image of the desired part, the material is held under pressure while it solidifies, then the part, gate and ,unner are )!ected from the mold. M'*$in1 m#. ine The function of an n!ection Molding Machine is to convert pelleti%ed or granular plastic material into a part. n!ection Molding Machines are typically referred to by their si%e. +lamping tonnage and $hot si%e 4o%.5.

In-e.ti'n M'*$in1 M#. ine

C''*#nt M#ni('*$ #n$ C'nne.t'r%

S*e$

N'&&*e #n$ /#n$ He#ter%

P*#ten% #n$ C*#m) S*'t%

St#ti'n#r0 P*#ten #n$ L'.#tin1 Rin1 H'*e

E*e.tr'ni. C'ntr'* P#ne*

M'3#"*e P*#ten #n$ 8n'.4 '!t /#r H'*e%

#roper Fenting in an n!ection Mold is critical to producing -uality parts. The si%e, location, and amount of Fenting re-uired for proper molding, varies with part geometry and the material used. &low analysis can be used to predict approximate venting locations. Typically the mold ma"er during mold tryout, will develop the vents. #roper Fenting will eliminate short shots and burn mar"s on parts due to trapped gasses not being vented properly. Fenting will also provide for even flow of the material. Cin.i 9:;

M#teri#* n!ection molding raw material typically arrives at a processing facility in a pelleti%ed form.

Materials for n!ection Molding come in a wide variety of types for thousands of different applications. Materials can be custom blended for a particular application. Material arrives to a molding production facility via one of three ma!or methods9

:; *" /#1%

G#0*'r$ (A))r', <9;; *"%) 1r shipped via railroad boxcar and placed in a silo at the facility. M#teri#* t0)e% There are literally thousands of types of in!ection molding materials. )ach material has a uni-ue set of properties that enable the eventual product to have specified characteristics, or have an effect on the processing conditions. *eneral plastic material classifications and their processing melt temperature and related mold temperature are listed below.

Material AB$ #A EE #+ #)-8D #)-(D ## #$ #F+ $A/ A$iti3e%

Melt Temperature + =>>-=<>-=D> =D>-=H>-<=> =C>-<>>-<<> ;C>-==>-=C> ;C>-==>-=C> =>>-=<>-=C> ;C>-=<>-=C> ;E>-;H>-==> =;>-=<>-=D>

Mold Temperature + @>-E>-C> D>-C>-;;> D>-D>-;;> =>-B>-D> =>-B>-D> =>-B>-D> =>-@>-D> =>-B>-D> @>-E>-C>

The physical and2or mechanical properties of plastics can be changed to a desired level by using ,einforcements, Additives and &illers. C'*'r#nt% ($0e%) A reduction in thermal and IF effects on plastics can be accomplished by adding9 +arbon Blac"s, +hromates, and Metal oxides F*#me Ret#r$#nt% A reduction in the combustibility, and the ability to limit the speed of combustion can be accomplished by adding9 +hloride, Bromine, Metallic $alts, and #hosphorous

C'n$!.ti3e Fi**er% )lectrical and Thermal conductivity can be enhanced by adding9 Aluminum #owders, *raphite, +arbon &ibers Rein('r.ement Fi"er% An increase in Tensile $trength, &lexural Modulus, and 8eat-Deflection Temperature, as well as reducing $hrin"age and 'arpage can be attained by adding9 .evlar, *lass, Baron, +arbon, and &ibrous Minerals

CAE (i** #n#*0%i% +omputeri%ed Mold &illing Analysis9 1ptimal &low of material thought the Mold +ycle, can be predicted with a high degree of accuracy using +omputeri%ed Mold &illing Analysis. The analysis can also aid in the balancing of family molds so that pressure, temperature, and time of the fill are balanced before tryout. Fi** time

Air tr#)%

Pre%%!re $r')

