- Explain the different type of material
- Use of the different material.
- Identify the different material.
- Explain the necessity of mould
- Explain the working principle
- Explain the functional requirement of each parts.
























 










  

  

 



 






~ Plastics is a unique class of materials, came into existence by the virtue of their
superior properties and cost performance balance over to conventional materials
like wood, ceramics and metals.
~ Plastic materials based on their characteristic performance were classified as
(
(
 and (

((  materials.
~ It is well known that the former class of materials distinguished from the latter by
their processing behavior and characteristic properties.
~ Example for thermoplastic includes PS, PP, PVC, PET, PA,POM
~ Examples of thermo-sets include PF, UF, and MF etc.


( (


 

~ Commodity plastics
~ Engineering plastics
~ Specialty plastics.
  


These are low performance, high volume resins, characterized by: HDT  100c
and tensile strength, <50MPa. Two of them, PE and PP are semi crystalline,
thus their properties depends on nucleation and annealing. The glossy resins
(PS, PVC, and PMMA) are available as either rigid or impact modified varieties,
viz. GPPS, PVC-R, and PMM or HIPS, PVC-F, and HI-PMMA. All these polymers
can be formulated as filled and reinforced grades excellent for film blowing or
blow molding.


Five types of resins belongs to this category polyamides (PA), polyesters (PEST),
polycarbonates (PC), poly-oxy-methylene (POM) and modified poly-phenyleneether (PPE). By definition, the resins are characterized by HDT 100c and
tensile strength >40MPa. They can be formed to precise and stable
dimensions. Their consumption is about 12% of total plastic. There is a great
diversity of performance within each of this type, especially considering the great
chemical verity within the PA, PEST & PC type as well as profusion of blends,
filled, and reinforced systems comprising engineering resins.




To this category belong low volume, high performance, high temperature, and
high cost polymers. Their consumption amount to less than 0.1% of total plastics.
By definition, the resins are characterized by high modulus, tensile and impact
strength. They can be formed to precise and stable dimensions. Their continuous
use temperature is CUT 150c. Most of specially polymers are available as GF
or CF filled grades.











  
P

  

 

 

0hy we use plastic material in the first place instead of traditional and familiar
material such as metal. In general plastic offers impressive advantages over
metals. Some of it is listed below
~
~
~
~
~
~
~
~

They are not subjected to corrosion

They are light in ;weight with good strength to weight ratio
Very cost effective
The speed with which they can be produced.
They give design freedom
They provide with good electrical insulation property
They are available in wide range of colures
Reduced assembly time.
In addition to it each plastic material offers some special property which serves
a particular application or can be made to do so by the incorporation of suitable
additives with the plastic materials.

 


Thesuccessful use of plastics usually derives from a combination of cost savings
and improvement in performance or appearance, but often the cost saving alone
is sufficient to justify the choice of a plastics material. Plastics can offer the
following technical advantages.



All plastics have low densities, generally in the range 830 to 2500Kg/m3.These
figures can be extended upwards or downwards. For example, foamed materials
can have densities as low as 10 Kg/m3, and filled plastics as high as 3500Kg/m3.
In comparison the density of aluminum is about 2700 Kg/m3 and that of188
stainless steel about 7900 Kg/m3.There are two consequences of the low
densities of plastics. Large volume of material for unit weight that can be obtained
with metal.



Some plastics are extremely tough, and objects made from them are difficult to
destroy by mechanical treatment. Other plastics are less tough, and still other is
fragile.

Plastics show some of the behavior associated with rubbers in accommodating
relatively large strains without fracture and in recovering their original shape and
dimensions when the stress is removed.


The quietness in use of plastics gear trains and bottle crates depends on the
inherently high degradation of mechanical energy to heat.







  
3

  

 







Some plastics appear to perform remarkably satisfactorily in situations involving
dynamic stresses or strains.
  
 

Plastics / plastics and plastics metals combinations have low coefficients of
friction and can often perform un-lubricated without fear off seizing.




Plastics are good insulators, their thermals conductivities being many orders of
magnitude lower than those of metals. This low conductivity may be exploited in
handles for utensils and in the design of pipes for carrying hot fluids, where a
lagging effect may be built in.
   

In general, plastics are complementary to metals in their chemical resistance, in
that they are resistant to weak acids, weak bases and aqueous salt solutions,
although strong oxidizing acids may cause some attack, leading to discoloration
and possible embitterment. On the other hand, organic solvents to which metals
are generally inert, may cause swelling, deterioration of properties and eventual
dissolution. The plastics material of the environment and on the temperature.
 
 

Some plastics are transparent, some are translucent and a few are opaque.
Acrylics, polystyrenes, methyl pentene polymers, polycarbonates and certain
grades of PVC can be very transparent indeed to visible light. All plastics can
be colored by incorporating a wide range of dyes or pigment s, thus avoiding
the need for painting. However, subsequently painting or plating is possible with
some, if required




 
A variety of automatic and semi-automatic techniques allows easy, economical
and reproducible fabrication of articles and components. Although often
unnecessary, further finishing operations are easy to carry out on most plastics.
 

 


~
To know the material. Used in any product
~
For processing of scrap material.
~
For product indigenization







  

  

 






~ Appearance
~ Method of fabrication
~ Penetration to hot rod and cutting with knife
~ Floatation Test
~ Scratch resistance
~ Colour
~ Odour
~ Tear
~ Solubility
~ Burning characteristics
~ Melting Point
~ Melting Point
~ Confirmation test

~ Transparent - PS, SAN, PMMA, PC, PVC, PET
~ Translucent - PE, PP
~ Glossy
- ABS, PC, POM
~ Milky 0hite- PTFE
~ Dark colors- Phenolics
~ Yellowish - Epoxy Resins and unsaturated polyesters

  

~ Injection Moulding - Thermoplastics and injection mould able thermo-sets
(Gate marks, Flash Marks)
~ 0ithout any mark - Nylons (Polyamides), HDPE, PTFE.
~ Films - PE, PP, PVC, PET, CELLULOSICS




 




~ If a shaving can be pared of with a knife it is probably thermoplastics.
~ If the material s rigid and difficult to pare off it is probably thermo-set
~ PMMA and polystyrene are difficult to pare off
~ 0hen a hot electric soldering iron is kept on the material.
~ Thermoplastics melt and sink but thermo-set do not melt but degrade
~
 




~ Drop a piece of sample in water, if it sinks then it is PC, PS, SAN, CA, PVC,
NYLON, PTFE, PMMA, Poly-acetals
~ If it floats then it is PE or PP but mineral filled grades sink in water



~ Low gloss easily scratch able - LDPE, LLDPE
~ High gloss can be scratched
- HDPE
~ High gloss can not be scratched - PP









  
{

  

 




~ Take the sample and drop on the hard surface
~ Metallic Sound PC, PS, SAN, PPS
~ Dull sound CA, PVC, NYLON, PTFE, PMMA, POLYECETAL



~ Camphor smell Cellulose Nitrate
~ Plasticizer
- Plasticized PVC smell



~
~
~
~
~

Tough, stretches before tearing - Polyethylene

Tough stretches a lot before tearing - Polypropelene
Tears Straight
- Polystyrene
Stretches then tears raggedly - PVC
Tear easily and straight - Cellulose Acetate



~ Bends and tends to remain unbend - PE, PP
~ Cracks but retain unbend - Polystyrene
~ Bends and tend to remain - ABS
~ Bends easily and spring back PVC(Rigid)
~ Cracks and splinters difficult to bend - PMMA
~ Spring Back - Nylon


 
   



~ Thermoplastics
- solvents
~ Cellulose Esters - Ketones, Esters
~ PVC
- Cyclohexane one dimethyl formamide
~ Polyacrilic Acid Esters - Aromatic Hydrocarbons, Acetone
~ Polymethyl Acid Esters - Chloroform, Dioxin, Aromatic hydrocarbon
~ Polyesters - Ketones
~ PET - Cresol, Conc. H2SO4
~ PC - Chlorinated Hydrocarbons, Dioxan
~ PE - At elevated temp. Dichloroethelene, Tetralene, Decalene
~ PS -Toluene, other aromatic hydrocarbons, Ethyl Methyl Ketone,
~ Polyvinyl Acetate - Acetone, Methanol, Aromatic Chlorinated
Hydrocarbons.







  

  

 


  


(
( 
 
(
 (


PE

  



Blue base yellow tip

burns Continuously

(

 



No smoke

Drips

0axy
smell

PP

Blue base and yellow

tip

No smoke

Drips

Lubricating
oil
smell

PS

Orange yellow flame,

fast and continuously
burns

Black soot

No
dripping

Merry
Gold Smell

HIPS

-do-

-do-

-do

Burning
Rubber
smell

ABS

-do-

-do-

-do-

-do-

SAN

-do-

-do-

-do-

Merry
Gold Smell

.









 ABS and HIPS can be differentiated by detection of nitrogen by

elements analysis

: SAN and PS can be differentiated by detection of presence of
extra elements










  

  

 

 
 
  






(( 



(




Thermo-sets undergo a chemical
Thermoplastics are softened by heat, and become
change during moulding, becoming solid on cooling. This process can be repeated
solid, and therefore, they Cannot
many times.
be melted.
Overall chemical resistance of
thermo-sets in Unequalled by any
thermoplastic.
Dimensional stability is excellent.

Chemical resistance of thermoplastics is limited to

fewer compounds than is the case with thermo-sets.

Creep over a prolonged time

period is well below even glassreinforced engineering thermoPlastics. This means better
dimensional stability and better
resistance to property deterioration.

Creep is one of the major problems with the

thermoplastics 0hen subjected to long term loads.
This means sizable Dimensional changes and
Strength degradation. Creep Resistance is improved
by filler s and reinforcements.

Moulded-in stresses with compression moulded parts are parts are

lower than in other moulded parts ,
and where minimal distortion
is a factor, it can be a deciding
consideration.
Toughness is a property that can
be found in Thermo-sets at a
considerable cost; by using
reinforcing materials such as
fabrics and/or Fiberglass mat.

Since thermoplastic respond more readily to the

influence of heat, they also tend to fluctuate in dimensions. Some polymers vary more than others, but
as a group they would Rank second to thermo-sets.

Injection moulded thermoplastics have moulded in

Stresses in varying degrees that are caused by part
design, Processing parameters and mould design.

Most thermoplastics are inherently tough materials

and for this reason one used whenever this
requirement is needed. They provide good
toughness at low cost.

Colors in thermosetting compounds Thermoplastic materials can be coloured to any

are limited in variety and their
desired shade of appearance and normally maintain
stability is not Satisfactory. The
the colour throughout the life of a product.
resins tend to discolour over Prolonged periods of time.
Very few thermo-sets are available
in clear, see Through materials.

The selection of clear material in thermoplastics is

quite large.







  
x

  

 



1. Plastics are generally --------material.
2. As per their characteristic performance plastic materials are classified as -----------and -------------material.
3. Give some examples of thermoset and thermoplastic material?
4. 0hat do you mean by commodity plastic?
5. 0hat do you mean by engineering plastic?
6. 0hat is specialty plastic or modern plastics?
7. 0hat are the benefits or characteristics of plastic?
8. 0hat are the technical advantages of plastic?
9. How plastic materials can be identified?
10. -------, -------, ------- are transparent materials.
11. ------, ------are glossy material.
12. 0hat is floating test in water of plastics?
13. ------flames appear in case of PP.
14. 0hat is the behavior of plastics in flame?
15. Differentiate thermoset and thermoplastic material.
16. ------ materials can be reused and ------materials cannot.
17. 0hat is the full form of ABS, PP, PE, LDPE, HIPS & PVC?
18. Plastic materials based on their characteristics performance were classified as
.. & . Material.
19. Based on applications plastics are classified in .. , .. & plastics.
20. 0rite two identification techniques to identify the plastic material.
21. & are used to produce transparent components.
22. 0hich plastic undergoes chemical change during demoulding ?
23. .. gives metallic sound on hitting. (PC, SAN, PS)
24. Cellulose nitrate produces. Smell.
25. ------plastics can not be reused.
26. A mould is an assembly of & .
27. gives external shape of components.
28. . gives internal shape of component.









  

  

 


It is an assembly consists of an Impression, which is a recess or gap similar to
the Component formed by the two Mould members termed as CORE and
CAVITY , into which the molten Plastic Material is Injected under Pressure an
is allowed to be cooled either by water or air till the component gets hard.



It is female part of the mould, which gives the external shape of the
Component. Pockets, Slots, holes are considered as Cavities. These are highly
polished to a mirror finish, requires better finishing appearance on the outer
surface of the component.

 
It is male part of the mould, which gives the internal shape of the Component.
All Projections are considered as Cores. These are not required high polish as
the Component is to be sticks on to core







  

  

 




  

~
~
~
~
~
~
~
~
~
~
~
~
~
~
~
~
~
~

Top Clamping Plate / Top plate:

Location Ring or Retainer Ring:
Cavity Plate :
Core Plate :
Core back plate :
Bottom Clamping Plate / Bottom plate:
Spacer/ Riser :
Ejector Plate:
Ejector back plate :
Feed Buttons:
Guide pillars / Leader pins:
sprue Bush :
Sprue Puller :
Return Pins / Push back pins:
Guide bush :
Cavity:
Core:
Parting Surface:







  

  

 



 (

Holds the stationary part of the mould to the stationary platen of the injection
machine.

(  
Fits into a counter bore in the top clamping plate and is used to locate the
mould on the platen of the press so the nozzle and sprue bushing are aligned.
 (
( 
(

Part of the stationary section of the mould into which the leader or guide pins
are mounted. Also used to hold core, cavity blocks, and sprue bushings.


( 
(

Top plate of the movable section of the mould. Forms the parting line of the
mould with cavity retainer plate. Used to hold the leader pin bushing as well as
core and cavity blocks.


(

Mounted behind the core retainer plate to keep this plate from bending under
the high pressure used in injection molding:
(( (

Holds the moving portion of the mould to the movable platen of the injection
machine.



Mounted on the bottom clamping plate under the support plate to form a space
which allows the ejection bar to move when the piece parts are ejected.









  
P

  

 



(
( 
(

Counter bored for the heads o0f ejector pins, ejector return pins, and spur puller
pin.


(
(

Bolted together with the ejector retainer plate to form a unit. Acts as a back up
plate for the pins in the ejector retainer plate.


((
Pressed into the bottom clamping plate, they are lands for the ejector plate.
 
Round bars placed between the support plate and bottom clamping plate . The
same height as the parallels. Bolted to the bottom clamping plate, they are used
as additional support for the core retainer plate.

 
Butted up against the nozzle of the injection machine. Has a conical-shaped
hole through which the material is forced into the mould runner.


 
Pin located directly under the opening of the spur. Used to pull the moulded
spur out of the bushing after shot has been made.
 
 
Located in the ejector retainer plate. Force the ejector plate and ejector retainer
plate, and therefore the ejector pins, to the bottom position as the mould closes.


 
 
Hardened and ground steel pins pressed into one of the plated. Align the two
halves of the mould base.



Hardened and ground steel bushings which are pressed into one of the plates.
Serve as bearing surfaces for the leader pins. Some injection mould bases are
manufactured with the parallels welded to the bottom clamp plate. The unit thus
formed is called the Ejector housing.
 (
The female portion of a mould which gives to the moulding its external form.


The male portion of a mould which forms the internal shape of the moulding.
( 


That part of the mould plate, adjust to the impression, which butt together to
form a seal and prevent loss of plastic material from the impression.







  
3

  

 




 









 
  


   


- Distinguish the different moulding processes
- Explain the individual process.
- Distinguish different types of mould
- Explain the application of different types of mould &
its limitation, advantages & disadvantages.

  







  

  

 


 

COMPRESSION
MOULD

TRANSFER
MOULD

INJECTION
MOULD

BLO0
MOULD

EXTRUCTION
MOULD

THRRMOFORING
MOULD

ROTO
MOULD

COMPRESSION
HAND

FLASH

POSITIVE


 !


(
 


 


 



 !

 (:
:



 


TRANSFER MOULD

POT TYPE

PLUNGER TYPE


INJECTION MOULD

 





 











 

"





 


 















  
{

  

 




BLO0 MOULD

EXTRUCTION

INJECTION

STRETCH







  














EXTRUCTION MOULD
FILM EXTR.

PIPE EXTR.






 

Plastics are shaped by a Varity of methods such as molding, calendaring,
extruding, blow molding, vacuum forming, etc. For thermo-setting materials hot
compression molding, Transfermolding, laminating and castings are the most
common methods.
  

~ The hot compression molding method is the most commonly used method of
shaping a thermo-setting plastic to some desired form. The basic principle in
molding is that plastic material softened by heat and pressure takes the shape
of cavity due to pressure acting on it and it gets hardened by the heat and
pressure causing a chemical change and the desired shape is obtained
~ In general, compression and transfer moulds are made of High Carbon and
High chromium of hot die steel. The core and cavity should be heat treated to
the required hardness for maintaining the dimensional accuracy of product and
also the life of mould. There are different types of compression moulds in use.








  

  

 




Thermo plastic materials are used in injection moulding. The thermo plastics
soften and become plasticized in state by the application of heat and harden
when cooled. There is no chemical reaction taking place during the process of
heating and cooling. These materials have linear molecular chains that flow
over each other when heated and solidify into a new shape when cooled
without significant chain breakage.

 

~ Basically, blow molding is intended for use in
manufacturing hollow plastic products: a
principal advantage is its ability to produce hole
low shapes without having to join two or more
separately molded parts. Although there is
considerable difference in the available
processes, as described below, all have in
common production of a parison (precursor).
Enclosing of the parison in a closed female
mold, and inflation with air to expand the
molten plastic against the surface of the mould,
where it sets up into the finished product.
~ Differences exist in the way that the parison is
made (i.e., by extrusion or by injection
molding); in whether it is to be used hot as it
comes from the extruder or injection molding
machine (as in conventional blow molding), or
stored cold and then reheated (as in cold
perform molding); and in the manner in which the parison is transferred to the
blow mold or the blow mold is moved to the parison.






(

 (

 


1. Melt the material.
2. Form the molten resin into a tube or parison.
3. Enclose the parison in the blow mould.
4. Inflate the parision inside the mould.
5. Cool the blow moulded part.
6. Remove the part from the mould.
7. Trim flash, as needed.
~

In many cases, all theses steps can be carried out automatically, with the
finished products conveyed to downstream stations for secondary operations
and packaging.

Although there are many variations, the two basic processes are extrusion
processes injection blow molding. Extrusion processes are by far the more
widely used, but injection blow molding and injection stretch blow molding have
captured significant market segments. 0hile reviewing these methods, the
reader is urged to refer to Chapters 4 and 5 additional background material







  

  

 





~ In rotational molding, the product is formed from liquid or powdered
thermoplastic resin inside a closed mold or cavity while the mold is rotating
biaxial in a heating chamber. To obtain this mold rotation in two planes
perpendicular to each other, the spindle is turned on a primary axis, while the
molds are rotated on a secondary axis
~ Rotational molding (also popularly
know as roto-molding) is best suited
for large, hollow products requiring
stress-free
strength,
complicated
curves, a good finish, a variety of
colors, a comparatively short (or very
long) production run, and uniform wall
thickness.
It has been used for
products such as fuel tanks, furniture,
tilt trucks, industrial containers,
storage tanks, portable outhouses,
modular bathrooms, telephone booths,
boat hulls, garbage cans, light globes,
ice buckets, appliance housings, and
toys .The technique is applicable to
most thermoplastics but is most widely
used with polyethylene.