G*#%% m'$e*

In-e.ti'n )re%%!re

P*#%ti. (*'5

We*$ *ine%

F*'5 Fr'nt Tem)er#t!re

T''* %tee*%
The proper selection of the type of Tool $teels used to form the part cavity is an important consideration to successful n!ection Molding. Farious alloys are available to meet the performance needs of the mold. +ertain molds may need wear resistance, and, high hardness at the #arting (ine. 1ther molds may re-uire higher toughness to reduce mechanical failure. The give and ta"e of the desired properties is a constant concern with the selection of molding materials. f high hardness and wear is needed for the cavity steel, the brittleness becomes a factor. f toughness is re-uired of the cavity steels, a reduction of resistance becomes a factor, especially when molding mineral and glass fibers. P69; #-=> Tool $teel is perhaps the best overall steel for forming a cavity in an n!ection Mold. Advantages of using #-=> Tool $teel include9 )asy to machineK $upplied in a pre-hardened state at ,c <>-<=K Fery ToughK

(arge si%es are minimal ris"s during heat treat +an be used for abrasive materials, for short runs. Disadvantages of #-=> include9 /o moving of mating steels of #-=> as galling will occur, 8-;< is a suitable alternative steel for this application. H6<= 8-;< Tool $teel provides significant toughness in an in!ection mold. At a ,c of @>-@= mechanical fatigue resistance is reduced, compared to other higher hardness steels. Advantages of 8-;< include9 Toughness Disadvantages of 8-;< include9 (ow hardness 4relative to $-D5 S6> $-D is similar to 8-;<, as it has very high toughness, and resistance to mechanical fatigue. Advantages of $-D include9 Toughness 8ardness Mechanical &atigue resistance Disadvantages of $-D include9 (ower abrasive resistance 4relative to 8-;<5. Ot er t''* %tee*% Miscellaneous Tool $teels A-=, D-= and M-= Tool $teels are typically used for *ate nserts when molding materials filled with glass or mineral additives. C'rr'%i'n +orrosion may occur during9 The storage of the in!ection mold The operation of a mold in a high humidity environment The molding of material that emits gasses that are prone to aiding the corrosion process. #reventing +orrosion is important to an in!ection mold that is re-uired to produce parts over a long period of time. #reventative measures include9 $praying the mold with a protective coating

/ic"el plating Ma"ing the mold cavities from $tainless $teel

A*tern#ti3e Pr'.e%%e%
C'6in-e.ti'n

F!%i"*e C're

G#%6A%%i%te$

L'56Pre%%!re

P!% 6P!**

C'm)re%%i'n

Str!.t!r#* F'#m

L#me**#r

Li3e6Fee$

Mold Design Cutting-Plane Line Determination and Section View Representation

1b!ective9 To show as clearly as possible the entire inside of the mold.

C!ttin1 P*#ne Line:

#lace the +utting plane line so that it cuts through the part, gate, and runner sprue, sprue puller. Then add to the cutting plane line to include e!ector pins and core pins 4if used5. /ext you should include the coolant features and the support pillars. Then add as many standard Mold base components as possible. ,emember9 :ou must include at least one representation of every component in the section view4s5, it may be cut through 4preferred5 or it may appear as a hidden feature.

L'.#tin1 Rin1
$how the locating ring cut in one view, and a solid in the other view regardless if the cutting plane line passed through it or not.

Line% "e0'n$ t e .!ttin1 )*#ne *ine

$how all solid lines beyond the cutting plane line 4)!ector pins, support pillars etc.5 This includes above and below the e!ector plates.

Hi$$en *ine% in %e.ti'n 3ie5%

Do not show any hidden lines that would duplicate any other feature.

F#%tener%
#lace two small $0 s of the end of the fastener about one dia. into the tapped portion. $how no threads in the untapped portion.

Center*ine%
Be sure to include all centerlines of all features.

C!ttin16)*#ne Line Dre%%6!)

1ptional on the cutting-plane, you may place thin lines on the outside corner of the cutting-plane as the cutting-plane ma"es a right angle cut.

Se.ti'n Linin1
f you cut thru a $1( D cylindrical ob!ect, D1 /1T section line this itemL Ise double lines for Tool $teels.

Note:
'hile not a standard 4A/$ , $1, M ( etc.5 :ou may use a thin line with two $0s in the sectional view to represent the right angle cut of the cutting-plane line.

PLEASE???