((  

 (


1. Virtually unlimited design possibilities (parts as small as a golf ball to a
22,500- gallon agricultural tank).
2. Relatively low machinery cost.
3. Low tooling costs.
4. Economical prototyping.
5. Strong outside corners in virtually stress-free parts.
6. Part finish from matte to high gloss.
7. Simultaneous processing of multiple colors.
8. Simultaneous processing of different parts.
9. Quick mold changes.
10. Possibility of moulding in metal inserts.
11. Molded-in multicolor graphics.
12. Multilayer moulding for chemical resistance or strength.
13. Double-walled parts molding for additional rigidity.
14. Possibility of minor undercuts.
15. Virtual 100% usage of material (no scrap).







  
x

  

 

(

~ There are essentially four basic steps in rotational molding: loading, molding or
curing, cooling, and unloading. In the loading stage, either liquid or powdered
plastic is charged into a hollow mold. The Mold halves then are clamped shut
and moved into an oven where the loaded mold spins biaxial. Rotation speeds
should be infinitely variable at the heating station, ranging up to 40 rpm on the
minor axes and 12 rpm on the major axes. 4:1 rotation ratio generally is used
for symmetrically shaped objects, but a wide variety of ratios are necessary for
molding unusual configurations.
~

In the oven, the heat penetrates the mold. Causing the plastic, If it is in powder
form, to become tacky and stick to the mold surface, or if it in liquid form, to
start to get. On most units, the heating is done either by air (as in a units, gas
fired hot-air oven) or by a liquid of high specific heat, such as molten salt; where
jacketed molds are used (see below), heating is cone with a hot liquid medium,
such as oil

  


~ Thermoforming is the process of heating a plastic material in sheet form to its
particular processing temperature and forming the hot and flexible material
against the contours of a mold by mechanical means (e.g., differentials in air
pressure created by pulling a vacuum or using the pressures of compressed
air). 0hen held to the shape of the mold and allowed to cool, the plastic
retains the shape and detail of the mold. Because softening be heat and curing
by the removal of heat are involved, the technique is applicable only to
thermoplastic materials and not to thermo-sets.
~

Examples of thermoformed products are plastic or foam dinnerware, cups, meat

and produce trays, egg cartons, refrigerator liners, computer housings, interior
and exterior automotive parts, blisters for packaging, and countless others.
These common and often taken-for-granted products are not usually thought of
as the result of detailed tooling design, precise controlled heating and forming,
expert material technology, and trimming/ finishing operations. Clearly, the
thermoforming process is an important link in the plastics industry.

Advantages of thermoforming over most other methods of processing plastics

include lower tooling and machinery costs, high output rates, the ability to use
pre decorated plastic sheet, and good- quality physical properties in finished
parts.

Its disadvantages include the need to begin with sheet or film rather than less
costly basic resins, trimming material used to clamp sheet for forming, and the
problem of trim scrap reclamation.










  

  

 



  

 
 (( 

 
(


~ Hand moulds
~ Semi-automatic moulds
~ Automatic moulds
  
Hand Moulds are usually small
in size and do not weight more
than about 10kg for ease of
handling. The material is put
into the cavities and the two
halves of the mould are
assembled and placed between
the platens of the press. After
the press has been closed and
parts molded, the mould is
removed from the press closed
and the parts molded, the mould is removed from the press and the parts
ejected from the mould on a conveniently located bench. The process is then
repeated. Hand moulds are used for making sample parts, or when a limited
number of small parts are to be produced. Hand moulds, being removed from
the press, facilitate the loading of inserts.

 ((
 
Vary greatly in size.
These moulds are
mounted on to the
platens of the press
by clamps. The
mould is loaded
with material and
the
two
halves
close. After the
pieces have been
molded some sort
of
ejection
mechanism pushes
the parts out of the
cavity or off the
plunger. The press
operator
then
places the molded
parts in a suitable
container or on a
bench
for
flash
removal etc. The
operator cleans the
mould of the excess material and the process is repeated.







  
P

  

 

((
 
~ Are similar to semi-automatic moulds but do not need and operator once the
mould has been set up for production run. The automatic moulds, through the
use of combinations of loading devices, timing devices positive ejector systems,
sweeps, micro-switches, safety devices and cleaning apparatus, lend
themselves well for molding many articles. There is a purpose for each type of
mould, and many factors such as the size of the piece part and the production
requirements, determine which of the three is used.







  
P

  

 



. &. are two main members of a mould.
P . is a female part of mould, which gives the external shape of the
component.
3 . is a male part of mould which gives the internal shape of the component.
is used to located the mould into the moulding machine platen during
loading a mould
{ . Act as a channel through which molten material flows from the machine
nozzle to the cavity.
..forces the ejector assembly to its original position.
Bottles are manufactured by moulding process.
x Food packaging products are manufactured by moulding.
Pipes are manufactured by------ moulding process.

Big size plastic products like water tank are manufactured by ------process.
.. is the most commonly used method for thermoset plastic materials.
P .. is a semi solid form of plastic material enclosed in blow moulding process.
3 . Materials are used in injection moulding.
Incase of bottles having thicker cap area or having variation in thickness at
cap portion are manufactured by .. blow moulding process
{ ......, .., .. & .. are four basic steps in rotational moulding.
Thermoforming moulding method is applicable only for .. .. material.
. are usually smaller in size and operated manually.
x . & . are two methods of thermoforming moulding process.
.. pins are used to pull the moulded sprue out of the bushing after processing.
P
& .. are used to align the two halves of the mould base.
P . & .. are two methods of blow moulding process.
PP The taper angle of sprue bush generally varies from to V
P3 gives a proper landing to the ejector assembly and provides provision for
easy assembly of mould ejector.
P Generally the component shrinks on to the . after opening.







  
PP

  

 


 

   







 
  


   

- Explain the types of compression moulds
- Distinguish different types of compression moulds.
























 "












  
P3

  

 


 

   


~ Compression and Transfer Molding Processes are mainly used for the
manufacture of thermosetting plastic products such as Electrical Switches,
Cooker Handles, Miniature Circuit breakers, Ceiling roses, Switch gears, Switch
boxes and also various consumer oriented products. To some extent this
process is also used for thermoplastics components which are otherwise not
possible to produce by other conventional processing methods due to
processing limitations. Example includes PTFE liners, Gears and 0ashers,
UHMHDPE products etc. Several technological advancements have taken
place in these areas which are mainly aimed at improving the quality of the
product and enhancing the production rate Robotics and process automation
with microprocessor based on control systems have revolutionaries, the entire
compression and transfer molding line and specially designed thermo set
injection molding process.
~

The quality of products largely depends upon the machine and the mould.
In this context, the requirement of precision mould can not be less emphasized.

(( (



  


Three important factors that must be controlled in compression molding are:
~
~
~

Temperature
Pressure
Cure Time


(

Thermo-setting materials which are used in compression molding are cured by
heat and pressure. Heating is and important phase in the molding operation.
Heat softens the material sufficiently to allow it to flow under the influence of the
press pressure into any openings in the mould to the desired shape. Heat
causes a chemical change or polymerizes the material into its hard infusible
finished state. Temperatures for molding thermo-setting materials vary from
270F to 350F. Temperatures for molding the various materials can be
determined by experimentation or by getting the information from the
manufacturer of some particular material. Temperatures the finishe4d article.
Temperatures which are too low do not allow the material to flow properly and
result in incompletely filled cavities and insufficiently cured piece parts of poor
consistency. Mould temperatures must be maintained within 5F. For best
results molding temperatures not only vary with the material used, but with the
geometry of the molded article, the type of mould, and whether loose powder or
pre-heated performs are used.








  
P

  

 


(  
( :
The two methods most commonly used in heating press platens and moulds
using thermo-setting materials are steam and electricity. Steam is favored by
many molders because of its economy and heating qualities. Electric heating of
moulds is replacing steam in many instances because of its cleanliness and
lower maintenance costs.




Pressure as well as temperature must be regulated in order to produce
satisfactory parts economically. Pressure needed to mould a particular article
depends on the flow characteristics of the material, the cavity depth, and the
projected are of the piece part. Generally, It is recommended that minimum
molding pressure of 225kg/cm of projected area be used. However, in practice,
about 375kg per Cm of projected area is used to compensate for any variables
that may be encountered.

( 

Varies with the materials use. The size and shape of the molded article, and the
method of molding. In compression and transfer molding, cure time is the time
elapsed when the movement of the press stops until the pressure on the molded
part is released. For smaller and thin wall pieces, cure time may be only a minute
or two. On larger pieces, and pieces with thick sections, the cure time may be as
high as 15 minutes.

(
During the process of compression
molding, gases are formed as the
chemical reaction takes place in the
material. Some provisions must be made
to get rid of the gases otherwise poor
quality piece parts will be the result. Gas
pockets can cause incomplete shots or
blistered piece parts. One method of
getting rid of the gases is to allow the
mould to breathe that is the mould is



(


(
closed and then opened again for about
3mm to get rid of the gases and then
closed again. Other methods used are in
small flats ground on the periphery of the
plunger that telescopes ground on the
periphery of the plunger those telescopes
into the cavity. Small grooves 0.050 to 0.25
mm deep and about 3mm wide ground into
the top portion of the cavity wall. This type
is used on large cavities.

(
(








  
P{

  

 

 (
  
  

To prevent the wastage of material for efficient molding, it is important to load the proper
amount of material into the
mould. This is done by one
of the following three
ways:
 
(

 
 (
" 

(
 
 


~ The
volumetric
method is most
efficient
when
used with ferrous
materials. A containner of predatermined volume is
filled with material
and the contents
poured into the
cavity.
~ The weight method is used with
materials in which
the amount of
material cannot be
controlled rea-dily
by volume. A predetermined amount of material is weigh-ed on a balance and then placed into
the mould.
~ The third method used is a predetermined amount of material which has been
compressed into pre-form of desired shape size and weight. The use of
performs is a very efficient method of loading moulds.

 

 
~ Smaller in size and weight not more
than 12kg for Easy Handling.
~ Production is limited to small parts,
short runs or Prototype 0ork.
~ Overall height of the molding is
controlled by land areas on mating
surfaces of the top force and cavity
Maximum Density of the molding
may be maintained by clearance
between the side wall of the top
force and the cavity. Used as a
single cavity mould on a Rotary







  
P

  

 

Press and molding pressure is controlled at each station. Flash must be

removed in the land area otherwise it will result in damage or breakage of the
lands. It is advisable to provide additional pressure pads outside the cavity.
 ( 
 # 

($

~ The POSITIVE type of compression mould. The plunger telescopes within the
cavity compressing the material and molding the piece as shown. There is very
little clearance between the plunger and the cavity wall. In the positive mould,
almost all the pressure is exerted on the material and very little material is
allowed to escape, the clearance between the plunger and cavity varies
between 0.036mm to 0.130mm per side, depending on the size of the mould
and the material to be molded. The amount of material that escapes through the
clearance between the plunger and cavity is called flash. The flash is formed
vertically on the type of mould shown. The disadvantage of the positive type of
mould is that after frequent operation the cavity walls become scored and
ejection of piece parts is difficult. Flash is formed on every piece part molded by
the compression method. The thickness and position of this flash depends on
the design of the mould, type of material being molded, and accuracy of the
mould. Flash is removed by filling, sanding, and tumbling. The positive mould is
used primarily with material containing coarse fillers. The amount of material
placed into the mould cavity must be measured accurately as there is very
limited means for the excess material to escape.

~
~
~
~
~

Used for high bulk materials and large deep draw parts when maximum density
is required.
It is single cavity mould and uses and accurately weighed charge of material.
All the applied pressure is exerted on the material.
Flash between the top & bottom force can be produced in the direction of
pressure.
Flash thickness varies according to the clearance between the loading chamber
and top force.










  
P

  

 


  ( 
 :

The principle of the semi
positive type of mould.
As the two halves of the
mould begin to close, the
mould acts much like a
flash mould as the
excess
material
is
allowed to escape. As
the plunger telescopes
into the cavity, full
pressure is exerted on
the
material
and
produces piece parts of
maximum density. The
mould
becomes
a
positive mould for the
distance X as shown on
the illustrations. The
distance X varies with
the size of the mould and material used. There is very little clearance between
the plunger and side walls of the cavity, which results in a very thin vertical flash
being formed. This type of mould takes the advantages of the free flow of
material in a flash mould and the quality of producing dense parts of the positive
mould.


  ( 

(
 (

~

It
controls
maximum
density
and
critical
dimensions as related to
cavity and top force.

Easy removal of flash on

large parts and leaves no
flash line scar on the side
of the parts


  ( 


 ( (

~

It is less costly and more

popular.

It is recommended for close tolerance parts and assures minimum flash finish.







  
Px

  

 

  # 
 

~ The FLASH type of mould.
The cavity is filled with
material and the excess is
squeezed out over the lands
which are about 3mm. 0ide.
External landing bars are
provided so the plunger does
not crush the top of the cavity
when the mould is completely
closed. Clearance between
0.050mm and 0.125 m is
provided so excess material
can escape and the cavity is
not damaged. Fig. shows the
flow of the material and illustrates the thin horizontal flash
formed with this type of
mould. The flash type mould is not generally used with coarse-filled materials or
for pieces which require a high density. The flash type mould lends itself well to
shallow-depth articles such as dinner-ware plates and saucers.

 (

 
Another type of mould
construction is the
split wedge or split
cavity mould. This
mould
is
used
primarily for articles
that have undercuts,
such as spool shaped
pieces. These projections or under cuts
prevent the piece part
from being removed
from a conventional
mould cavity. In order
to
overcome
this
difficulty, the cavity is
constructed in to two
or more sections.
0hen these sections
are
together,
the
C plunger
inside surface has A & B - Conical Cups
E upper heating plate
required shape, and D lower heating plate
F
mould
casing
L heating bandage
the exterior of these
G

location
dowel
&
CAM
combination
sections has a wedge
like
shape,
  K knock out pin







  
P

  

 

illustrates one type of split wedge mould in

closed position.   illustrates the semi-automatic type of construction with the mould
mounted on the platens of the press,  shows the two sections of the cavity split, the
projections on the piece part released from cavity, and the piece part ready for removal
from the mould. As the mould is closed, the spring loaded pins heads of which are in
T-slots in the wedges pull the wedges up the wear plates on the angle shown and the
two halves of the cavity close. By proper timing of the knock out system which controls
the action of the pins, the cavity is closed before the plunger enters the cavity. In the
type of mould shown in  per forms are generally used and are placed on the top of
the plunger. After the piece part has been molded, the plunger is withdrawn and the pins
are activated to push the wedges down the wear plates, opening the two halves of the
cavity. The wedges are held along the wear plates by T-slots and keys. Landing buttons
or bars are provided for the wedges to make certain that there is no gap between the
two halves of the cavity at the parting line when the mould is closed. This type of mould,
some times called a basket mould, is mounted on the press as shown because of the
ease of removal of molded pieces and ease of cleaning the mould. Moulds of this type
can be of single as well as multiple cavity variety






:







  
3

  

 

:
:
1. Compression and transfer moulding is used for ------materials.
2. ------ are used for articles having undercuts.
3. ------plates are used on the headed block or split to resist wear and can be
removed.
4. ------, ------ & ------are three main factors that affect the compression moulding
process.
5. Temperatures for moulding thermosetting material vary from ------ to ------VF.
6. ------ Or ------are generally used raw materials for compression moulding.
7. The overall area of the component top view is known as ------.
8. The time taken to get the thermoset material permanently asset is known as ------.
9. As the thickness of the moulding increases the area time of the process------.
10. ------ are given in the mould to escape out the air from the cavity on the moulding.
11. Generally the width and depth of the vents are ------ & ------ respectively.
12 as the projected area increases the pressure ------..
13. 0hat is positive type compression mould?
14. 0hat is semi positive type compression mould?
15. 0hat is the difference between semi positive vertical flash type and horizontal
flash type mould?
16. 0hat is the use of knockout plate in compression moulding.










  
3

  

 

 












 
  


   



- Explain the functional feature of compression mould & transfer mould.
- Explain the application & limitation of compression mould & transfer mould.
- Select the mould & moulding process for a particular given component.






















 %














  
3P

  

 


 


Transfer moulds are of the semi automatic type and are made in single and
multiple cavities, There are two basic types of transfer mould according to
construction;
~ ((
 
~ 
(
 

(

 :
The pot transfer is used in the conventional compression moulding press.
 
 illustrate the pot type transfer mould and the functioning of this type of
mould.   Shows the mould in the position in which the pre-form is loaded
into the pot or loading chamber. The pre-form is shown in place. The arrow to
the right indicates the movement of the mould in the press.





The material is heated
by the hot mould and
combined with the
pressure 0f the pot
plunger, the material
becomes fluid and is
forced into the sprue,
runners, gates, and
into the cavity to form
the piece part. This is
illustrated
in
 
Pressure is kept on the
material until the piece
parts
are
cured.
Excess material forms
a cull at the bottom of
the pot and also forms
a dovetail shape in the
plunger called the cull
pickup. After the parts
have been cured, the
mould opens
as shown in  . As
the plunger comes out
 

of the pot, the sprue is
broken at the small diameter of the taper. The cull pickup on the plunger carries
the cull out of the pot and the spure out of the spure bushing. As the press
continues to open the down ward movement of the plunger plate is halted, while
the rest of the mould below the parting line continues to move. The mould is
constructed as that the molded pieces remain in the cavities. Continuous
movement of the press activates the knockout bar and the molded parts are
ejected from the cavities. The mould in the completely open position is shown in
 .







  
33

  

 

To protect the edges of

plunger, a soft headed
mallet is used to drive off
the cull pickup and cull from
the plunger. The piece parts
are removed from the mould
and the runner are scrap
and cannot be re-used. The
piece parts are set aside for
further
finishing
if
necessary.
All
excess
material is removed from the
cavities pot and plunger.
The mould is closed until the
parting line is mated and the
mould is again in loading
position. (See  .) The pot
is then loaded and sequence is repeated.   illustrates another version of the
pot transfer type of mould. In this design, the material flows directly from the
sprue into
the cavity; no runner or
gates are used. If the
material is forced directly
into the cavity as shown in
   the small diameter of
the
sprue
should
be
constructed
as shown in  . A break
point is furnished so the
sprue does not pull material
from the surface of the piece
part. The operation of the
mould follows the same
sequence as described for
the previous transfer mould.
Another variation has two
sprues feeding the material
into a single cavity.







  
3

  

 





 
~ The plunger type of transfer mould in the closed position with the pre-forms in
the target area and the plunger on its down ward stroke. The combination of the
heat of the mould and the pressure of the plunger on the pre-forms causes the
material to become fluid and to flow through the runners and gates into the
cavities. The plunger transfer differs from the pot transfer in that the plunger is
part of the molding press and not a part of the mould itself. By the use of this
plunger, the sprue is eliminated and very thin cull of small are is formed above
the target are, thus reducing the loss of material. The top clamp plate is
fastened to the stationary platen of the press. The arrow at the right indicates
the movement of the mould base at the parting line. This type of mould is loaded
in one of two ways.
~

The pre-heated pre-forms are placed or stacked in the target are. As the mould
is closed, the pre-forms are lifted into the transfer sleeve. After the mould is
completely closed, the plunger is activated for its downward stroke.







  
3{

  

 

~ The mould is closed, and the pre-forms are loaded into the closed mould
through the opening at the top of the transfer sleeve. The plunger is then
activated, forcing the material throughout the mould.

~ Fig. Illustrated two other methods used in feeding the material into the runners
in a plunger type transfer mould. The view at the left shows the construction
when the round type of runner is used. In order to maintain a constant volume
flowing into the runner system, the runners are machined at an angle in the
runner plate. See sections A-A and B-B. On the right is shown the construction
used for trapezoidal runner. See section C-C Distance X should be two or three
times the width of the runner. The type of loading depends on the height and
size of the press used.
~ It is recommended that a clamping pressure 700 to 800 Kg per square Cm be
used to keep the mould together at the parting line. Pressure on the transfer
plunger is generally about 550 kg per cm. All transfer moulds must be vented to
allow air to escape from the cavities.








  
3

  

 

 



~ Both the pot and plunger are made from a good grade of wear resistant tool
steel which is heat treated and ground. Pots and plungers are made square,
rectangular or round in shape. The shape is determined by the shape of the
piece part, number of cavities, and available space in the mould base. Round
pots and plungers are preferred because less machining difficulties are
encountered. A clearance of 0.025 to 0.075 mm per side is provided between
the pot and plunger.
~ The area of the pot should be 20% to 30% greater than the area of all the
cavities and runners. The dimensions of the pot, if it is round or square, can be
calculated once the area is known.
~ To determine the volume of the pot, the total volume of all the piece part, the
runner and the sprue, plus a small amount for a 0.375 to 0.75 mm thick cull, is
approximately calculated. At least twice this volume is to be used for the pot
volume. Knowing the area and the volume, one can easily arrive at the depth of
the pot by dividing the volume by the area. The additional volume in the pot is
provided to compensate for the bulk factor of the pre-forms used and to allow
the plunger to enter the pot a short distance before exerting pressure on the
material. High bulk factor materials are generally not used in transfer moulding.
The bulk factor of the pre-forms used in transfer molding is approximately 1 to
2.Figs. illustrate some of the construction details of the pot and plunger.
~ For sufficient strength, horizontal distance Y should be equal to the depth of
the pot Y, - A1.5 to 3mm radius is provided at the top edge of the pot. A1.5
mm radius is machined at the bottom of the pot to facilitate the flow of the
material and to simplify the machining of the corner. A 2.5 to 3mm radius is
machined at the bottom of the plunger. The difference in the radii on the plunger
and the bottom of the pot results in a clearance so that the plunger will not
wedge in the pot but will land on the flat surface of the pot. In assembly there is
a small clearance between the plunger and the transfer pot.
~ In practice it was very difficult to maintain the clearance for long time. Fitting the
plunger to the cold pot size the plunger staying relatively cold during operation
but the pot having to heated the clearance widened between them allowing
material outflow.
~ Adjusting the plunger to the chamber when expanded by heat prevented its
entrance in the cold state was difficult. So it frequently occurred that the plunger
was forced into the pot strongly on clamping the mould and there was seizing
the cracking and other damage occurred.
~ This problem is solved by adjusting the plunger to the cold pot with running fit,
but permitting material flow around the plunger so as to form
~ a collar when solidified according to the hot pot size, thus preventing material
flow out, during molding. A sealing groove approximately 2.5 mm wide and 0.8
mm deep is cut into the perimeter or periphery of the plunger.
~ During the operation of the mould this groove fills with the molding material and
acts as a natural sea, allowing very little material to escape past the bearing
surface of the plunger. Flats or grooves are ground on the bearing surface of the
plunger for venting purposes. A clearance of 0.75 mm per side is machined
above the bearing surface of the plunger. This clearance keeps the bearing
surface narrow to prevent galling, and allows flash and excess material to







  
3

  

 

escape. The sprue and the interior or the pot is polished so the material can flow
easily. The sprue has a taper of 2 to 3 per side. The large diameter of the sprue
varies in size from 9 to 12 mm with a 1.5 to 3 mm radius at the entrance of the
sprue. The small diameter (at the runner or piece part) varies from 3 to 6 mm
depending on the size of the piece part. 0edge-shaped slots called cull pickup
are machined in to the plunger. The thick or heavy section of the cull pickup is
located directly above the sprue as shown in fig. The length of the cull pickup
varies from the width is generally 2 to 3 times the diameter of the sprue.




 
 



~ The clamping pressure provide by the chamber is an important consideration,
~ If the total cavity area is greater than the total pot area , the hydraulic pressure
exerted by the plastic compound would tend to open the mould at the parting
line.
~ So insure perfect mould locking, the area (Ap) should be 25% to 30% greater
than the combined area of the molding surface and the area of all runners and
sprues.


 
 (
If it is round or square can be calculated, once the area is known.

(
( Ap
= total projected area of cavities, runners and sprues
+ 25% to 30% of total projected area.







  
3x

  

 


(
= total volumes of all the piece parts, runners and sprues
+ Approximate volume of a small amount of .5 to 1mm
Thick cull multiplied by bulk factor of the compound.

( ( = Vp/Ap

























  
3

  

 

:
:
1. 0hat is the use of transfer mould?
2. How many types of transfer moulds are there?
3. 0hat do you mean by cull and what is its purpose?
4. 0hat is plunger transfer moulding?
5. 0hat is the use of transfer sleeve in plunger transfer mould?
6. The area of the pot should be ------greater than the area of component and runner.
7. How the volume of the pot can be calculated.
8. 0hat is bulk factor?
9. 0hy a clearance is provided in the bearing surface of the plunger.
10. ------to ------taper angle given in the sprue.
11. Depth of the pot is calculated by ------.
12. 0hat is champing pressure?








  

  

 








 
 









After end of the lesson/session trainees should be able to
- know the injection mould
- know the injection moulding process
- know the injection moulding machines
- know the injection mould parts materials
Flow chart for designing injection mould
- Different

steps for designing injection mould

- Know the calculations point of view

- Know the different parts of moulding machine
- Explain the mechanism & functional feature of moulding machine.
- Specify the moulding machine according to production requirement.
- Explain the safety precautions to be taken during operation  







 &











  

  

 


 
 





~ Injection moulding is one of the most versatile processing methods by means for
manufacturing small clips to large industrial crates. Technological advancement
was taken place over the last two decades. Sophisticated Micro processed
Control of injection moulding; Structural From Molding,
   


 
 , Gas Assisted injection Moulding etc., are gaining
more and more popularity in developing countries. Precision moulds are
essential to meet the stringent quality requirements of the end product. 0ith this
point in view the necessary in put data required for the mould manufacture in
the area of design and fabrication of moulds has been provided in this chapter.
~ It is not for being true to say that there are probably as many design for injection
mould as there are different plastics products, each product to be molded has its
own peculiar problems which most be considered when designing the moulds.
~ From a practical point of view, a classification of injection moulds should be
based on the main design features and manner of operation.



 


~ The type of gating and means of de-gating
~ The type of ejection
~ The presents or absence of external & internal under-cuts on the products
~ The manner in which the product is released form the moulds


 

((
 

(  

~ Standard moulds (two or three plate moulds)
~ Split cavity moulds
~ Stripper plate moulds
~ Stack moulds
~ Hot runner moulds
~ Insulation runner mould
 

 

 

(  
~ The process of injection moulding essentially consists of plasticize the raw
material in a cylinder by the application of heat and then injecting it under
pressure through a nozzle by means of a ram into a closed mould, where it is
allowed to cool, and then opening the mould and removing the moulded
component.
~ There are two methods employed to inject the plastic material into the mould:



 and (



 which transports
the materials during which time it is plasticized and then it is injected.
~ Shows a simple injection mould in the closed position after a shot has been
made shot is a term used to describe the total amount of material that has been
injected into the mould in one cycle, including piece parts, runners, gates, and
sprues.The material is placed in a hopper, in the form of a granules or pallet; the







  
P

  

 

hopper is located at the end of and electrically heated cylinder. To distribute the
heat evenly throughout the material
~ The spreader causes the material to flow against the wall of the heating
cylinder. The material heated in this cylinder softens and the plunger forces the
molten material (when has the consistency of thick syrup) through a nozzle into
a sprue and fills any opening in the closed mould. The material cools in the
relatively cold mould and hardens to a solid state.
~ The injection plunger is retracted, the mould is opened at the parting line, and
the piece parts are ejected from the mould. As the mould opens, the sprue
puller pulls the sprue out of the bushing. The sprue is separated from the molten
material at the small diameter at the nozzle as shown in Fig.
~ The piece parts, runners, gates, and sprue are ejected from the mould as a unit.
The place piece parts are then removed from the sprue and runners at the
narrow gates. 0ith the mould in the open position and the injection plunger
retracted, material is fed into the heating cylinder, the mould closed and the
sequence repeated. Illustrate the simple gravity type of feeder arrangement.
Other more practical and efficient methods of feeding material into the heating
cylinder include volumetric, weighs type, and pre-plasticizers.


 ( ( 

 (

(


SL.NO PARTS NAME
MATL.
HRC
1
2

Top plate
Cavity plate

Core plate

4
5

Core back plate

Spacer or Riser
block
Ejector plate
Ejector back plate
Cavity back plate
Core
Cavity
Locating ring
Sprue bush
Pillar
Bush
Spure puller
Ejector pin
Pushback pin
Or Return pin
Rest button

6
7
8
9
10
11
12
13
14
15
16
17
18

REMARKS

MS
MS, Tool steel
(P20, EN8-31-24)
MS, Tool steel
(P20, EN8-31-24)
Ms/ EN8
Ms/ EN8
Ms/ EN8
Ms/ EN8
Ms/ EN8
P20,H11,H13,EN24
P20,H11,H13,EN24
Ms
P20,OHNS,H11,H13
EN36,31,24
EN36,31,24
Carbon steel, D2
Carbon steel, D2
Carbon steel, D2

50-52
50-52
45-50
48-50
48-50
48-50
48-50
48-50

STD
STD
STD

Carbonsteel,D2,En31 48-50







  
3

  

 

 
 
 









  


  



 







 






 










 


 


 






 

 







 













 
  


 















  




  

 






 





















 




 






















 

















 
 













  
{

  

 

"
 




~ STUDY OF PLASTIC COMPONENT
~ STUDY OF MOULDING M/C TO BE USED
~ METHOD OF CONSTRUCTION OF MOULD
~ DETERMINATION OF NO. OF CAVITY
~ SELECTION OF PARTING SURFACE
~ TYPES OF LAYOUT OF CAVITYS
~ SELECTION OF RUNNER
~ SELECTION OF GATE
~ SELECATION OF TYPE OF MOULD
~ COLLING SYSTEM
~ TYPES OF EJECTER GRID
~ EJECTION SYSTEM
~ MOULD VENTING













  

  

 



  
  

1. material, 2.shrinkage, 3. quantity, 4. density, 5. accuracy, 6. shape and size
~ Material - material with which the component is to be moulded.
~ Shrinkage after cooling how much mm. per mm length will shrink.


Acrylonitritle butadiene styrene #
~ High impact
~ Heat resistance
~ Medium impact
Acetal Acrylic
~ Easy flow
~ Heat resistance
~ High impact






0.005 - 0.007
0.004 - 0.005
0.005
0.020 - 0.035
0.002 - 0.007
0.002 - 0.009
0.003 - 0.010
0.004 - 0.008

1.01 - 1.04
1.06 - 1.08
1.04 - 1.07
1.42
1.09 - 1.14
1.11 - 1.18
1.09 - 1.14
1.09

0.002- 0.005
0.002 - 0.005

1.22 - 1.34
1.15 - 1.22

0.007 0.016
0.010 0.025
0.010 0.025
0.010 0.025
0.008 0.020
0.004 0.006
0.005 0.010

1.12 1.14
1.07
1.08 1.14
1.04 1.05
1.01 1.02
1.23
1.34 1.42

0.015 0.035
0.015 0.030
0.010 0.030

0.92 0.925
0.941 0.965
0.860 0.960

Polystyrene #
~ General purpose
~ Heat resistant
~ Toughened

0.002 -0.008
0.002 -0.008
0.003 -0.006

1.040 1.100
1.040 1.100
1.040 1.100

Poly tetraflourethylene #


0.050 -0.100

Poly vinyl chloride #

~ Unplasticized
~ Rigid
~ Semi rigid
~ Flexible
Styrene-acrylonitrile#
Poly carbonate #

0.002 -0.004
0.002 -0.004
0.005 -0.025
0.015 0.030
0.002 0.006
0.006 0.007

Cellulose acetate
~ Hard /medium / soft
~ Cellulose acetate butyrate
nylon
~ Type 6
~ Type 6.1
~ Type 6.6
~ Type 11
~ Type 12
~ Transparent
~ Glass filled
Polyethylene #
~ Low density
~ High density
~ Polypropylene

1.35 1.45
1.16 1.35
1.00
1.075 1.100
1.20

Quantity as per requirement

Density depends upon resine used( to be decided form table 1)
Accuracy - as per components used
Shape and size to be studied from component







  

  

 



  





(  



~ The injection moulding machine essentially consists of two units namely the
mould clamping unit and the injection unit. The mould clamping unit performs
the function of closing the mould, locking the mould and opening it, the injection
unit. The mould clamping unit performs the functions of closing the mould,
locking the mould and opening it. The injection unit plasticize the material and
injects it in to the moulds. Fig. Shows an injection moulding machine. The left
side is the clamping unit and the right side the injection unit.
~

The mould clamping unit comprises of the fixed, movable and end platens.
The cover half of the mould is mounted on the fixed platen and the ejector half
of the mould is mounted on the moving platen. The fixed and end platens are
held by four tie bars and the movable platen moves over the four tie bars. There
are, in general, two methods employed to move the movable platen and to
apply the locking force these are direct hydraulic locking system and the
mechanical toggle system.

The injection unit is required to plasticize the material and inject it into the
mould cavity and exert a holding pressure on the molten material in the mould
cavity. Almost all of the injection moulds are of the semi automatic or
automatic type. Depending on the size of piece part and the size of press
available, moulds are made in single or multiple cavity. A variety of ejector
systems, which are generally an integral part of the mould, are used to eject the
piece parts, runners etc., for the mould. All injection moulds are cooled by
having water circulate through channels drilled into the various part of the
mould. Injection moulding offers vary efficient and economical method of







  
x

  

 

moulding pieces from a wide range of thermoplastic materials. Parts moulded

by this method possess very little or no flash, thus eliminating secondary
operation of sanding, filing, and tumbling. Very high production rates are
possible because of shorter moulding cycles than in moulding thermo setting
materials of comparable size. There is no wastage of material in the injection
moulding of the thermo plastic materials, as the scrap, runners, sprues, and
incompletely moulded pieces are reground and remoulded.







  

  

 






The plunger type machine is often rated in terms of maximum SHOT 0EIGHT (in
gm) with Polystyrene. The rating in terms of another material can be determined
as follows:
 (

( ( (
 
= (Shot capacity with material ) ' Density of 'Bulk factor of 
Density of Bulk factor of 
0here,

= Polystyrene
= Plastic to be used

The screw type machine is normally rated in terms of S0EPT VOLUME (in cc)
of the injection cylinder.
Shot capacity = 
(
#

'#

'


0here,

= Density of plastic material at normal temp. In gm/cc


= 0.85 for crystalline Material.
= 0.93 for Amorphous Material

(
 


(

(
 


(

ABS, ACETAL,
ACRYLIC

1.8 - 2.0

PP

1.9 - 1.96

SAN

1.9 - 2.5

POLYTHENE

1.8-2.3(LD)
1.7-1.9(HD)

NYLON

2 .0 - 2 .1

POLYSTYRENE

1.9 1.96

POLYCARBONATE

1 .7 5

PVC

2.3 (Rigid)
2.2 (flexible)


















  
{

  

 

(
 

(
Plasticizing rate of B (m/hr) [(
 (
# '

0here, A - Polystyrene
B - Plastic to be used.
QA -Thermal Capacity of A in cal/gm
[



( #
' (
 
QB - As same as A for B
(
 (
# 
[( #'#
  

 





  (
(


*)+ ((
 (
 ((
 

(


Cycle time (tc) when press is limited by plasticizing capacity is given by 

(
["())


0here,

m = weight of shot (g)

P = plasticizing capacity with polymer to be moulded and
K = 1000 (metric unit).




225





250




0 .3 8




ABS




0 .3 5

ACRYLIC

0 .0 3 5

225

300

0 .3 0

PC

ACETAL

0 .3 5

225

240

0 .5 5

PE

PP

0 .4 6

250

180

0 .2 4

PVC

PS

0 .3 2

200

200

0 .3 5

CAB

SAN

0 .3 3

220

195

0 .3 6

CA




NYLON-6










  
{

  

 


 
This includes
~ Distance between tie bars
~ Maximum Day lights
~ Size of mould plates
~ And other details of platen from machine manual
 

The clamping force required to keep the mould closed during injection must
exceed the force given by the product of the opening pressure in the cavity and
the total projected area of all impressions and runners.


(



Clamping force (tons) 
[

(

 Including runners in
 ' ("
 

( 

 
 



(



 "(  

( 

  
(
.






The injection pressure may be obtained from manual or may be calculated as
follows:


( 

#
 
[ 
 



#
 # 
  
,
#
( 
 
  
,


# ,#,[ )
(










  
{P

  

 

:


:
1. ------& ------ are mainly two main units of an injection moulding machine.
2. Ejector half of the mould is loaded in the------ of the machine and the other half
is located on fined plate.
3. ------ and ------ systems are two methods used for clamping system.
4. Plastic granules are fed into the injection unit through-----5. The process of pulling the ejector assembly of a mould during closing a mould
is known as ------.
6. ------ and ------ Are used for cooling the mould during running.
7. The left hand side of an injection moulding machine is the------ and right hand
side is .. .
8. ------is used to plunge the method from the injection chamber to the mould.
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:













  
{3

  

 


   



 

:
:
:




 
  


   


-Know the method of construction of mould for a given component
-Determine the no. of cavities for a specific component as per the requirement
Know the designing of guide pillars & guide bushes
-Explain the use & different types of guide pillars &guide bushes
-Know the designing of locating ring
-Explain the functions & use of different types of locating ring
-Know the designing of sprue bushes
-Explain the use of sprue bushes in moulds
-Know the suitable layout of cavity for a specific component
-Know the selection of appropriate runner for a specific component










 (



















  
{

  

 



   


 



(


(  

0hen core and cavity is made in a single block of steel without any bolstering is
called integer method. In these method two halves contains two solid blocks only.