$tudy these simple rules,

Try to apply them 1/ :1I, 1'/, and as" -uestions if you do not understand anything about them.

De%i1n %t#n$#r$%
Dowels: Ise .;= increments on the dia. (engths must be standard. /1 blind dowel holes. 1n
rare occasions relieved dowels can be used. )ffective length on dowel is = times the dia engagement per steel. Fasteners: Ise only .;= increments on dia. $eldom will you use less than .<D@ dia fasteners in this class. :ou must order the fastener shown in the design. $ectioning of fasteners must be shown properly. All fasteners must be shown in the plan view unless there is a symmetrical pattern, then centerlines may be shown. &asteners must be shown at least once for each different situation in the section views. 8alf fastener 2 half dowel may be used including tail curve brea"s. )ffective thread engagement is ;.@ times the dia. He, i% re@!ire$ ("'t %'*i$ #n$ i$$en )*#n 3ie5, chamfer is re-uired for both hidden and solid applications for side view of fastener

Dowel and fastener centers: can be no closer that ;.@ Dia from the edge of the steel. Two
times Dia is recommended if possible and it loo"s good. Ise the same si%e dowel and fastener per steel if possible. ,elieve hole if the depth of exceeds B times Dia.

Steels: used in the design must be 'r$er#"*eL 4si%e $tated in B-1-M must be from a steel
catalog M#eerlessN, Design to si%e when ever possible. The B-1-M will be stated in order9 $mallest $i%e first, +ut-off dimension last

Label: O#lan Fiew of +avity4ies5P and O#lan Fiew of +ore4s5P above 4or below5 each respective
view. (abel O+( of M1(DP on +( of mold both directions both ends both views. (abel O1ffsetP for both return pin 4if used5 and guide pin and bushing.

St#m): #lace a general note9

$tamp9 &erris $tate Iniversity +AD Drafting Tool Design Tool Q MMDD::-MR 4Month Date:ear-start with M>;5

#art /umber is the same as Tool /umber except replace M with a #

Cutting Plane Line: will be #hantom 4see handout on determination5.

!ic"ness: .>@> Thic" for plotter, .>;< Thic" for printer. Ise proper setup in +AD for both plotting and printing. Section #D$s: 4AA, BB etc.5 are placed in bac" of the arrows and are .<C in height. Section View #D e%t: 8eight is also .<C Section &rrows: are to be created with a curve on the bac" end and with a colored gradual shadeing fillin 4as" for example5. $ection arrows must be in a ratio of approx B to ; 4length to width5. Cutting Plane Line must contain offsets: These are Soutside cornersT for dress-up and clarity 4as" for example5. 'nderline: all lettering except lettering inside the $toc"(ist. #nserts: $ymmetrical inserts must be fool proofed. ,adius machined poc"ets for proper standard si%e cutter +hamfer $teels to fit machined poc"etss. (alloons: 'ill be placed in a logical order. Balloon Dia is .B< with .;C number height.. Leaders: will have a gradual curve, and point int' the detail at the edge of the detail 4not on5. A period on the detail may be used with permission. ool Steel Cross )atc!ing: is two lines double gap. DO n't #t. t'' .*'%eL Ise a wide spaced hatch pattern for support pillars, code pattern for return pins is upper right lower left, e!ector pins upper left lower right. Re$ S #$in1 ('r P#rt: ,unner, *ate, and $prue, is re-uired in the $ection view only. )dges of steels need to be blac". e%t Si*e: will be .;C in height. $ection D letters will be .<C in height. Steel si*e selection and specification: Mold +avity tool steels will be 8-;< and2or #-=>. $i%es must be orderable if possible. $mall-medium-largest, will be the order si%es of specification in the stoc" list. )xample9 ;.>>> x =.>>> <.;=. &urthermore, add a .;= inch more than your designed si%e for stoc" cutoff to the largest si%e. The si%es will have <-place R <-place R =-place decimals

in the stoc" list 4see example5. All carbon steels will be specified as +-;>;C, +-;;(;D, +-;>B@, or +-;>E>, D1 /1T use +,$, +&$. Position of detail: f details are shown out of position it must be noted on the leader line, and or on the detail itself. Center line: #lace centerlines on A(( appropriate features, this is re-uiredL. e%t: All &onts )xcept $ection D and #lan Fiew (abels, on layout shall be9 ,omans with an 1bli-ue setting of ;@. /otes Text 8eight is .;C. Bill of Materials and Title bloc" 4ddedit but, be sure to change the font5. $ectioning 4$ee $ectioning28atchine5. $toc" list examples9 @ B < = ; C ;> = ; ; $TD $TD #I, 8 ;< #I, .=@> D A R ;.@> D'( .<D@-;E R =.>> $8+$ DM) )6)+T1, # / ;.>>> R =.>>> R <.;= DM) M1(DBA$) 4$)) /1T)5 $ ?)2D)$+

A(T),U)R-HM-E

; ; $8T /1.

D)T ,)V MATP(

N'te: Be sure to study the exact ordering specification re-uired by catalog vendor to ensure that the stoc"list contains all the information needed for the purchasing agent to place the order. Mold base is always Detail Q ; N'te: &or all $tandard parts9 The +ompany is stated with the item name 4should be the same as the index name5, and the order Q is to the left of the Detail Q M$ee Q< aboveN. N'ti.e: for detail number < 4a standard purchased item5 that the company name is /$ D) the si%e2description along with the catalog name of the item, and order number is to the left of the detail number. &or each catalog vendor, place an U for the first, and UU for the second etc. n the upper right hand portion of the design add the following9 T)M$ MA: B) #I,+8A$)D &,1M9 U4name and address of vendor one5

UU 4name and address of vendor two5

/ote9 $tandard in our shop will be9 A(( fasteners 4$8+$, and $tripper Bolts5 washers, and nuts. 'hen ordering $teels, place the material type is the Material +olumn

Ise /1 &ractions in the B-1-M

C e.4*i%t /e('re T!rnin1 in # P*'tte$ De%i1n (9; t in1% t #t e((e.t 0'!r 1r#$e)
Note9 This is a guide that when applied in a serious manner, will provide for eliminating errors that you should have "nown either before this class or have been given information as to the re-uirement, it is n't intended to cover all drafting and design re-uirements.

Line%:
;. =. <. B. +enterlines placed on all features that re-uire them. +utting #lane (ine is .>@> thic" when plotted. All $olid lines are shown in section view 4$upport #illars, )6 pins etc5. 8idden (ines are clear and correct.

Te,t:
@. E. D. C. H. #lan Fiews 4+avity2+ore5 are labeled. )ight +2( of Mold indicators. &ont is to specification. 1ffset is labeled, two places. All lettering is underlined 4except inside B-1-M5.

/6O6M #n$ Tit*e /*'.4:

;>. Bill of Materials are correct per drawing standards. ;;. #art and Tool numbers are correct. ;=. $teels are orderable and stated as $-M-( in the B-1-M. ;<. &asteners are stated correctly. ;B. Drawing is plotted to stated scale.

/#**''n #n$ St'.4 Li%t

;@. Balloons are .BB Dia. and placed in a logical order. ;E. (eaders are curved and pointing to the edge of the detail.

Mi%.+
;D. $ection views are correct per +utting #lane $ectioning $election handout. ;C. Machine /ame and $i%e are placed in .1 holes. ;H. +ounter drilled holes are correct for )6, $prue, and others features. =>. All Threads are correct per lecture.

P*'ttin1
Y'! m!%t !%e m0 /'r$er #n$ Tit*e"*'.4 ('r #** )*'t%A
DO NOT scale my Titlebloc" to fit your drawingLJ nstead9 file your drawing for bac"up. Then scale your drawing to fit my Titlebloc". And save it under a new name. All #lots M!%t be plotted to stated scale 4/1 scale to fit plots5 Minimum plotting color re-uirements9 $olid fill color red of part, gate, runner, sprue sections 4edge of steel will be blac"5. +oolant lines cyan +utting plane ,ed All +enterlines are to be ,ed All others entities blac" 1ptional #lotting 1ption of using your color scheme upon approval

/ote9 /1 plotting of any yellow lines at anytime L Design review9 Mar" 8ill D)$ */ D)#A,TM)/T +8)+. ( $T #art /ame9WWWWWWWWWWW Tool QWWWWWWWWWWWWWWWMetric2)nglish #art &ile /ame9WWWWWWWWWWW Tool &ile /ame9WWWWWWWWWWWWMetric2)nglish

A+
>;. >=. ><. >B. >@. >E. >D. >C. >H. ;>. ;;. ;=. ;<. ;B ;@.