~

Single impression mould.

For more strength.

Big component.


  (


~ Difficult to make multi-cavity mould because even if one part of cavity and
core becomes misaligned then the total block is rejected.
~

Higher machining cost because big machine with high accuracy is required.

High material cost.







  
{{

  

 






 
In this method core and cavity is made from a small block of steel Known as core
insert and cavity insert respectively and fitted in core holding cavity holding plate.



~
~
~

Multi impression mould.

Small components.
Replacement of insert easy.



To machine recess for collar of insert machining cost increases and mould
become little weak.







  
{

  

 



 
 


 (

(

Ns = 0.85 0
m


*&+(
 (


(:

(
 

(

Np = 0.85 X P X Tc

*&+(
(
 

(:
3600m


 

(

Nc =
C
.
Pc X Am
0here,
Ns, Np & Nc = Number of cavities based on shot, plasticizing and clamping
capacity respectively.
0 = Rated shot capacity for polymer in gm
m = Moulding wt per cavity in gm. (Volume* Density)
P = Rated plasticizing capacity for polymer (gm/hr)
Tc = Over all cycle time (sec)
C = Rated clamping capacity in tons
Pc = Clamping pressure in Tons/cmof projected area (0.630T/cm)
Am = Projected area of moulding including runner (cm)
- 
 (. (
( 
 ( 
(( 
 

 (
:

 (#
0.3-0.5


(
1.5

 (# 
(
5-10
1.15

0.5-1.0

1.4

10-20

1.10

1.0-3.0

1.3

Above 20

1.05

3.0-5.0

1.25










  
{

  

 



 

Diameter of guide pillar to be used depends on the size of the mould and side
thrust. Mould having deep and heavy cross sectional cores exerts more side
thrust.
 = Stem. dia of pillar ( P0 + 7 to 8mm)

= Collar dia of pillar (Ps +2 tcp)


 = 0idth/thickness of collar of pillar (from table)

 (
 # (


 ( #(



( )

"

)%)

%

%)()

&

()))

(

)) ))

*

[
(  #


 (
   




 (


   (
(
 
 (

:
   
#
(  ( 
))))
))&)
&) ))
)) &)
&)"))
"))%))
%))())
())))







  

#
)
"
(
/

&
" 
"*




  
{x

  

 


 



Bi = Guiding dia of bush = Guiding dia of pillar Po
Bo = Outside dia of bush = stem dia of pillar Ps.
BC = Collar dia of bush = collar dia of pillar Pc
Bl = Length of bush
= Thickness of mounting plate.







  
{

  

 


  


D1d8 = Fixed platen hole dia 0.1mm (say 125)
d1

= Dsp = Collar dia of sprue bush +0.1mm

D2

= 7mm (for M6 screw)

D3

= Dia of screw head (10mm)

= 20, = 45

H1

= 10mm for small and 12mm for big mould

PCD = 70 90mm
H

= 6 8mm

= 4mm

= 6mm

  





~ Reduced diameter type
~

Constant diameter type

Increased diameter type







  

  

 

Increased depth type

 


~ The pact of mould having the tapered channel, connecting the cavity and
machine nozzle is known as sprue bush.
~ The taper channel is called as sprue.







  

  

 

0here,
= Collar dia. of spur bush (From table 1)
= Outside dia. of spur bush based on spur dia (From table1)
(=Collar thickness of spur bush based on spur Dsp (From table 1)
= Length of sprue bush
~
~
~

As minimum as possible.
Normally 45 to 100mm
Equal to height from top surface of cavity plate to the top surface of top plate.

 =
 =
=
 =
 =
 =

Depth of radius (1.5 - 4mm) Approx

Nozzle sitting radius (From table II)
Nose radius of machine nozzle + 2mm
Smaller dia. of sprue (Nozzle orifice dia + 0.5-1mm)
Bigger dia. f sprue (calculate) (table II)
2 LSP tan/2+dy

0here,


= 60mm usually

= 2 to 5
Normally di is kept equal to dia of runner.


 #
2.5 - 3.5
3.5 - 5.5
5.5 - 7.5




# #
12
24
16
32
20
40




  
P

(#
16
18
22

 #
2.5 - 3.5
3.5 - 5.5
5.5 - 7.5

  

 


 





( 
 

  
 
(


30
3
10
80
3
10
130
5
10
180
5
10
300
5
10



 

 
:
:
~ Cavities should be placed in such a way that when they are connected with
sprue through runner and gate will ensure the uniform filling of impressions.
~ In general multi-cavity mould having same shape and size of impressions are
connected through runners and gates of similar cross sectional area and length
and cavity should be placed at equidistance from the centre of the sprue.
~ For multi cavity mould having differently shaped impressions should be
connected through following system:







  
3

  

 

 
 



 
 
.
R= Distance between sprue centre and cavity insert or distance at which cavity insert
to be placed from the centre of cavity holding plate
R = (CLd+5)/ (2Sinx/2)
CLd = Collar dia. of cavity insert.
C I = I.D. of cavity insert.
GL = Gate length (0.5 1mm)
CE = External dia of cavity insert.
X = 360/Number of cavities.
L = Runner length = R-(CI/2+GL)


 

(


( 
(

( 
~ Gate should have similar cross-sectional area.
~ It is required when dissimilar cavities are placed at equidistance
centre of the sprue.
~ It is called runner balancing.

from the






( 
 
( 
~ Gate should have different cross sectional area
~ This is done when dissimilar cavities are placed at equidistance from the centre
of the sprue.
~ This is called gate balancing.

 

(


( 
 
( 
~ Gate should have same cross sectional area.
~ 0hen cavities not placed at equidistance from sprue centre.







  

  

 

~
~
~
~


 

Runner is a channel in the mould which connects the spur with gate
For a single day-light mould runner is made on the parting surface.
Runner may also be placed below the parting surface for complex mould.
Runner cross sectional shapes should be so design that it provide maximum
cross sectional area from the pressure transfer point of view and at the same
time it should have minimum contact on the periphery from maximum heat
transfer point of view.


 (

 
(
 



( 




- Round
- Trapezoidal
- Modified Trapezoidal.

~ Out of this round runner is most efficient from heat transfer point of view, but
cutting half of the runner in fixed half and other half in movable half matching of
two halves to get full round runner is difficult.
~ Instead of round runner if half-round runner is used it leads to problem of
ejection of component and feed system.
~ Round and Modified Trapezoidal runners are mostly used.







  
{

  

 

~ Runner length is kept as short as possible for rapid filling of cavity & to reduce
pressure loss. Corners formed at the junction of main & secondary runner
should be rounded off to reduce flow resistance.



 

 =

0 X 4L
3.7

0here, w = wt. of comp. in gm, (volume X density)

L = runner length in mm





[

 
(

~ Area is important to ensure the delivery of particular volume molten plastic
material into the cavity in specific time duration i.e. within injection time.
~ Perimeter of the runner profile is important as less perimeter is preferred for less
heat loss from the molten plastic material . There by maintaining proper melt
condition for smooth flow of the molten plastic through spure, runner , gate and
finally into the impression

 



  
(
~ Runner length
~ 0t. of moulding
~ MFI of the moulding
For high viscose material the runner size will be higher than the calculated value.
As the behavior of the plastic material has the restriction for easy flow .in addition
to the this care May taken in the flow path to maintain high surface finish there by
reducing the frictional flow restriction during the filling of the cavity












  

  

 

   





 (

(


(  
 



Up to 15
Under 50
2 .5
Up to 15

Over 50

15- 50

Under 50

15- 50

Over 50

50- 200

Under 80

50- 200

Over 80

Over 200

Under 100

Over 200

Over 100

10





































  

  

 






 












 
  


   


-Select the suitable gate for a specific component
-Know the different types & use of gates
-Use of different sprue puller.


















 











  
x

  

 


 


 

(
(



(  for temperature-sensitive
& high viscose materials, high-quality
parts and those with heavy section.
 (
: results in high quality &
exact dimensions.
  (
 post-operation for sprue
removal, visible gate mark




(

(


~ The cross section being simple cheap to machine.
~ Gate dimensions can easily be modified.
~ All common moulding materials can be moulded by this.
~ 0itness mark is left on the visible surface of component. For polystyrene,
acetal; it is more clear.
~ Use of soap case, Instrument box etc.
~ Normal size is (3 X1) mm Approx. for components up to 30gm wt.
~ Large components with hard flow material size may (10 X 8) mm.
~ Components can be de gated at machine by operator.

If,

h = Depth of gate in mm
Then,
A = Surface area of cavity (mm)
t = Thickness of component.
Lg = Land length in mm. (1mm to 1.5mm).
n = Material constant







  


[(
[
")

  

 






(
 


.

0 .6

Polyethylene, Polystyrene
Poly acetal, Polycarbonate,
Polypropylene

0 .7

Cellulose acetate,Acrylic Nylon

0 .8

Pvc

0 .9



(

~ In this type of gate the material coming from the gate is forced to impinge on an
opposing face of the impression and then the material progressively fills the
impression displacing the air.
~ If a gate is provided at the centre of on end of a solid rectangular block then the
material will enter the cavity with a jet form and will be solidified when comes in
contact of cool mould walls. After this the material required for filling the4 cavity
will flow around the original jetted material giving rise to a flow line.







  

  

 

It is used for block type component, radio knob etc.

Land length
Gate width
Gatelength
Gate Height

[)&)&
[") (n = Material constant)
 [!
[((t = component thickness)

(

~ This is a modified rectangular edge gate.
~ The width of the gate increases with the decrease of depth towards impression
to get a constant cross sectional area through out the gate length.
~ Land length is little more than rectangular gate.
~ Used for the component having large volume and thin wall thickness like scale,
jeweler box etc.
0idth of gate at bigger end, [
")
Minimum depth of gate, [(
Maximum depth of gate,

[





Land length, ["

0here,




N = Material constant
A = Area of cavity surface (mm)
t = Thickness of component (mm)




  

  

 



  (


~ It has a circular runner which is connected with the sprue centrally.
~ A gate is cut to connect the impression with runner.
~ If bore is not important gate is cut in the core which is easy to cut.
~ This is used for tubular shaped moulding in a single cavity mould (baby cycle
wheel, lamp shade).







  
P

  

 

 (

~ In this case as usual runner is used with a gate all round the external periphery
of the component.
~ It ensures uniform feeding around the core pin.
~ Ring gated components are normally provided with stripper plate ejection.
~ The gate is in the form of a concentric film between the runner and impression.
Used in producing tubular mouldings like body of a float valve, water gun,
plastic bangles with multi impression two-plate mould.
L= Length of gate
h= Depth of gate
n= Material constant
t= Thickness molding

 (

~ Long rectangular type edge gate is called film gate.
~ Due to longer length wrap age of the component reduced.
~ Depth of gate is kept lesser than rectangular edge gate.
~ Runner is extended beyond the end of component.
( 
( 



( 


( 



(

  



(

0here,

=Depth of gate, = Land length of gate,= Material constant

(= Thickness of component







  
3

  

 







(

~ 0hen a gate is provided below the parting line is called a subsurface gate
~ It is a circular or oval gate
~ The runner is terminated at distance X from impression.
~ A secondary runner usually of conical form is machined at an angle to the
impression wall and is stopped short of the impression wall by a distance L.
~ It is used for moldings of injection syringe

(Land length)[/ (minimum)
[")0%&0








  

Angle subtended by centre line of

Secondary runner and impression wall 

  

 




( primarily for smaller parts in
multy-cavity molds and for elastic
materials.

 (
: automatic gate removal.

  (
 for simple parts only
because of high pressure loss.







  ((


(  for multi-cavity moulds &
center gating.
 (
 automatic gate removal.
  (
 large volume of scrap &
higher mould cost.







  
{

  

 





~ A projection or tab is moulded on the side of the
component.
~ At right angle a rectangular gate is provided to join the tab and runner.
~ This is an alternative to overlap gate.
~ This was designed specifically for use with acrylic material to obtain stress free
high optical clarity.
~ This is used for solid block or thick type job where mark is allowed on side of
the component only, like clock glass, lens etc.

 (  Y= D


(  X = 0.9t


(  Z = 1.5D
0here,
D = Runner diameter,
t = 0all thickness of plastic component







  

  

 


(  for high-quality
technical parts, independent of
cycle time, also suitable for
material difficult to process

 (
no material loss
from runner system & automatic
gate separation.
  (
: expensive
moulds especially due to control
equipment.






( for materials with large
softening & melt temperature range&
rapid sequence cycles
 (
 automatic separation
material loss from only after shut
down
  (
 danger of cold material
gating into cavity after interruption



























  

  

 

 






d = 5-8mm
D = 2-20mm
Dc=D+5mm
Tc=0.25D-0.4D
L1=8-10mm
L2=5-8mm
= 4 -6




$ (

~ Reverse taper cold slug well sprue puller
~ Grooved slug well
~ Z type
~ Mushroom headed
Reverse taper







  
x

  

 

:
:
:
:


 


:
:
:
:
:
:
:
:
:




 
  


   


- Know different Ejections system
- Explain functions & use of different Ejections system
- Know the function of Knockout rod,
- Knockout bushes,
- Auxiliary guide pillar
- Auxiliary guide bushes
















 *











  

  

 



 

~ Plastic material shrinks on solidification this property compels plastic
components to sit tightly on the core and makes the removal difficult. The
mechanism of removal of moulded part from the core is called ejection system.
~ Injection moulding machines are provided with an automatic activation of an
ejector system which is situated behind the moving platen.


( 
~ Ejector grid is the portion of the ejection system which provides a space into
which the ejector plate assembly is mounted. This grid allows to and fro
movement of the ejector plate assembly within the grid.
~ The grid normally consists of back plate and spacers

 

 


( 
~ Inline type of grid consists of two support block and a back plate. Usually on top
of spacers core back plate is mounted.
~ This type of system is suitable for small mould when the distance between two
riser blocks increase additional block may be incorporated in between in stead
of increasing the thickness of core plate or core back plate. Sometimes
additional local support pillars may be used
:











  
x

  

 



(



( 
~ Some times grid is made by enclosing all the four sides which is called frame
type ejector grid.
~ It prevents foreign particles to enter and there by ensures smooth and accurate
functioning of ejector assembly movement.
~ It provides better support than inline grid.


 
(  
~ Ejection grid can be made by mounting circular support pillars on to the back
plate and enclosing these circular pillars by thin metal plates to prevent foreign
particles in ejection system used for large moulds.








  
x

  

 




((


~ It consists of retainer plate
which holds ejector element like pins, sleeve etc
and ejector plate, which
supports the ejector pin
etc and helps in actuating
pins.
~ An ejector rod is screwed
with ejector plate and
other end of ejector rod is
free which is pushed by
the actuating rod of the
injection moulding machine.
~ This assembly system
shall depend mainly on the
size of the mould. For
smaller mould and ejector
rod bush is fitted into the
back plate in which the
ejector rod slides.
~ For heavy moulds two or
four bushes are fitted in the ejector plate assembly itself. This assembly with the
help of guide pillars mounted on the back plate is made to slide to eject the
component.
~ Length of the ejector rod depends on the ejection stroke which is again
dependant on the max depth of hole of the plastic component.
~ After placing the ejector elements in the retainer plate, ejector plate is placed at
the back of retainer plate and screwed together tightly.
~ Thickness of retainer plate is governed by the thickness of head of ejector
elements length and breadth depends on the distance between ejector element
placed at max distance in the direction of x and y.
~ Thickness of ejector plate depends on the ejection force required to eject
component. Length and breadth is same as retainer plate.


((


((


~ In general two systems are used for the purpose of returning of ejector plate
assy. For the next shot.
~ One is  
(
 and other  
((
.
~ In push back pin system four pins called push back pin are fitted at four corners
in the ejector plate assy. Just opposite to these pins four more pins called
returning pins are fitted in the fixed half of the mould. 0hen mould starts closing
these returning pins pushes the push back pins there by the ejector plate assy.
Returns to rear most position.







  
xP

  

 

In spring return system the spring is fitted to the ejector rod supported by cap or
washer screwed at rear end of ejector rod so that it is slightly at compression
between ejector back plate and cap or washer. This system is used for smaller
mould. For larger mould more than one spring are used between retainer and
core back plate.

 

((


~ Push back pins (return pins) are basically large diameter ejector pins fitted
close to the four corners of the ejector plate assembly. A cross section through
part of a mould which illustrates a push back pin is shown in Figure 5-13. In the
molding position as shown at (a) the push back pins are flush with the mould
plate surface. In the ejected position the push back pins protrude beyond the
mould plate surface (b). Thus when the mould is in the process of being closed,
the push back pins strike the fixed mould plate and progressively return the
ejector plate assembly to its original position (a).

Push-back return system



condition(a)








push-back return system

 
 condition(b)




  
x3

  

 


 
((

For small mould, where the
ejector assembly is of light
construction, a spring or stack of
Belleville washers can be used
to return the ejector plate
assembly. A typical arrangement
of the spring actuating method is
shown in Fig. 5-14. In this design
the spring is fitted on the ejector
rod. A cap is attached to the end
of the ejector rod to hold the
spring in position under slight
compression. In operation when
the ejector assembly is actuated,
the spring is compressed further.
Immediately the mould closing
stroke commences, the spring
applies a force to return the
ejector assembly to its rear
position.





( 


 

~
Pin ejection
- Stepped pin ejection
- D shaped ejection
~
Sleeve ejection
~
Blade ejection
~
Stripper plate ejection
 
 

Cut = Thickness of plastic component
Dep = Diameter of ejector pin
Cd = Depth of hollow portion of plastic component.
Bs = Bearing surface of plastic component for







  
x

  

 



(
((


[C




0here,

Cid = Inside diameter of component = core dia



))

 






(  




Total area of ejector pins = Bs
.
100
Max. Diameter of pin = Thickness of plastic component.
Nep = Number of ejector pins required
[%[
))C#
  &C#
 




(   


((

( (
(


( 
  


 
( ((
 (
(
   


( 



This is the most common type of
ejection as in general it is the most
simplest incorporated in a mould
with this particular technique the
moulding is ejected by the
application of pressure a circular
rod called as ejector pin. The
ejector pin headed to its attachment
to ejector plate assembled, the
working diameter of ejector pin is
must be good slide fit. In matching
hole in the mould plate, if it is not
the plastic material with creep
through the clearance and the mass
of material will progressive of build
of bending the mould plate. The
rare part of ejector pin is fitted into a
suitable hole which is bored and
counter-bored in retainer plate. The
rare case of ejector pin is back up
of
the
ejector
plate.
The
accommodation
provides
must
allow the ejector pin float way the
feature is necessary. As taken
above, the ejector pin must be slide







  
x{

  

 

fitted in the hole in the mould plate. The direction of movement of ejector pin is
therefore controlled by this hole should not be bored absolutely in right angle
when the ejector unity assembled.