PART DATA B LINE UP INFO

C 4C$

8as the !ob folder been +reated3 8ave part edits been reviewed3 .ic" off notes reviewed3 8as the customer specs been reviewed3 8as die draw been supplied by the customer or determined by the designer3 8as draft analysis been run with minimum draft established3 s draft analysis copy included with folder and chec"list3 8as the part been completely reviewed for molding3 s part data complete3 $M X 1$M3 Are part changes re-uired3 f so, are s"etches attached3 Do all ribs have ade-uate draft3 Are ribs too thic" at the base3 4B>A - @>A Max.53 Do bosses have ade-uate draft3 4Min. >.@ on 1.D. X .D.5 3 'hat is the shrin" factor3 Are parts identical3 Mirrored or rotated3

/+
>;. >=. ><. >B. >@. >E. >D. >C. >H. ;>.
Are vents shown3

RUNOFF

C 4C$

8as the parting line been completely defined3 s relief shown3

'ith a blow up detail of vent on the sheet the vents are on3

s runoff complete3 Do mold loc"s have counter loc"s3 Are all loc"s on ;>3 s shutoff shown on correct half of mold3 +an the return pins fit into shutoff3 s there shutoff around drops and runners 4Min. ;.>>53 s there clearance in the core for hot drop expansion3 4'afer if possible53

C+
>;. >=. ><. >B. >@. >E.

GATING

C 4C$

8ave gate and drop locations been supplied or determined3 Are gates balanced and shown complete3 Are all runner si%es and locations shown3 Are gates shown in a BR si%e view3 s a manifold or sprue re-uired3 Are cashew inserts and screws designed if re-uired3

D+
>;. >=. ><. >B. >@. >E. >D. >C. >H. ;>. ;;. ;=. ;<.

MOLD SIDE

C 4C$

Does mold fit into customerPs press3 Do parts clear tie bars3 s part completely de-molded3
Are stac" up dimensions and high point shown with overall bloc" si%es called out3

s S1T corner shown3 Does mold fit min. and max. shut height3 s top of mold and operatorPs side called out3 'ill design function in press3 Are eyebolts 2 clamp slots shown3 )yebolts to correct si%e3 )yebolt sheets filled out3 )yebolts designed in all loose pieces weighing in excess of B> pounds3 8as >,> been set to +( of +ore3 C 4C$

E+
>;. >=. ><. >B. >@. >E. >D. >C. >H. ;>. ;;. ;=.

Li(ter%

8ow many lifters3 Do lifters travel without any interference3 Are lifter poc"et covers surfaced and on the correct layers3 Are all fillets correct si%e3 Are the layers all correct3
Are all lifters written out individually, labeled, and named properly3

Do lifters X labels match design file3 s edm re-uired3 Are bloc"-ups complete with si%es and setups3 Are lifter rod pinning re-uirements on bloc"-up sheets for straight up lifters3 Are rib cuts re-uired and complete3 8ave designs been compared for lifter material3 C 4C$

F+
>;. 8ow many slides3

SLIDES E CORE PULLS

>=. ><. >B. >@. >E. >D. >C. >H. ;>. ;;. ;=. ;<. ;B.

Do slides have sufficient room to travel in slide poc"et3 Do slides have @ or < lead in3 Are slide wear plate poc"ets surfaced3 Are all fillets correct si%e3 Are the layers all correct3 Are all slides written out individually, labeled, and named properly3 Do slides and labels match design file3 s edm re-uired3 Are bloc"-ups complete with si%es and setups3 Are core-pull bloc"-ups re-uired and complete3 Are screw locations re-uired and incorporated into surface file3 Are rib cuts re-uired and complete3 8ave designs been compared for slide X core-pull material3 C 4C$

G+
>;. >=. ><. Ba. Bb. Bc. Bd. >@. >E. >D. >C. >H. ;>. ;;. ;=.

INSERTS

8ow many inserts3 Are inserts burned or cut3 1/(: if cut, is insert tapered <-@ deg3 1/(: if cut, are poc"et covers surfaced and on the correct layers3 1/(: if cut, are all fillets correct si%e3 1/(: if cut, are inserts written out as individual files3 s the insert cleared correctly for spotting3 Are the layers all correct3 Do inserts X labels match design file3 Are screws and dowels shown3 s edm re-uired3 Are bloc"-ups complete with si%es and setups3 Are screw locations re-uired and incorporated into surface file3 Are rib cuts re-uired and complete3 8ave designs been compared for insert material3 C 4C$

H+
>;. Are sleeves re-uired3 >=. 8ow many3

SLEE7ES

Are spares re-uired3

><. Are they standard Y and lengths3 >B. Are carrier2extensions re-uired to "eep standard length3 >@. 8as the sleeve been designed to achieve between .D@T-=T ream on D3 ZT for the 1D3 >E. 8ave the sleeves been labeled and sections cut through all of them3

>D. Do the sections have depths of part from core surface and the D and 1D dimensioned3 >C. Are sleeve assemblies ready to fabricate3 >H. f special si%e sleeves are re-uired, are they ordered3

I+
>=. ><. >B. >@. >E. >D.

CORE PINS (/LIND E THROUGH)

C 4C$

>;. Are pins blind 4press fit from the front5, or through 4stationary core pin from the bac"53 f pin are through pins, are they "eyed3 f so, how many3 'hat is the purpose3 Are pins shown complete3 Are pins dimensioned at part area to show depths, [, and draft3 Are pins labeled in #lanviews X $ections3 C 4C$

J+
>;. >=. ><. >B. >@.

CORE PULLS

Are core pulls re-uired3 8ydraulic or mechanical3 8ow many are re-uired3 Are sections cut through all core pulls 4and labeled53 f hydraulic, is design complete9 a. s cylinder mounting shown3 b. s standard pin carrier used3 c. 8ave cylinder orders been written, chec"ed, and given to purchasing3 d. s pin carrier "eyed and retained3 >E. s pin carrier spring loaded3 >D. s part feature formed by pin dimensioned with tolerance3 >C. Are core pull assemblies ready to fabricate3

8+

WATER SPECIFICATIONS AND REQUIREMENTS

ncorporated3 \ Bubbler si%e [ 4$tandard std. ; si%e larger than water line [5 \ +ounterbores
\ Manifold or Falves \

C 4C$

>;. 8ave the customerPs specs been reviewed3 (ine Y \

&itting type 4Main connections5

+ircuit layout 4i.e. flood, forced5

\
8ose color or type

C 4C$

L+

WATER DESIGNS

>;. Are sections cut through all lines and labeled R or : value3 >=. Are any coolant lines taped into core steels3 ><. Are all lines labeled in #lan Fiews with #( heights3 >B. Do all sections match #( labels3 >@. Are all inPs, outPs, and loops labeled3 >E. Are flow arrows or layout sheets re-uired to help follow flow 4i.e. complex bumper53 >D. 'ater line spacing suitable for part and mold si%e3 $mall =-<T Medium <-BT (arge <-@T >C. Bubblers, spacing same as '( spacing3 #rototype

C 4C$

M+
>;. >=. ><. >B. >@. >E. >D. >C. >H. ;>. ;;.

EJECTION

Are e!ector pins std. Y and lengths3

Are e!ector pins YPs the maximum the part allows without having more than < si%es3 Are pins near all ribs and bosses 4= per feature as close to ribs as possible53 4.>E>5

Are all pins pushing on best possible areas3 4,ads, walls, etc.5 8as e!ector pin program been run to verify pins are pushing in best location3 s proper2standard ream shown ZT standard for in!ection molds3
s proper2standard ]T ream shown with .>E dia. clearance for compression molds3 s proper ream shown for gate and runner pins and special 4non-std.5 ream noted3 Are ring pins re-uired3 Are they called out in #.F.3 s there a blow-up view3

Are return pins shown complete with clearance for screw if applicable3 Are return pin springs re-uired3 f yes, are they shown3

N+
>;.