~

Consider the case of where the small

diameter (3mm) ejector pin are required the
stepped ejector pins, now slender long
length diameter ratio in ejector pin have the
tendency to construct in use. It is desirable
to keep the working length to such as
ejector pin to minimum this is achieved by
designing ejector pins. A stepped ejector
pin manufactured from a solid rod,
alternating. It could have to be steel. The
small diameter portion being fitted as
suitable hole matching in large diameter
portion. The two parts will brazed together
.this later method has advantages that
should the ejector pin break only the
smaller diameter portion be remade. The stepped ejector pin is normally used
face pin for ejection of moulded bushes and ribs, note that the main ejection is
provided the standard plain type ejector pin. The length should be kept as short
as possible. This length is need only equal length in contact with the mould plate
is kept into minimum by in corpora ting a clearance diameter hole in the mould
plate .A suitable length the small diameter ejector pin is 5 to 6 times the diameter.




~

This is the name given to a flat sided

ejector pin. It is the made quite simply
by machining. A flat on to a standard
ejector pin. It is used primarily for the
ejection for the thin walled box type the
procedure adapted for producing D
shaped hole as shown in figure.

~
~

Mark required position of ejector pin.

Bore the required diameter hole in the
bolster.
Machining
out
the
recess
to
accommodate the insert.
Fit the inserts and hold back with
screws.

~
~









  
x

  

 



~ The main purpose of blade
ejector is for the ejection of
vary slender such as ribs and
other projection. 0hich can
not satisfactorily be ejected by
the standard type of ejector?
The blade is basically a
rectangular ejector pin, while
the blade ejector is machined
solid rods
~ It is more usually fabricated
the element in which case a
blade of steel is inserted into a
slot machine into a standard
type of ejector pin.
~ The blade may be pinned or
alternated it may be brazed
.the advantage of two part
construction is that the blade
can easily replaced should
become damaged.
~ The blade ejector element is
fitted to the ejector assembled in a manner to that described for the standard
ejector pin. The rectangular plate ejector accommodated in a completely
shaped hole in the mould part.





The sleeve ejector is

mounted into the ejectors
pin
plate
like
a
conventional ejector pin.
The core pin which fits into
the sleeve is mounted into
the clamping plate. As the
ejector unit is activated,
the sleeve pushes the
piece part off the core pin.
Sleeve ejectors are used
to push bosses and knoblike piece parts off core
pins. It is undesirable to
allow the sleeve to be in
contact with the core pin over its entire length. To reduce frictional wear, to
facilitate fitting and to lesson the possibility of scoring, the surface contact
between the two parts is kept to a minimum.







  
x

  

 

( 
(


( 

Stripper plate ejection is generally used
where ejector pin marks would be
objectionable on the piece parts and
where maximum ejection surface is
required. Stripper plates are used on
single and multiple cavity moulds. An
angle of approximately 5 is machined in
the stripper plate and on the plunger, as
shown in fig. 5-18. This prevents scoring

of the plunger as the stripper plate

moves in and out over the plunger. The
illustration shows two methods of
keeping the stripper plate from coming
completely off the plungers and out of
the mould. View at shows the use of a
stripper bolt to limit the travel of the
stripper plate. View at B shows the
return pin held to the stripper plate by a screw. This allows the stripper plate and
ejector plate to operate as a unit. In more complicated designs, pull rods mounted
in the stationary portion of the mould are used to activate the stripper plate.







  
xx

  

 


  

 
L = Length of the ejector rod.
= Height of ejector rod bush + Ejector stroke length +10mm
Ejection stroke length = Max. Depth of component +8mm
H = Thread diameter length
= Ejector plate thickness 3mm
= 15 to 20mm in general
D = Ejector rod diameter (Table-1)
d = Threaded diameter (Table-1)

Design of 
 ( & 



. 
. 
.  
Up to 150

15

M10

150-200

20

M12

250-300

25

M16


  



H = Height of the ejector rod bush = Thickness of back plate
H = Thickness of collar = 4to 5mm
D1 = Internal diameter of bush= Outside diameter of ejector rod.
D2 = outside diameter of bush

= D1 + 8 to 10mm

D3 = Diameter of collar of bush =D2 + 6 to 8mm










  
x

  

 





  










 
  


   


- Use of different Cooling system.
-Select the suitable cooling system for a mould
























 /












  

  

 


  

~ One of the most important acceptation of mould design is the provision of suitable
and adequate cooling arrangement in all injection moulding. Even though it
involves having a heated mould, the purpose of mould is to cool the molten
plastic. The means of cooling and insulated to prevent any escape of heat by
conduction or radiation. It would quickly cool the material will be mould and would
no longer fulfill its function. The cooling system is an essential mould feature,
requiring special attention in mould design. It should ensure rapid and uniform
cooling of the moulding. In design of mould component and layout of the guides
and ejectors. The allowance should be proper size and position of the cooling
system. Rapid cooling improves process economy, while uniform cooling product
by different shrinkage, internal stresses and mould will relies problem. In addition
uniform cooling ensure a shorter moulding cycle. A rapid and uniform cooling is
achieved by a sufficient number of properly located channels. The location of this
channel should be consist with shape of moulding and should be as close as
cavity will allowed by strength and rigidity of the mould.
~

Increasing the depth of cooling line from the moulding surface reduces the heat
transfer efficiency and to wide a pitch gives a non-uniform surface. A straight drill
line are preferred to bubblers they should be designed so that cross-sectional
area remains constant for entire circuit for tube bubblers area in the both side of
the tube should be equal material with higher thermal conductivity should be
used. If all the heat cannot be removed with a steel mould.

The described location of this heating-cooling phase is the mould close to where
most of the heat decapitated that is where the most of the material is located.



   :
dT= Diameter of cooling
hole
C = Distance between
centre of the cooling
hole and the surface
of the plastic component. = 2 to 3 dt
t = Thickness of the
plastic component
b = Centre distance
between two adjacent holes = max. 3dt
( 

 

Up to 2
2- 4
4- 6

8- 10
10- 12
12- 15







  

  

 






 
 

~ These are the most common cooling channels found in the mould.
~ They are normally in series of drilling package of series and that are round in
diameter.





 


 
~

This type of cooling is used commonly found in backup plate rushed in mould
cooling.

These are the usually series of package but a rectangular shape that
compromises the cross-sectional area.







  
P

  

 





 
~

Circular sections are used to cool round plate, cylindrical stroke, cone shape
cores and cavity, etc. this arrangement, when properly interfered makes it
possible to follow close radius of the round core or cavity so that the distance of
channel is kept as a uniform depth.





 
~ These have the rectangular cross-section area for easy of machining.


~ This channel component are normally connected with straight section round flow.
They are used in cooling of pins, cores and deep draw area. Epical two channels
are parallel the surface of the back plate of the different depth. In bottom channel
tubes are screwed go to that top area to be cooled (pin and core) the inlet water
groove & lower channel fills the tube, and then overflow of the outlet each core
tube receives same cooling with maximum velocity.







  
3

  

 


~

These constitute an alternating method for cooling pins, cores, and deep draw
areas, unlikely baffles they are tied together in series triple straight section stroke
the coolant extruded section that intersect with all of the baffles of the channels,
each baffle is a round drill section, with blade to divided in cross-section area in
half. The coolant flowing in straight section runs baffles blades, and makes it
bends to the baffles. In as much as the blade does not extend all the way of the
end of the baffle. If they run blow the back side of the plate, make another so turn
back into straight into as goes next baffle. This is an expectable method for
smaller number of cavity from side to side or very large diameter channels and
baffles.














  

  

 

 
( 


As molten plastic enters the mold, it quickly displaces air in the tightly scaled mold,
although some air escapes through the parting line or loose-fitting ejectors or slides, most
molds need strategically placed vents for rapid and complete air removal. This section
discusses vent design and placement.
(  

(
As a first choice, place vents along the mold parting line. Typically easy to cut and keep
clear of material, vents in the parting line provide a direct pathway for air escaping the
mold.  
  standard parting-line vent guide lines for thermoplastic resins. To
prevent material form flowing into the vent during filling, the depth of the first 0.150 inch to
0.300 inch of vent length must be small, typically less than 0.0020 inch for amorphous
resins and less than 0.0015 inch for semi-crystalline resins. Your resin selection and
processing conditions determine the vent's maximum depth. The ranges given in  

apply to typical molding conditions. Other rules of thumb for venting:
~
~
~

The amount of venting needed increases with part volume and filling speed;
Add more vents or widen existing ones to increase venting; and
To avoid flash, do not increase vent depth beyond the guidelines.

For the vast majority of resins and part geometrics, more vents are better. The
exceptions are resins with components - usually flame retardants or other additives that
can boil to the surface at the flow front and deposit on the mold surface and vents. These
resins rely on pressurized air in front of the flow front to hold volatiles in the materials.
Over-venting can prevent the flow front from generating the required pressure. Add vents
sparingly in molds for these materials. Carefully review product information bulletin for
specific venting recommendations, particularly for flame-retarded materials.







  
{

  

 


(


(
Vents should be placed at various locations along the runner system and part perimeter,
but they are especially needed at the last areas of the mold to fill. Typically these areas
are located on the parting line and lie farthest from the gate. 0hen the last area to fill is
not vented, air may become trapped in the mold, preventing complete filling of the cavity
and causing a gas burn on the part. The trapped air is supper heated during compression
and in severe cases can pit or code the mold steel.
0hen feasible, move gates or vary part thickness to change the filling pattern and direct
air to parting-line vents. If air-trap areas persist, consider using ejector pins modified with
flats for venting #

 



( 
( usually self clean with each ejection stroke. Air trap areas not
accessible by ejector-pin vents may require vents placed along mold inserted or splits in
the mold. This type of vent usually required periodic type of vent usually requires periodic
disassembly for cleaning. Porous metal inserts can also provide venting for difficult airtrap areas but may require periodic cleaning.
Part features produced by blind holes in the
mold, such as posts and bossed, require
venting at the last area to fill, usually the tip
or end. Bosses can usually vent along the
core insert forming the inside diameter of
the boss. Posts usually require ejector-pin
vents at the tip of the post. Other venting
issues you should address:
~
~

Direct mold filling along the length of

the rib so gasses can escape at the
ends; and
Round or angle the ends of standing
ribs to prevent air entrapment#


 


Air trapped in unvented pockets or

recesses in the mold can exit these areas
behind the flow front and lead to splay or teardrop-shaped surface defects.
Severe weld lines often form where flow streams meet head on, especially at the end of
fill. You can often improve the strength and appearance of these weld lines by installing
overflow wells #

 
 Overflow wells are modified vent features that provide an
extra-deep vent channel, usually about one- third the part thickness, that empties into a
cylindrical well .Venting air escapes the well around a shortened ejector pin fitted with a
0.002-inch clearance. Cool material at the leading edge of the advancing flow fronts
merges and enters the overflow well leaving hotter material to mix and fuse at the weld
line. The overflow well is ejected with the part and clipped off after moulding. Overflow
wells can also provide ejector pin locations for parts such as clock faces or instrument
lenses that cannot be tolerate ejector pin marks on the part surface.








  

  

 




1. 0hat do you mean by shrinkage?
2. 0hat do you mean by shot capacity?
3. 0hat do you mean by swept vol. of an injection cylinder?
4. 0hat do you mean by platen size?
5. Define clamping force and write its unit.
6. Define injection pressure and write its, unit.
7. Plasticizing shot and clamping capacity is required to determine .. .
8. State different types of runner.
9. Define runner length.
10. 0hat are the factors determine size and type of runner?
11. Define rectangular edge gate, overlap gate, fan gate diaphragm gate.
12. Define subsurface and tab gate.
13. 0rite one advantage of tunnel gate.
14. 0hat is a sprue bush?
15. Define working dia of guide pillar.
16. 0hat is nozzle sitting radius?
17. 0hat do you mean by ejection system and ejector grid?
18. 0hy locating rings are used.
19. 0hy push back pins are used in a mould.
20. 0hat is feed button.
21. 0hat is day light?
22. 0hy riser blocks are used.
23. 0rite down different types of ejectors & their uses.
24. 0hy cooling is provided in a mould.
25 use to locate the mould on the platen so that the nozzle and sprue bush are
aligned.
26 are used to bring back the ejector plate & ejector back plate to bring back its
original position as the mould closes.
27. The surface at which core & cavity are separated is known as .
28. moulding is most commonly used method of shaping a thermosetting plastic.







  

  

 

29.. Plastics are used in injection moulding.

30. For manufacturing hollow plastics .. moulding method is used.
31 Moulding is a process of manufacturing components from plastics in sheet form.
32. Injection moulding machine consists of three units ., .. &
33. 0hy sprue bush consist of angular hole.
34. 0hat is Z-type cooling? U=-type cooling?
35. How to determine the type of mould to be used/
36. 0hat are the considerations made before designing as mould?
37. 0hat are the materials used for guide pillar & guide bush
38. How many types of sprue pullers are there and what are those?
39. 0hat is the use of sprue puller?
39. sprue puller is widely used.
40 . . . . is the portion of the ejection system which provides a space into which
the ejector assembly is mounted.
41. Give some examples of different ejector grid.
42 . . . . and. are two methods of ejection return system.
43. 0hat is push back ejection system?
44. 0hat is mould heating?
45. 0hat is a baffle?
46. 0hat is the use of cooling?







  
x

  

 






 












:

 
  


   



-Know the designing of core & cavity inserts
-Know the designing of Cavity holding plate,
- Core holding plate,
- Ejector plate,
- Ejector back plate
- Riser block














 )















  

  

 

 

 

CI = Internal dia of cavity insert
= OD of plastic component +
Shrinkage value of plastic.
Ce = External dia of insert
of width of cavity insert.
= ID of insert + (wall thickness 2)
1



2

t = 0all thickness of insert (in mm)
CT = Collar Thickness of cavity
Insert in (mm) 1



 2
Cw = Collar width of cavity insert
CLd = Collar Dia or 0idth of cavity insert
= Outer diameter or 0idth + collar width of insert



(
 
( 
 


(

 ( 

 (

 (
30
08
12
30- 50
10
12
50- 75
12
15
75- 100
12
16
100-125
15
18
125-175
16
21
175-225
19
25
225-300
22
35
300 & Above
25
45

 














  ( 
 (
 
( 
Up to 20
20- 40

40- 60
60- 100
100-200


 ( 

 
3
4
5
6
8




  

  

 


  


0here,
D= Diameter or width or length of
Core inserts.
I = Height of core insert without collar.
b= Bearing length of core insert.
T = Core Holding plate thickness.
Tc= Thickness of collar.
Ts= Stripper plate thickness.


0 = Collar width.
L= Depth of hollow portion of plastic component.


(
 (

 
(
= [(L+ Shrinkage value of plastic
on depth) + b + Tc + Ts (if
stripper
plate is used)

 
(
   (   
(  



(
= Inside dia or width or length of
component+ Shrinkage value of plastic


 (

 
(
= Depth of hollow portion
of component +shrinkage value
of plastic + bearing length of core
in core holding plate + stripper plate thickness (if used) + Collar thickness
of the core.
Collar dia. Of the insert = Core dia + 2(collar width)
Collar width = collar thickness.







  

  

 

Table used in cavity insert collar dia and thickness is also applicable here.


 

 
#





 





Up to 10

Up to2
Above2

1 .5 D & 1 0
2 to 3D & 10

Lesser I/D ratio

Lesser bearing length

Up to 20

Up to 2
Above2

1.25D
D to 2D & 10

20 - 30

Up to 2
Above2

0.75D - D
D - 1.5D

30 - 40

Up to 2
Above2

0 .7 D - D
D - 1.5D

40 - 60

Up to 2
Above2

0 .6 D - D
D - 1.3D

60 - 100

Up to 2
Above2

0.5D - 0.75D
0 .8 D - D


 
 








  

P

  

 

Lchp

= Length of cavity holding plate.

0chp = 0idth of cavity holding plate (similar calculation of Lchp tn ydir)

CE

= External dia of cavity insert.

CI

= Internal dia of cavity insert.

dT

= Dia of cooling hole.

DP

= Dia of guide pillar.

CDp

= Collar dia of guide pillar

= DP + (2 x collar width of pillar)

Ctd

= Thickness of cavity holding plate

= Height of cavity inserts.

Lchp

= [R + 1.5dp + 0.5dp + 5 + dT + 5 + 0.5CE] 2


(
(
(
[


   



L = Length of core holding plate
= same as cavity holding.
0 = 0idth of core holding plate
= Same as cavity holding.
T = Thickness of core holding plate = tc + b
Tc= collar thickness of core.
b = Bearing length of core holding plate.
D = dia of core or width (max)
I = Length of core (Height) = tc+b+L
L = Depth of cavity.
0c = collar width of core = tc







  

3

  

 

 




[
( 
( 
(

= Perpendicular distance between two ejector element to be placed at opposite
extreme ends of the retainer plate in X axis + collar diameter of ejector
element + 10 to 15mm
[ ( 
( 
(

= Perpendicular centre distance between two ejector elements to be placed at
opposite extreme ends of the retainer plate in Y axis + collar diameter of
ejector element + 10 15mm

[



( 
(

Collar thickness of ejector element such as ejector pin, sleeve etc + 5 to 8mm
#

(

 (
 (&


 


Lep = Length of ejector plate = same as retainer plate.
0ep = 0idth of ejector plate = same as retainer plate.
Tep = Thickness of ejector plate (cm)
[(
*:
0here,
M =Perpendicular centre distance between two core inserts placed at opposite
extreme end of the core holding plate in x axis (cm)
P = Ejection force (kgf)
L = Length of ejector plate (cm)
S = Permissible working stress (840 kg/cm)







  

  

 




( 

. = #(

   
 (%(

0here,
s = Thermal contraction of plastic across diameterd = cte dT d
Cte = Coefficient of thermal expansion of the plastic material used (Table)
dT = Temperature difference between softening and ejection = (T soft T eje.)
d = Dia of circle of circumference equal to length of perimeter of
molding surrounding male core (cm)
E = Elastic modulus (Kgf/cm) of plastic material (Table)
A = Total area of contact between molding and mould faces (cm)
= dh (if circular)
0here,
H = Depth of component (cm)
Y = Poissons ratio of plastic (0.4 0.5 on average)
U = Coefficient of friction between plastic and steel (table)
Material




Cte

Tsoft

Teje

ABS

0 .5

6- 13

85

20

0 .1 - 0 .3

Acrylic

0 .4

5- 9

90

20

3 .1 4

PC
LDPE

0 .5 5
0 .4

7
16- 18

165
86

20
20

2 .3
0 .0 2

HDPE
PP

0 .2 5
0 .3 3

11- 13
11

125
150

20
20

0 .1
1 .0 5

PS

0 .4

6- 8

90

20

1 .8




  

{

  

 

 





~ These are two plates on which two halves of moulds are built and finally these
two are mounted on m/c platens.
~ These must be robust enough to hold all parts of mould.
Lt/b =
=
0 t/b =
=
Tt/b =

Length of top and bottom plate

Length of cavity holding plate.
([((
(((

0idth of top and bottom plate
0idth of cavity plate + 50 mm
Thickness of top and bottom plate (From table)

L t/b

Up to 250

250-350

350-450

450-550

Tt/b(mm)

22

27

37

47


  
Hrb = Height of Riser Block
= Retainer Plate thickness + Ejector plate thickness
+Depth of max hollow portion of the plastic component
+ Shrinkage on this depth + 20mm
Lrb

= Length of Riser block

= Length of cavity or cavity holding plate

0rb = 0idth of Riser block

= (0idth of cavity or cavity holding plate) - (width of Ejector plate + 2mm)
2
























  

  

 



















 
  


   

- Explain the classification & know different types of Split mould
- Determine the split movements of a given component by using different calculation
methods



















 
















  

  

 







 












 









 












  

x

  

 

 (

(

(( 
# 
 
(( 

~ M = L sin
C
Cos
~ L = M + 2C
Sin sin 2
~ M = split movement
~ = angle of finger cam
(10 to 25 maximum)
~ L = working length of finger cam
~ C = clearance
~ D = delay movement
~ D= C
Sin

.


 
(( 

~ M = H tan 




M = movement of each split

H = height of locking heel

 = angle of locking heel (20V to 25V)

M = 0.2 H












  

  

 


(

(( 

~ M = La tan  c
~ La = M + c
tan 
~ D = Ls + c + r 1
1.
tan 
tan 
sin 
~
~
~
~
~
~
~

M = movement of each split

La = angle length of cam track
Ls = straight length of cam track
= cam track angle
c = clearance
D = delay
r = radius of boss














  

  

 




(( 

~ M = La tan c
~ La = M + c
tan
.
~ D = (Ls e ) + c
tan 
~ M = movement of each split
~ La = angle length of cam
~ Ls = straight length of cam
~ = cam track angle
~ c = clearance
~ D = delay
~ e = length of straight position of hole














  

  

 




1. 0hat is split mould.
2. Type of split mould.
3. How split moulds are classified.
4. 0hat is a finger pin?
5. 0hat is a cam track?
6. 0hy dog leg cam are used.
7. 0hat is a slider in a split mould?







  
P

  

 


















 
  


   

-Explain the functional feature & uses of three plate mould
-Know the different parts of three plate mould

























  










  
3

  

 




(
 

~ Figures illustrate the
principle of one of the
numerous varieties of
the 3 plate mould
construction. The third
plate or floating plate is
located between the top
clamping plate and the
cavity back up plate. The
material from the nozzle
is forced through the
primary sprue, into the
runner system, into the
secondary sprues, and
into the cavity. Fig.
shows the mould in the
closed position
with
sprues, runners, and
cavity filled with material.
~

The mould opens first at

parting line 1. The
compressed spring (S)

starts the cavity back up
plate and the cavity plate
moving with the plunger portion of the mould. The floating plate stays with the top
clamping plate. As the mould opens, the runner is held to the floating plate by
pins (P) containing undercuts. This allows the gates to break at the piece part.
The mould then opens at parting line 2, pulling the piece part and plunger out of
the cavity.







  

  

 

At a predetermined distance, the

pull rod A pulls the cavity plate
and attached back up plate, thus
freeing the secondary sprues
from the cavity block. 0hen the
secondary sprues are clear of the
cavity back up plate, the head of
the stripper bolt B engages the
shoulder of the counter bored
hole in the cavity plate, pulling
the floating plate away from the
top clamp plate at parting line 3.
This movement frees the runners
from the undercut pins and
breaks the primary sprue at the
nozzle. Stripper bolt C limits the
travel of the floating plate. As the
mould continues to move back, the stripper plate ejects the piece parts from the
plungers. The stripper plate, which rides on guide pins mounted in the support
plate, is activated by return pins. Pin D limits the travel of the stripper plate.
Both ejector pins and stripper plates are used to remove piece parts from the
plunger. Often a poppet valve (through which a stream of compressed air is
released) is installed in the plunger to facilitate the removal of piece parts from
plungers. The 3 plate mould construction lends itself well to automatic molding,
as the piece parts are ejected from the mould free of runners, sprues etc. These
moulds, generally built with multiple cavities, are a very efficient method of
molding bowl or tumbler shaped articles.

   
  (
 ( 

 (


 

1. Moldings produced on multiimpression moulds can be centre
fed.
2. Off

centre

feeding

can

be

achieved for both single and

multi-impression moulds.
3. Multi-point feeding can be
accomplished
on
single
impression moulds and on multiimpression moulds







  
{

  

 





































  

  

 


















 
  


   

-Explain the detail process of hot runner system
-Know the advantages, disadvantages & economics of hot runner system
-Explain the concept of expansion theory






















 "













  

  

 


 

 




All injection molds in variable in corporate Runner which are flow paths for
carrying molten plastics materials form its entry point into the mold to its
ultimate destination i.e. the impression. Molten material enters into the
impression through a narrow opening at the end of the runners called gate. In a
conventional 2 plate or 3 plate injection mold , the entire network of runners and
gate along with the molded component has to be some how ejected out of the
mold ,in order to clear the passage for the next cycle. The material that has
solidified as runner is the necessary evil .It is finally the molded component that
is desired. But the runners can not be eliminated altogether. Sometimes incase
of multi-cavity injection mould especially, it happens that the volume of plastic
material solidified in the runner is more than the volume of moulding
themselves. More volume in the runner means more wastage. However this
wastage is minimized by reusing the runner material. In parts, still the
economics of moulding is adversely affected.
A great deal can be saved upon moulding, if somehow, the ejection of the
runners could be eliminated. This is what exactly is achieved in a hot-runner
system. This is also called runner-less moulding. Because what we get finally
out of the mould, is the moulding without runners. The runners are not
eliminated together in a runner-less system. These are simply not ejected out
the mould. In a hot runner system, the plastic material is kept at the nozzle
temperature right up to its entry point into the impression i.e., the gate. During
the ejection stroke only the moulding is degated and ejected out the mould.
How, all this is achieved, may be point of interest at this stage. But before we
proceed any further, let us understand why we should opt for the hot runner
system. 0hat are the relative advantages and disadvantages of hot runner
moulds over conventional moulds?







  
x

  

 







  

  

 

(
 

~

Figure gives and example of one type of hot runner mould. Hot runner moulds are
more efficient than other designs when molding rather large articles. The cavity
can be filled uniformly and quickly as the material is kept molten in the hot runner
block located close to the sprue feeding the cavity. There is not need for the
material to go through a long runner system before it reaches the cavity. The hot
runner block is insulated from the press and the rest of the mould by a series of
spacers and buttons which form and air gap (See G in Fig. 90) the material is
constantly kept molten in the hot runner block by a number of heating elements.
See Fig. for a section view of the hot runner and heating elements.

The pin located at the end of the hot runner is ground at approximately 30 to
divert the flow of material into the sprue. The hot runner is made approximately
16 mm in diameter. The cavity in Figure is filled through a hole in the piece part
from the runners and gates connected to the sprue. There is no pressure on the
material as the mould opens at the parting line. The plunger pulls the piece part
out of the cavity and the under-cut in the plunger, acting as a sprue puller, causes
the sprue to break at the small diameter where the material is still molten.
Continued movement of the press activates the ejector system and the piece part
is removed from the plunger by ejector pins or a stripper. The ejector pin located
opposite the sprue pushes the material out of the under-cut as the part is being
ejected (See figure) Variations:







  
P

  

 








  
P

  

 

Hot runner moulds are also constructed so that runners are eliminated and the
sprue feeds the material directly into the cavity. Multiple sprues fed by the hot
runner can be used to fill a single cavity producing a large part. Slides or Splits:
Figures illustrates the principle of using slides to produce under cuts in spoolshaped pieces. Fig. 90 shows the mould in the closed position. The positive locks
push against the slides to keep the surfaces of the two slides firmly together to
the vertical parting line (Parting line 3 ) to prevent the formation of any flash as
the mould opens at a parting line 1, the part stays with the core pin and the
angle pins force the slides out of the undercuts. The slides move along parting
line 2 at a 90 angle to the movement of the molding machine. 0hen the slides
have completely cleared the undercuts, the sleeve ejector pushes the piece part
free of the core pin (see Figure). The angle pins are generally set at an angle of
20 to 25 . The distance which the slides will travel depends on the angle and
the length of the angle pin. The positive lock is machined at an angle
approximately 5 greater than the angle of the angle pin.

The slide movement of the splits must be prevented to ensure that the split
halves always come together in the same place.










  
PP

  

 



 


 


  



Omission of demoulding the runner system: Hazard of thermal degradation of
permits the simpler automation of process.
sensitive polymers.
Heated runners allow the realization of long
flow paths: option to place the gate at an
optimum location.

Area near the gate may show

blemish
or
difference
in
appearance.

Diameters can be kept larger: resulting in

easier machining and less pressure loss.

Changing the material or colour

may take more time.

Longer holding pressure is made possible.

  




Savings in materials for runners and cost More work necessary in moulding
for regrind.
design: higher experienced designers
required.
No regrinding required.
Higher mould cost:
 (




~ Time for demoulding runner
system is omitted.
~ Shot size is reduced by volume for
runner.
~ Larger shot volume is available for
filling larger number of cavities.
~ Smaller opening stroke than for a
3-plate mould.
~ Cooling time only for the moulding
and not for thicker runner.
(   (  ( 
 (


 


~ nozzles
~ Manifolds, readymade as well as
tailor made.
~ heaters
~ thermocouples

Installation of auxiliary equipments like

heaters, temperature sensors, control
units, etc.

Less moving parts than in 3-plate mould.

More difficult assembly of the mould and

handling.
Better trained operators are required




Costlier in maintenance and repair.




  
P3

  

 

 
The temperature of the manifold is controlled by means of one or more
thermocouples.
The manifold is situated between the top plate/cavity back plate and cavity
plate. The contact points with these mould plates are kept as small in area as
possible, in order to keep the heat losses low. Hot runner blocks are made of
hot die steel e.g. H12.The manifold receives material from the machine nozzle
through a sprue bush, which is generally heated by a band heater or a hollow
pipe heater. It is firmly attached to the manifold and made of hardened steel. It
may have its own thermocouple. The heart of hot runner systems manifold
which, infect is a heated block, housing the runner network distributing the
material to various cavities. Depending upon the number of cavities it may have



  
Rectangular forms
H forms
Cross forms
Circular forms














  
P

  

 

  

(

#


(


~ Cartridge heaters
~ Tubular heaters
Induction
Band
Zigzag

( 

(
#placed in the drilled holes)







  
P{

  

 

The most common method of manifold heating is the one with cartridge heaters
they are placed parallel to the runner. Their advantages lie in ready availability.
One can form individual heating circuits for each nozzle or can couple them
together. The holes for them are required to be very accurate; otherwise there
is risk of their burning out. The design shown here depicts a quick method of
replacement.




(
 :-( placed in milled slots)
Tubular heaters have the advantage that they can be bent and placed
conforming to the form of cavities. However, they form only one circuit for all
cavities; therefore they cannot be regulated for individual nozzles. They have a
longer life as compared to cartridge heaters, owing to less wattage density.

 
(  :-( heating coil)
Heavy gauge copper wire is wound onto a former and then bound with a tape to
form a coil of convenient size. The induction heating coil for this application is
normally made to specification and is generally, not available as standard part.
The coil is fitted into an accommodating recess machined into the sides of the
manifold block. A cover plate secures the coil in position. As noted previously,
when a current is passed through a coil, eddy currents are induced into the
surface of the manifold block and heat is transferred from the immediate vicinity
of the coil to the melt flow-way by conduction. All of the above external flow-way
heating techniques related specifically to the rectangular cross section manifold
block. 0e now consider the methods adopted for heating cylindrical manifold
blocks. Basically, two types heater are applicable, the band heating elements
(and variations) and the low voltage coil heater.

 (low voltage heating element)







  
P

  

 

A length of high-resistively wire is formed into a zigzag configuration, the

adjacent parallel lengths being relatively close together. Terminals are fitted to
either end of the wire to facilitate its connection to low voltage supply. The
overall length of the wire required depends upon a number of factors including
the receptivity value of wire, the voltage used and the power input required. The
zigzag element is fitted into a recess in the side wall of the manifold block and
secured by a cover plate in a similar manner to that described for the flat
heating element.
 :-(heating elements)
The main voltage resistance type of element is enclosed within a casing which
is in the form of split hollow cylinder. This is mounted on the external surface of
the cylindrical manifold block and secured in position by clamp screws. The
band heater is available as standard part in a wide variety of diameters, width
and wattages. In many composite cylindrical manifold block designs, use of the
conventional band heater necessitates dismantling the unit each time a heater
has to be replaced. To overcome this limitation, half shoe heating elements
may be used. These half shoes can be clamped round the manifold to form
what is, effectively, one continuous heating element. The band heating element
has other applications in hot runner unit design, such as the heating of
secondary nozzles, manifold bushing, etc.













(
 
It is difficult to quantify the pros and cons of a hot runner gate mould in items of
cost without having a particular job in mind.
For that matter, lets consider the case of a four cavity injection moulding in a







  
P

  

 

3-plate version, with a cycle time of 45sec

Hot runner version, with a cycle time of 30sec



(
( (

~ Total quantity to be produced

= 25, 00,000pcs. Per yr.

~ Additional cost for hot runner system

= Rs.3,50,000

~ Machine cost for 3-plate mould (with operator) = Rs.150 per hr.
~ Machine cost for hot runner mould (automatic) = Rs.130 per hr.
~ Time for moulding 100pcs. in 3-plate mould

= 100(45/4) = 1125sec

~ Time for moulding 100pcs. in hot-runner mould =100(30/4) = 750sec

~ Cost of 100pcs. in case of 3- plate mould =1501125/3600 =Rs. 46.875
~ Cost of 100pcs. In case of hot runner mould =130750/3600 =Rs.27.08
~ 0e have saving from 3-plate to hot runner = Rs 46.875 Rs 27.08
[//))

~ Pay back quantity=3500000100
19.79
~ 0e have saving in case of hot runner =1768570pcs
~ Rest quantity 2500000 1768570=731430pcs
~ Profit on rest quantity=73143019.70/100
=Rs144750

(Saving on regrinding the runners as well as electricity have not yet been included)










 
(
  


~ 0attage per kilograms weight 200-300
~ Size of manifold




2007636




  
Px

  

 

~ 0eight of the manifold

4.27kg--------(1)

~ Maximum energy required

3004.27=1281watt---- (2)

~ Number of heaters

~ Effective length

200-20 =180mm

~  . 
(
 
(


~ Surface area of heaters
~ Permissible watt density
~ Total wattage

3.14d182=113.1d cm2
10/cm2
= 113.1d 10
=1131d -------- (3)
=1281
from ----- (2)



[ *["


"




~ Diameter selected =12.5mm--------(5)

.(4)

Required for molding 25,00,000pcs = (2500000750) ==5208.3hrs.

(1003600)
~ 0ith 3 shifts and 80% efficiency =

5208.3 = 271 days (say 1 year)

(240.8)

~ 0ith 3-plate mould one needs 50% more that is another machine, thus
investment on a new machine is saved.


' 
  

The value for the thermal expansion of steel is in the region of 12-13*10-6 mm/mm

c. The prcised value depending upon the specific type of steel used. In this case,







  
P

  

 

in the manufacture of manifold block. The general equation for calculating

expansion is as follows:


[ 





[
(  
 #

[ #
 [


((

 #


[


 (
#



A manifold block is to be heated from 200C to 230 C. Calculate the increase in
dimensions between the secondary Nozzles situated 635 mm apart.
Use a value of the thermal expansion of steel of 1310-6 mm/mm C


[ 


L= 635mm
= 1310-6 mm/mm C


[ 200C to 230 C. = (230-20)
=210
e = 635  (13 10-6) (210)
=1.73 mm
Such a large increase in the dim. Between the secondary nozzle centers and the
impression Centers could not be ignored.

3







1. 0hat is a manifold?







  
3

  

 

2. Different parts of hot runner

3. 0hat is a heater
4. 0hat is a tabular heater?
5. Different types of manifold.
6. Among is-plate mould and hot runner mould which has higher efficiency.
7. 0hat do you mean by cartridge heater?










  
 
Clear shut off valve start injection later, adjust nozzle pressure check radius of
nozzle spure bushing, reduce nozzle temperature.







  
3

  

 

  


Increase injection pressure, increase cylinder temperature, increase nozzle
temperature, clear nozzle, increase injection speed , increase back pressure,
enlarge nozzle size, increase mold temp., increase size of gates, provide vents in
mold, increase feed.
"  



Increase screw r.p.m. decrease back pressure, fill hopper or clear, and reduce
temperature of rear zone.
% 
Increase holding pressure and time, increase nozzle temperature, decrease
injection speed, decrease back pressure, enlarge nozzle, decrease mold
temperature increase size of gates, increase feed , decrease material temp.
&  
Decrease stock temperature, decrease injection speed, enlarge nozzle, increase
size of gates, and provide vent in mold.
( 


 

Increase stock temperature, increase nozzle temperature, Increase screw r.p.m.,
decrease injection speed, increase back pressure, increase mold temp. Or
decrease, polish mold, increase size of gates, enlarge cold slug well.
  
Decrease injection pressure, decrease stock temp., decrease holding pressure
and time, increase clamping pressure, decrease mold temp. rework mold.
* 


Increase stock temp., increase screw r.p.m., decrease injection speed, increase
back pressure, enlarge nozzle, increase mold temp., polish mold, and increase
gate use dry material.
/  ( 
Increase stock temp., increase screw r.p.m decrease injection speed, increase
back pressure, enlarge nozzle, increase mold temp., increase gate use dry
material.
) ((
  
Decrease stock temp., decrease holding pressure, decrease injection speed,
increase or decrease mould temp., polish mould, rework mold, use mold release,
provide air for ejection.
11. 


Decrease holding pressure & time, decrease mold temp., polish sprue, runner &
gates, check radius of nozzle, lengthen cooling and mold open.
12( ((







  
3P

  

 

Decrease injection pressure, increase stock temp., decrease holding pressure,

decrease injection speed, increase back pressure, increase or decrease mold
temp., and lengthen cooling.
13 

Increase injection pressure, increase stock temp., increase injection speed,
increase bad pressure, enlarge nozzle increase mold temp., increase size of
gate, provide vents in mold, use dry material, and increase feed.
14.  ((
(
Increase stock temp., decrease holding pressure, increase screw r.p.m. decrease
injection speed, increase back pressure, increase mold temp or decrease,
increase gate, and use dry and uncontaminated materials.
15


Increase injection pressure, Increase stock temp., increase holding pressure,
decrease injection speed of increase, enlarge nozzle, decrease mold temp.,
increase feed length cooling.
16

(
Increase cylinder temp., increase nozzle temp., increase screw r.p.m. decrease
screw speed, increase back pressure, enlarge nozzle, increase gate, and enlarge
cold slug well, use dry material.
17(


(
(  
Decrease stock temp., decrease holding pressure and time, decrease screw
r.p.m. decrease back pressure, increase mold temp., shorten cooling and mould
open.
18(
(
Increase stock temp., or decrease, decrease screw r.p.m., tighten nozzle temp.,
decrease injection speed, increase back pressure, use dry material, length
cooling and mold open time.
19.   (
Decrease stock temp., increase holding pressure and time, increase nozzle
temp., decrease injection speed, increase mold temp. of decrease, increase size
of gate, increase feed.
20.  
( 
Decrease cylinder temp., decrease nozzle temp., decrease screw speed,
decrease back pressure, decrease cycle, vent mould, increase gate, decrease
residence time, and check material and pigments.
    