HYDRAULIC EJECTION

C 4C$

s hydraulic e!ection re-uired3

>=. Are cylinders shown complete X designed to customer specifications3 A. Dowels3 B. ,etainer .ey3 +. Mounting #late3 D. 8-/ut3 ). 8ave cylinders been ordered3 ><. s hydraulic routing through rails3 f yes, is it shown3

>B. Are rest buttons located directly next to hydraulic cylinders3 >@. Are limit switches shown X protected3

O+ MISCELLANEOUS
>;. Are standoffs re-uired2shown3 >=. Are safety straps shown3 ><. 8as all plate wor" been written up, chec"ed, and given to purchasing department3

C 4C$

P+

EJECTOR /OF

C 4C$

>;. .noc" outs wor" for customerPs press3 >=. .noc" outs wor" for tryout press3 ><. .noc" out clearance si%e =.=@ Y clearance or ;.=@ Y clearance3 >B. .noc" out threads called out3 >@. ,est buttons designed to $tandard std3 >E. ,est button under return pins and sprue pins3 >D. ,est buttons E-CT apart on small molds and C-;>T apart on large molds3 >C. Are e!ector screws re-uired for pin plate3 >H. s .@> Y !ac" screw shown on or near +(3

;>. Are .@> Y dowels shown on +(3 ;;. Are forward stops re-uired3 s there only B3 Are they near ..1. and hydraulic e!ection cylinders3 ;=. Are they support designed3 ;<. Do support have ]T Y soc"et head cap screw3 f yes,

;B.

s the e!ector guide pin assembly to $tandards3 s the e!ector guide pin assembly design complete3

;@. Are handling holes shown X the same si%e if possible in all of the following components3 a. Top of e!ector plate3 b. Top or retainer plate3 c. Top of clamp plate 4over E>T also in ends53 d. )nds of rails3 ;E. ;D. f -uic" "ic"ers are re-uired, are they designed3 s there clearance for lifter rod access3

;C. Are bolt holes re-uired3 f so, is design complete3 ;H. Does clamp plate re-uire valve gate manifold accommodations3 a. #oc"ets for valve gate cylinders3 b. +hannels for valve gate plumbing3 c. =>. =;. s water re-uired in clamp plate for valve gate cooling3

s standard 8-/ut used for hydraulic e!ection3 s all hydraulic plumbing shown3 a. Main ins and outs. 4Type3 (ocation35 b. Are flow dividers re-uired3

==.

s manifold electrical designed to customer specs3

=<. Are pla-ues and schematics re-uired3 f yes, are they designed3 a. 'ater3 b. 8ydraulics3 c. )lectrical3 d. .D. tab3 4A('A:$ ,)VI ,)D5

e. Any special purpose pla-ues3 =B. s stoc" list and purchase list complete3

=@. 8ave the final prints been sent to the customer3 =E. 8as the customer approved the designs3

Settin1 #n$ R!nnin1 '( #n In-e.ti'n M'*$

The ob!ective of this tas" is to provide an experience for a designer of an n!ection Mold, to reali%e !ust what it ta"es to produce a part once the mold has been made. This is a special opportunity to as" -uestions of an expert in this area. Be sure to as" -uestions, be alert to all activities that ta"e place, and be sure to wor"L

R!*e%:

DO N't: Touch or do anything, until you are told it is 1. by the instructor or Manager. DO: Ma"e an effort to ma"e the process as efficient as possible. Ma"e sure that you get a part2runner.

N'te:
Bring $afety glasses, and, you may get a little grease on you clothes so dress appropriately.

Position Manager #hotographer 'riter #ower#oint *runts

Main

&ssistant

1nce, we are finished with the running of the mold, we will return to the classroom, and create the ## presentation as a group. ## is due within BChrs. The #ower#oint #resentation is simply a documentation of each and every step necessary to create parts. $tarting with the Mold out of the press, and the plastic pellets in your hand ending up with the finished parts. :ou should ma"e a copy of the ## for your records.