(
  (  









(:

(




 









  
33

  

 

0rong location of gate:

Gates and/or runner too narrow:
Runners too large

Unbalanced cavity lay out

Non-uniform mold cooling

Poor or no venting

Spure insufficient tapered

Sprue too long

cold weld lines, flow lines, jetting air entrapment,

venting problems warping, stress concentrations,
voids and sink marks.
Short shots, Plastics overheated, premature, free
Zing of runners, sink and voids.
Longer molding cycle, waste of plastics and
Pressure losses.
Unbalanced pressure build up in mould, mould,
dimensional variation between Products, poor
mould release, flash and stress.
Longer molding cycle, high after shrinkage,
Stress (warping), poor mold release, irregular
surface finish and distortion of part during
Ejection.
Need for higher injection pressure, burned
Plastics, poor mould release, short shot, and
flow Lines.
Poor mold release higher injection pressure,
mold wear.
Poor mold release, Pressure losses, longer
moulds Cycle, and premature freezing of spure.

No round edge at end of sprue:

Notch sensitivity (cracks, bubbles) stress

concentrations.
Bad alignment and locking of cores: distortion of components, air entrapment,
Dimensional variant, uneven stresses, poor mold
Release.
Mold movement due to insufficient: Part flashes, dimensional variations, poor mold
Mold support
release, pressure losses
Radius of sprue bushing too small : Plastic leakage, poor mold release, pressure
Losses.
Mold and injection cylinder out of : Poor mold release, Plastic leakage, cylinder
pushed
Alignment
back, pressure losses.
Draft of Molded part too small

: Poor mold release, distortion of molded part,

dimensional variations.
Sharp transitions in part wall
: Parts unevenly stressed, dimensional
variations, air
Thickness and sharp corners
entrapment notch sensitivity mold wear.



1. To avoid flash--------- the clamping pressure and --------- the injection pressure.







  
3

  

 

2. 0hy burning mark occurs.

3. 0hy short shot occurs?
4. Due to high stock temperature and injection speed ---------occurs.
5. 0hy dull surface occurs?
6. How flow lines can be controlled?
7. Define streaks and its remedies?
8. How discoloration occurs?
9. 0hat is purging and what is its requirement?
10. How wavy surfaces of a part can be controlled?
11. How a part sticking problem can be solved?
12. 0hat are the problems of high melt temperature?
13. 0hat is jetting?
14. --------- runner length increases moulding cycle.
15. 0hat do you mean by cavity lay-out?
16. 0hat are the disadvantages of non-uniform cooling?
17. ---------runner size causes short shot.
18. Small draft of moulded parts causes poor mould release.
19. Improper nozzle radius causes plastic leakage, poor mould release.
20. 0hat are problems of low melt temperature?






















  
3{

  

 















 
  


   

- Explain the properties of Different mould materials
- Know the application different mould materials in different standards
- Know the recommended fits & tolerances for different parts of a mould























 %










~ It is well known that without proper mould material proper tooling cannot be
achieved. A wide range of mould materials are used for fabrication of moulds and







  
3

  

 

~
~
~
~
~
~
~
~
~

dies for plastics which includes Mild steel Alloy steel, Carbon Steel, Case
hardened steel etc. Mould material selection will have to be carried out based on
the requirements from product/Mould designer, Mould maker and Molder.
Essential requirements of steel for moulds and dies:
Excellent machinability
Excellent heat treatability
Good polishability
Good Compressive strength
High wear resistance
Sufficient corrosion resistance
The selection of steel for a given mould is governed by the above requirement.
The different grades of steel, characteristics hardening methods, surface
treatment methods and relative merits and demerits are given in the chapter.















  
3

  

 

 





( 


( 

T35Cr5Mo1V30

T35Cr5Mo1
0 1 V30
T35Cr5Mo1 V1

Cavities, Core, Ejector pins, guides, 0 ear pads of

mould.
Core and cavities of die casting die and moulds.

3
4

Cavities core Ejector pins, Guides and wear pads.

High tensile load applications max. strength when
hardened to 58-60 HRC used for cavity housing core
and cavity back plate shoulder screw and clamps etc.
- do -

40Ni2Cr1Mo28

6
7
8
9

13Ni3 Cr80

10

C10 and C14

Bolster, support block, plates, Backing plates, holding

plate etc.

11
12

C35Mn75
40Cr1

Moulds with a shorter run and on accurate cavities.

Pillar, Bush, Sprue bush, Locating Ring, Bigger dia
ejector pin.

13
14

50Cr1
T55Ni2Cr65Mo30

Used for coil and plate spring

Core and cavities.

T105Cr1
T 103

Cavity and core

Bright Steel, used for ejector pin, dowels etc
Used for guide pillar, Bush and wearing purposes
Used as a wear plate, backing pad, delicate core pins
used in moulds and die casting dies.




 
 
  


Process
Injection Mould

Thermoplastics

Compression Thermo-set
Mould
Thru hardened
Process

Thermoplastics

P20
H11
H13

40CrMnMo7
X38CrMoV5 1
X40CrMoV51

H13

Pre hardened
Steel
Thru hardened
steel
X40CrMoV51

1.2311
1.2344

1.2344

SKD61

4550HRc

AISI

DIN

0 .Nr

JIS

Hardness






4










  
3x

  

 


 









T35Cr5Mo1V30

BH11

X38CrMoV5 1

H11

T35Cr5Mo 0 1 V30

BH12

X37CrMo0 5 1

H12

T35Cr5Mo 0 1

BH13


#




H13
Improved

1.2344

SKD6
1

420
Modified

1.2083

SUS4
20

H13

En110

34CrNiMo6

40Ni2Cr1Mo28

En24

30CrNiMo4

*9840

***6

13Ni3Cr28

En36

14NiCr14

*3318

BF1

1200 A4

F1

**7
(a)8

T105Cr1

En31

100Cr

13

(b)9

T103

B0 18

C1050 1

01

(c)10

C10and C14

En2A

*1006

11

C35Mn75

En8

*1040

12

40Cr1

En18

*5140

(d)13

50Cr1V23

En47

(d)14

50Cr1V23

En48

15

T55Ni2Cr65Mo30

(e)16

En560

50Cr84

6152
5152

X40Cr13

*51420

17
18

P20
X40CrMoV51

19

*SAE Specification
**Silver Steel
***case Hardening
a) Bearing Steel
b) Carbon Tool Steel
c) Mild steel
d) 1% Chromium Spring steel
e) Corrosion Resistance, direct quenching steel for moulds used for corrosive
plastics.








 










  
3

  

 


SL.N
O
1

Description

Nature of Fit

Injection

Compression

Main Guide pillar Main Guide bush

Slack running

***

H7/e7

Main Guide pillar Main Guide bush

Close running

H7/g6

***

Main Guide pillar and Bush Housing

Light Keying

H7/k6

H7/k6

Sprue BushCavity insert or Housing

Medium Drive

H7/m6

***

Core pin Cavity insert

Sliding

H7/h6

H7/h6

Side moving Core or sliding blockGuiding slot

Close running

H7/g6

H7/g6

Cavity insert Housing

Light Keying

H7/k6

H7/k6

Finger Cam Housing

Light Keying

H7/k6

H7/k6

Push Back pin Cavity insert or Cavity Nest

Close running

H7/g6

H7/g6

10

Ejector pin Cavity insert

Close running

H7/g6

H7/g6

11

Cavity insert Cavity insert

Sliding

H7/h6

H7/h5

12

Alignment bush Housing

Close running

H7/g6

H7/g6

13

Ejector Guide Pin Housing

Medium Drive

H7/m6

H7/m6

14

Ejector Guide pin Ejector Guide bush

Close running

H7/g6

***

15

Ejector Guide pin Ejector Guide Bush

Slack running

***

H7/e7

16

Ejector Guide pin Ejector Retainer plate

Light Keying

H7/k6

H7/k6

17

Ejector Guide pin Ejector plate

Running

H7/f 7

H7/f 7

18

Rest button Housing

Heav y Drive

H7/m6

H7/m6

19

Register Ring Machine Platen

Running

H7/f 7

***

20

Register Ring

Running

H7/f 7

***




  
 

AISI

DIN.




C.

Si.

Mn.

P.

S.




  

Cr.

Mo.

V.

0.

Ni.

  

 

M2

S-6-5-2

M35

S-6-5-2-5

T1
T4
T5

0.86 0.45MAX
0.94

0.40
MAX

0.030

0.030

3.80
4.50

4.70
5.20

1.70
2.00

6.00
6.70

0.88 0.45MAX
0.96
S-18-0-1 0.70 0.45MAX
0.78
S-18-1-2-5 0.75 0.45MAX
0.83

0.40
MAX
0.40
MAX
0.40
MAX

0.030

0.030

4.70
5.20

0.030

0.030

0.030

0.030

3.80
4.50
3.80
4.50
3.80
4.50

0.50
0.80

1.70
2.00
1.00
1.20
1.40
1.70

6.00 +CO.4.50
6.70
5.00
17.50
18.50
17.50 +Co.4.50
18.50
5.00

S-18-1-2-10 0.72 0.45MAX

0.80

0.40
MAX

0.030

0.030

3.80
4.50

0.50
0.80

1.40
1.70

17.50
18.50

+Co.9.00
10.00



  
 

AISI DIN.
D2
D2
D3
D6

C.

X16CrMoV12

1.55
1.75
X155CrMo121 1.50
1.60
X210 Cr12
1.90
2.20
X210 Cr0 12 2.00
2.25

Si.

MN.

P.

S.

CR.

MO .

V.

0.

0.25
0.40
0.10
0.40
0.10
0.40
0.10
0.40

0.20
0.40
0.15
0.45
0.15
0.45
0.15
0.45

0.030

0.030
0.030

0.50
0.70
0.60
0.80

0.10
0.50
0.90
1.10

0.40
0.60

0.030
0.030

0.030

0.030

0.030

11.00
12.00
11.00
12.00
11.00
12.00
11.00
12.00

Ni
.

0.60
0.80



  
 


AISI DIN
H10 X32CrMoV 33
H11 X38CrMoV 51
H12 X37CrMo0 51
H13 X40CrMoV 51

C.
0.28
0.35
0.36
0.42
0.32
0.40
0.37
0.43

SI.
0.10
0.40
0.90
1.20
0.90
1.20
0.90
1.20

Mn.
0.15
0.45
0.30
0.50
0.30
0.60
0.30
0.50

P.
0.030

S.
0.030

0.030

0.030

0.030

0.030

0.030

0.030

Cr.
2.70
3.20
4.80
5.50
5.00
5.60
4.80
5.50

Mo.
2.60
3.00
1.10
1.40
1.30
1.60
1.20
1.50

V.
0.40
0.70
0.25
0.50
0.15
0.40
0.90
1.10

0.

NI.

1.20
1.40


  
 

AISI DIN
C.
P20 40Cr 0.35
MnMO7 0.45
0.16
0.20
0.15

Si.
0.20
0.40
0.20
0.40
0.30

0.15

0.30

Mn.
1.30
1.60
1.40
1.60
1.00

P.
0.035

S.
0.035

0.020
MAX
0.025
MAX

0.007
0.013
0.005

Cr.
1.80
2.10
1.80
2.00
2.00

Mo.
0.15
0.25
0.35
0.45
0.20

V.

0.

Ni.

0.08 +Cu.0.10
0.15
0.10 +Cu.0.10

0.30

3.00(+Cu1.0
+Al.1.00)





  
 

AISI

DIN




C.

Si.

Mn.




  

P.

S.

Cr.

Mo.

Ni.

  

 

P20+S
P20+Ni
STAVA
K
RAMA
XS
AISI42
0

40CrMnMo S86 0.35

0.45
0.40
X42Cr13
0.38
0.45
X36CrMo17
0.33
0.43
X45
0.40
NiCrMO4
0.50

0.30
0.50
0.30
0.50
1.00
MAX
0.10
0.40

1.40
1.6
1.50
0.20
0.4
1.00
MAX
0.150
0.45


  
 

Grade
C.
Si.
Mn.

0.03
0

0.50
0.10

0.03
0
0.03
0
0.03
0

0.03
0
0.03
0
0.03
0

Cr.

1.80
2
1.90
12.50
13.50
15.00
17.00
1.20
1.50

Ni.

EN1A

0.07/0.15

0.10Max

0.80/1.20

*

)"&)%&

))&)"&

)()))

EN8D

0.40/0.45

0.05/0.35

0.70/0.90

EN8M

0.35/0.45

0.25Max

1.00/1.30

EN8AM

0.33/0.38

0.25Max

0.90/1.30

/

)&))()

))&)"&

)&))*)

EN18

0.35/0.45

0.10/0.35

0.60/0.95

0.80/1.10

EN19

0.35/0.45

0.10/0.35

0.50/0.80

0.90/1.50

EN19C

0.40/0.45

0.10/0.35

0.50/0.80

0.90/1.20

 %

)"&)%&

)))"&

)%&))

)/)%)

"

)/) )

)))"&

)"))&

))()

"(

) )*

)))"&

)))"&

EN36c

0.12/0.18

0.10/0.35

EN41b

0.35/0.45

EN110
EN354

0.15
0.25
0.20

1.00

1.00
1.30
0.15
0.5

1.00
MAX
3.80
4.30

Mo.

V.

0.20/0.35
")*)

) ))"&

)"))()

)())

"))")

0.10/0.35

0.30/0.60

0.60/1.10

3.00/3.70

0.10/0.25

0.10/0.45

0.65Max

1.40/1.80

0.40Max

0.10/0.25

+Al.0.90/
1.30

0.35/0.45

0.10/0.35

0.40/0.80

0.90/1.40

1.20/1.60

0.10/0.20

0.20Max

0.35Max

0.50/1.00

0.75/1.20

1.50/2.00

0.10/0.20


















  
P

  

 







(




 




   "








 

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$
$
"
%



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26 to
56
26 to
76
26 to
76
26 to
86
26 to
86
27 to
86
26 to
86
26 to
86
26 to
106

P-P 1616 156 156 120 120 72

66

130

38

90

31

10 24/16

20

P-P 1620 156 196 120 160 112

66

170

38

90

31

10 24/16

20

P-P 1625 156 246 120 210 162

66

220

38

90

31

10 24/16

20

P-P 2020 196 196 158 158 98

97

168

58

120 36

12 28/20

26

P-P 2025 196 246 158 208 148

97

218

58

120 36

12 28/20

26

P-P2030 196 296 158 258 198

97

268

58

120 36

12 28/20

26

P-P2035 196 346 158 308 248

97

318

58

120 36

12 28/20

26

P-P2040 196 396 158 358 298

97

368

58

120 36

14 28/20

26

P-P2525 246 246 200 200 136

94

218 132 150 46

14 32/24

26

P-P2530 246 296 200 250 184

94

268 132 150 46

14 32/24

P-P2535 246 346 200 300 234

94

318 132 150 46

14 32/24

P-P2540 246 396 200 350 284

94

368 132 150 46

14 32/24

P-P2550 246 496 200 450 384

94

468 132 150 46

14 32/24

26 26 to 106
26 to
26
106
26 to
106
26
26 to
26
106

P-P3030 296 296 250 250 184

144

268 182 200 46

14 32/24

26 66 to 146 46

P-P3035 296 346 250 300 234

144

318 182 200 46

14 32/24

26 66 to 146 46

P-P3040 296 396 250 350 284

144

368 182 200 46

14 32/24

26 66 to 147 46

P-P3045 296 446 250 400 334

144

418 182 200 46

14 32/24

26 66 to 146 46



 

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$
$
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(


 






   "






P-P3050 296 496 250 450 384




144

468 182 200 46

14 32/24




  
3

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26
26
26
36
36
36
36
36
36
36
36
36
36

 
46 to
66
46 to
66
46 to
66
66 to
106
66 to
106
66 to
106
66 to
106
66 to
106
66 to
106
66 to
106
66 to
106
66 to
106
66 to
106
66 to
106
66 to
106
66 to
106
66 to
106

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26 26 to 146 46

(
 



 

10 12

M8

M6

10 12

M8

M6

10 12

M10

M6

12 16

M10

M6

12 16

M10

M6

12 16

M12

M8

12 16

M12

M8

12 16

M12

M8

16 26

M12

M8

16 26

M12

M8

16 26

M12

M8

16 26

M12

M8

16 26

M12

M8

16 26

M12

M8

16 26

M12

M8

16 26

M12

M8

16 26

M12

M8

(
 


  
 

66 to
106

16 26

M12

M8

  

 

P-P3060 296 596 250 550 484

144

568 182 200 46

14 32/24

26 26 to 146 46

P-P3535 346 346 300 300 234

186

318 230 250 46

14 32/24

26 26to 146 46

P-P3540 346 396 300 350 284

186

368 230 250 46

14 32/24

26 26 to 146 46

P-P3545 346 446 300 400 334

186

418 230 250 46

14 32/24

26 26 to 146 46

P-P3550 346 496 300 450 384

186

468 230 250 46

14 32/24

26 26to 146 46

P-P3560 346 596 300 550 484

186

568 230 250 46

14 32/24

26 26 to 146 46

P-P4040 396 396 340 340 232

206

360 256 278 56

18 42/34

36 36to 186 56

P-P4045 396 446 340 390 282

206

410 256 278 56

18 42/34

36 36 to 186 56

P-P4050 396 496 340 440 332

206

460 256 278 56

18 42/34

36 36 to 186 56

P-P4060 396 596 340 540 432

206

560 256 278 56

18 42/34

36 36 to 186 56

P-P4545 446 446 390 390 282

256

410 306 328 56

18 42/34

36 36 to 186 56

P-P4550 446 496 390 440 332

256

460 306 328 56

18 42/34

36 36 to 186 56

P-P4560 446 596 390 540 432

256

560

306 328

56

18 42/34

36 36 to 186 56

P-P4570 446 696 390 640 532

256

660

306 328

56

18 42/34

36 36 to 186 56

P-P5050 496 496 440 440 332

306

460

356 328

56

18 42/34

36 36 to 186 56

P-P5055 496 546 440 490 382

306

510

356 328

56

18 42/34

36 36 to 186 56

P-P5060 496 596 440 540 432

306

560

356 328

56

18 42/34

36 36 to 186 56

P-P5070 496 696 440 640 532

306

660

356 328

56

18 42/34

36 36 to 186 56

P-P5555 546 546 490 490 382

356

510

406 428

56

18 42/34

36 36 to 186 56

P-P5560 546 596 490 540 432

356

560

406 428

56

18 42/34

36 36 to 186 56







  

66 to
106
66 to
106
66 to
106
66 to
106
66 to
106
66 to
106
66 to
126
66 to
126
66 to
126
66 to
126
66 to
126
66 to
126
66 to
126
66 to
126
66 to
146
66 to
146
66 to
146
66 to
146
66 to
146
66 to
146

16 26

M12

M8

16 26

M12

M8

16 26

M12

M10

16 26

M16

M10

16 26

M16

M10

16 26

M16

M10

16 26

M16

M10

16 26

M16

M10

16 26

M16

M10

16 26

M16

M10

16 26

M16

M10

16 26

M16

M10

16 26 M16

M10

16 26 M16

M10

16 26 M16

M10

16 26 M16

M10

16 26 M16

M10

16 26 M16

M10

16 26 M16

M10

16 26 M16

M12

  

 

P-P5570 546 696 490 640 532

356

660

406 428

56

18 42/34

36 36 to 186 56

P-P6060 596 596 532 532 424

390

560

440 462

64

18 50/42

36 36to 186

P-P6070 596 696 532 632 524

390

660

440 462

64

18 50/42

36 36 to 186 56

P-P6080 596 796 532 732 624

390

760

440 462

64

18 50/42

36 36 to 186 56

P-P6090 596 896 532 832 724

390

860

440 462

64

18 50/42

36 36 to 186 56

56

66 to
146
66 to
146
66 to
146
66 to
146
66 to
146

16 26 M16

M12

16 26 M16

M12

16 26 M16

M12

16 26 M16

M12

16 26 M16

M12












  
{

  

 
















1. 0hat are the required properties of mould materials?
2. ---------materials are widely used for core & cavity material.
3. ---------&---------are used for top plate and bottom plate.
4. ---------materials are used in compression moulding.
5. ---------is used for guide pillar & guide push material.
6. ---------, ---------materials are generally used for back plats, support block.
7. List the different parts of mould and write down the specific material for the parts.
8. List the different mating parts and the recommended fit for that.
9. For guide pillar and guide bush ---------fit is used.
10. For sprue bush and cavity insert ---------fit is used.
11. For register ring and machine platen ---------fit is used.
12. 0hy groove provided in the pillar.
13. 0hy stepped guide pillar is mostly used.
14. 0hat do you mean by standard mould base?
15. How standard mould base are specified?
16. Give some example of standard mold base.
17. List the design check list.
18. 0hat do you mean by parting surface of mold?
19. 0hat is shot height of mould?
20. 0hat is daylight of mould?
21. 0hat is double day light?
22. Define floating stripper in case of three plate mould?
23. 0hat is overflow well?
24. Define weld line.
25. Define shrinkage.







  

  

 




~ Latest issue parts drawing used
~

with mould-fit press for which cut ended are press ejector specified

Are day-light and stroke of press sufficient for trouble for ejection

Are reverse views correct

Are one guide-pin and one return-pin upset

Do guide pin enter before any part of mould

Can mould assembled and disassembled easily

Has allowable been indicated (draft angle is per side)

Is plastic material and shrinkage factor is considered or specified

Are more plate heavy enough

Are mould parts be hardened and clearly specified

Are sufficient pillar are located specifically

Are water line , steam line, thermo-couple holes specified

This water in stroke out location clear press tie bars and clamp location

Is ejector trouble sufficient

Are stop bottoms under ejector bars specified

Are ejector pins sufficient

Is the steel type for mould parts specified

Have eye-bottle holes been provided

If stripper type, this stripper plate ride on guide pin for full stroke

0ith mould parts stay on ejector side of the mould

Do lose parts fit in one way only (make fool-proof)

Can mould parts be ejected properly

Have trade mark and cavity number be specified







  

  

 

Have engraving been specified

Has mould identification been specified

Has plating special finish been specified

If there is provision for clamping position in the press

Are runner-gates and vents are shown are specified








 
  


   


-Explain the different die casting methods
-Know the different die casting machines
-know the different die casting materials, its properties & its applications
-Know the die casting faults & its remedies







  
x

  

 

 &


 





























 


 








  











( 
( 







  

  

 

Casting of molten metal in moulds is to shape metals into objects. The process
involves the filling of a mould with molten metal and allowing the metal to harden. A
great deal of this type of casting or molding was and still is done in moulds made of
sand. Sand moulds require a new mould for each piece to be cast for more efficiency
the permanent steel moulds were developed. The molding of non-ferrous material
and their alloys (with relatively low melting temperature) in permanent steel moulds
under pressure is called Die Castings.






~ Any die-casting die must be split into two sections so that the casting can be
removed after it has been formed. These two sections are called the cover die
and the ejector die. The cover die is fastened to the stationary platen on the
casting machine and does not move during the casting cycle. The ejector half is
mounted on the movable platen of the machine.
~ A cavity that is a reproduction of a section of the part that is so be cast is formed
or machined in each of these dies. It is conceivable that half of the casting could
be formed in the cover die and half in the ejector die, but this is seldom the case
because the parting plane, i.e., the mating surface of the die is usually the plane
having the greatest cross-section al area on the part, and parts to be die-cast are
seldom symmetrical. Although it is desirable to have the parting line in one plane,
design consideration sometimes requires that it be irregular, curved, or slanted
~ Both surfaces forming this parting line must be smooth and finished so that the
die halves fit closely together. Otherwise a gap would exist through which molten
metal could escape when forced into the cavity under pressure. It is also
apparent that the two halves of the die must be in exact register when the die is
closed, and the usual method of accomplishing this is to use dowel pins, as is
done in stamping or drawing dies. These dowel pins are always placed in the
stationary or cover-die member.
~ Other die components include the die base, an ejection plate and ejector pins,
and surface pins. The die base is a cast-iron or cast steel base on which the
ejector die is mounted and in which is provided means of ejecting the casting. In
the simple type of die, ejector pins are used to p0ush the part from the ejector
cavity after the casting machine opens. These pins are mounted in a plate called
the ejector plate, and slide through holes in the ejector-die half. 0hen the
machine opens this plate is pushed forward by some means, usually by a rack
and pinion that may be tied in with the machine cycle so that it is forced forward
automatically at a predetermined point. Since the ejector pins must be flush with
the parting surface of the ejector die when the casting machine closes, surface
pins and stop pins are incorporated in the die to ensure accurate location of the
ejector plate.
~ In addition to these die members, there are other components and considerations
that must be investigated by the die designer prior to detailing a die: die gates
and runners, which are the paths through which the metal flows to all portions of
the cavity; vents, which provide a path of escape for entrapped air and released
gases, cores and slides which form the hollow part or under cut sections of the







  
{

  

 

casting locks that hold the die halves in register when an irregular parting line is
specified: mounting holes land brackets for all die components: and of course a
means of actuating the movable-die components.





 
( 
( 
Die-casting can be classified broadly into two types as follows:~ Gravity Die Casting
~ Pressure Die Casting
 (
( 
~ The metallic mould is generally made into two halves to enable the casting to be
taken out. The mould is closed and the liquid metal is poured from the top. In this
process, liquid metal flows into the die entirely under its own weight and hence it
is known as gravity die casting.




( 
~ Here the molten metal is injected into the closed mould under pressure, thereby
producing accurately dimensioned, sharply defined, smooth surfaced parts.
 (
(



( 

:







  
{

  

 

~
~
~
~
~
~
~

More complex shapes can be produced by the pressure die casting process than
gravity die castings e.g. carburetor.
Since the dies are filled under pressure, castings with thinner walls, greater
length to thickness ratio and greater dimensional accuracy can be produced.
Production rates are higher in pressure die casting.
The castings are produced as almost completely finished parts.
Dies for pressure die casting can produce many thousands of castings without
significant change in casting dimensions.
Many die castings can be plated with minimum surface preparation.
Die castings produce fine grained structure there by having better mechanical
properties.


  (( 


( 


~ Casting size is limited.
~ Depending on the casting contours and gating, difficulty may be encountered with
air trapped in the die, which may cause porosities in the component.
~ Die casting equipments are quite costly and hence large quantities are required
for the process to be economical.
~ Commercial production is limited to nonferrous metals.

( 
( 
They find extensive use in thousands of consumer and industrial products such
as automobiles, house appliances. Electrical goods, photographic equipments,
toys etc.


( 
Only non-ferrous alloys are currently suitable for commercial
castings.

production of die




 
 ((
 ( 


~ Low melting point alloys (heavy metal alloys) Zinc, Lead and Tin
~ High melting point alloys (light metal alloys) Aluminum, Magnesium.
~ High melting point alloys (Heavy metal alloys) Silver, copper, Brass, Beryllium
copper.

( 

:







  
{P

  

 

There are two general types of die casting machines as identified by the
placement of the injection chamber or metal pumping systems.
~
~

(

#





  


# (#
(



(




In the hot chamber machine the goose neck containing the pressure cylinder and
plunger is submerged in the molten alloy. The molten metal is injected under
pressure of 280 700 Kgs/cm. Only low melting point alloys are processed by
this machine since these alloys do not pick up iron at higher temperatures.





( 



~ The basic components of a hot-chamber die-casting machine and die are
illustrated in Fig1 in the hot-chamber process; the plunger and cylinder are
submerged in the molten metal in the holding furnace. The power to pump zinc
into the die cavity is provided by a hydraulic accumulator. Oil is supplied to the







  
{3

  

 

accumulator by a hydraulic pump at a rate that will bring the accumulator

pressures up to the desired operating level each time a casting (shot) is to be
made.
~

The casting sequence in the hot-chamber die-casting process is illustrated in Fig.

2. 0hen a shot is made, the control valve opens causing the shot cylinder to
force the plunger down and force molten metal though the nozzle, past the sprue
pin, through the runners and gates, and into the die cavity. The gases that were
in the system and some of the molten metal from flow through the die cavity and
out through vents and / or into overflows. After the cavity is filled, the metal is
allowed to solidify, the casting is ejected, and the cycle is repeated. Since the
gooseneck and plunger are submerged in the molten metal, the system refills
automatically when the plunger is withdrawn.
Die is closed and hot chamber (i.e. goose neck) is filed with molten metal Plunger
pushes molten metal through gooseneck and nozzle and into the die cavity.
Metal is held under pressure until it solidifies. Die opens and cores, if any, retract.
Casting stays in ejector die Plunger returns, puling molten metal back through
nozzle and gooseneck. Ejector pins push casting out of ejector die. As plunger
uncovers filling hole, molten metal flows through inlet to refill gooseneck


  



~ The cold chamber machine is similar to hot chamber machine except the injection
side. Here the alloy is melted in a separate pot and the required amount of molten
metal is loaded into the shot sleeve from where the injection plunger forces the
molten metal into the die cavity. High melting point alloys are processed by the







  
{

  

 

cold chamber process in order to keep the iron pick up by these alloys at higher
temperatures to a minimum. 0hen the shot chamber is in a horizontal position it
is called horizontal cold chamber machine and when it is vertical it is called
vertical cold chamber machine.
 (
( 



~ Metal can be injected into the die cavities in minimum time.
~ The decreased in metal temperature is minimum.
 (
  



~ Relative freedom from attack of molten metal on equipment.
~ High injection pressure.
  (
  



~ Need for auxiliary method of feeding.
~ Longer cycle time is needed.
~ Possibility of metal defects due to loss of super heat.
  



~ The casting sequence
for the clod-chamber
process is illustrated in
figure. In this process,
molten metal is ladled
into the cold chamber
and then the plunger
advances to force the
metal into the die.
Except for the manner
in which molten metal
is fed into the shot
system and injected
into the die, the casting
sequence for the two
processes is similar.
~ Die is closed and
molten metal is ladled
into the cold chamber
Plunger pushes molten
metal into die cavity.
The metal is held under
pressure
until
it
solidifies Die opens
and plunger advances
to insure casting stays
in ejector die Cores, if
any, retract. Ejector p
pins push casting out
of ejector die and







  
{{

  

 

plunger return to original position.






 



a) Alloy composition
b) Metal Temperature
c) Shot 0eight


a) Accumulator pressure
b) Injection Line Pressure
c) Intensification
d) Plunger Speed
e) Locking Force
f) Mode of Injection
g) Plunger Diameter
h) Timing of Stages in the casting cycle
i)Lubrication
3. 
a) Die Temperature
b) Filing rate


 ( 
To ensure durable casting, the alloy composition must conform to specifications.
If the alloy composition is outside the specification range, immediate difficulties
are unlikely to be experience but its performance in services can be greatly
impaired. Satisfactory performance in casting is, therefore, no Indication that the
alloy conforms to the specification.


(


(


  
Most die-casting alloys, for example LM2, 4,6 and 24. Contain the alloying
elements silicon, iron and manganese, which for compounds that settle out when
a melt is held that too low a temperature. These metallic segregates form hard
spot inclusions, which can cause considerable difficulties when machining the
castings. The temperature, temperature of the shot sleeve, mode of injection and
delay between pouring and the start of injection.


Metal temperature has relatively little effect on casting quality within the normal
practicable limits of 395-450 C. If the metal by operating outside the normal
casting range of 410-450 C. If the metal temperature is too high, it shortens the
life of the plunger and gooseneck and it has been reported that the magnesium







  
{

  

 

loss increases substantially at 450C. Too low a metal temperature often results
in a build-up of metal on then plunger stem unless heating is used in this area.
This build up can reduce the injection speed by mechanical interference.

 (
 (
Variations in shot weight can influence the quality of castings by affecting.
~ The volume of gases in the shot sleeve (%filling of the shot sleeve);
~ The average metal temperature entering the die;
~ The size of slug, which in turn influences the transmission of force from the
plunger to the casting;
~ The position of the metal at the changeover from slow to fast injection;
~ The start of intensification on machines when it is initiated from a position switch.
~ In some cases and excessive shot weight can be dangerous because very long
slugs can burst and injure the operator as the die opens


( (
 
  
~ Alluminium and its alloys are used for products with intricate contour which are
normally processed by die casting dies.
~ Ex-cylinder heads, carburetor, crank casing, transmission housing (gear box),
cast alluminium wheel, vacuum cleaners, electrical irons, utensils handles.


$ (
Copper in its original state possesses some properties like
~ Excellent resistant to corrosion
~ Non magnetic properties
~ Moderate to high hardness & strength
~ High thermal & electrical conductivity
~ Good appearance
~ Good machinability
~ Resistant to fatigue, corrosion



Electrical parts, heat exchangers, screw machine products, household utensils,
for making alloys.
0hen Cu is mixed with other metals, it gives the alloy of following properties:~ Excellent corrosion resistance
~ Electrical & thermal conductivity
~ High strength &
~ Nice appearance
~ Cu alloys are mainly formed by addition of Aluminium, Zn, Tin, Barium, Ni, Si, Pb
with copper. Some of the alloys are Brass, Bronze, gun metal, bearing materials
etc.


 $ (
Magnesium is a silvery white metal having the lowest density other than common
structural materials. It has a specific gravity of 1.74 & a specific wt of 1.73 gm/cc.
Mg has the melting point of 650 c Mg is often coated or painted or given some







  
{

  

 

surface finish to avoid corrosion. It is used in aircraft industry due to its light
weight. It makes alloy with Al, Zn, Mn, Zr etc


 
 
(

~ High strength to weight ratio
~ Good fatigue strength
~ Good damping capacity
~ High thermal conductivity
~ High electrical conductivity.



~ airframes, engines, gear boxes, flooring, seating for aeroplanes,
~ Helicopters, missiles and satellites.
~ Body panels of ground transportation vehicles.
~ For material handling equipments such as hand trucks, barrel skids
~ For storage tanks ;and hopper
~ Moving parts of textile machines.
~ Furniture, lawn movers
~ Typewriters, calculator etc.
~ Binocular and camera bodies



(


~ Dow metal,
cast alloys of mg,
wrought mg alloys etc.


   (
Lead is the oldest among the softest of heavy metals. It is poisonous and should
not be brought into contact with food.

(

~ Low melting point of 327C and density 11.34 kg/dm3
~ Resistant to corrosion except against aqua-regain.
~ It is poisonous.
~ Low strength and less hardness.
~ High density and heavy weight
~ soft and malleable
~ Good lubricating properties
~ High co-efficient of thermal expansion
~ Low electrical conductivity.



~ Manufacturing of storage batteries
~ Tank lining for corrosion protection.
~ pipe and drainage fitting
~ Low melting solders
~ Lead sheathing of electric cable.
~ Radiation protection.


   



(
 
~ sheet and food
~ extrusions







  
{x

  

 

~ wool
~ castings
~ powder
~ lead alloys

  


Zinc is a blue to gray metallic element. It has the following characteristics~ low melting point, 419.5C
~ resistance to corrosion
~ Solubility in copper
~ Inherent ductility and malleability


( 
Stamping, anodes for electro galvanizing, coating on steel
Die-casting, shells for dry batteries, engravers plates




(

:
Accumulators are used to store up energy from the hydraulic pump during parts
of toe cycle when the demand from the pumps is low. This enables a fast
injection speed to be achieved with pumps of low output. Modern machines
generally use pistons to separate the hydraulic fluid from the nitrogen. For any
particular accumulator pre-charge pressure, the range of injection pressures,
which can be used, is small. Therefore, if a substantial change is made in the
injecting pressure, the accumulator pre-charge pressure must be adjusted. It is
very important to have the correct pre-charge. Too high a pre-charge in relation
to the injection pressure can result in the separator not being lifted, with the result
that the accumulator wills not operate. Too low pre-charge results in a low
injection pressure and a late build up to the full injection pressure.



(  



This (when no intensification is used) controls the maximum force on the plunger
and it also influences the speed of injection. It cases where intensification is
used, the line pressure influences the maximum injection force. On some
machines the hydraulic pressure control valve of the locking circuit is situated
upstream of the valve controlling the injection pressure, with the result that
lowering the locking pressure can also lower the injection pressure.
(
 
( 
The pressure build-up at the end of injection, the intensification stage can have a
large effect on the porosity of castings. Intensifiers enable large changes to be
made in injection force without changing the line pressure and accumulator precharge pressure. The rate of pressure build-up should not be too fast; otherwise
it may cause the die to flash. Alternatively, too long a delay in the pressure buildup results in a low pressure being applied during solidification.





The plunger speed is usually set by a valve which simply restricts the flow of
hydraulic fluid from the accumulator to the injection cylinder or air receiver to the
injection cylinder. Small variations in plunger speed can occur due to fluctuations







  
{

  

 

in the injection line pressure and also with large variations in die temperature
when producing thin section castings. If a large change is made in injection
pressure, this can produce a significant change in the injection speed. Fast
injection can increase the amount of flash because of the heavy impact and the
metals more fluid condition at the completion of fill.


 


~ Locking force is dependent upon the locking pressure, tie bar nut setting and
temperature the die and surroundings. As the die heats up, the locking force
increases and unless allowance has been made for this increase, the machine
will stall when locking. For a given tie bar nut setting, increasing then pressure to
the locking ram does not increase the locking force.
~ Locking force, injection pressure and projected area of the casting together with
die distort are the main factors controlling flash. For the best results, the die
should, where possible, designed so that the center of pressure produced in the
cavity acts in the center of the within the tie bars, i.e. the impressions should be
positioned centrally within the tie bars.
~ On some machines the hydraulic pressure control valve for the locking circuit is
situated stream of the valve controlling the injection pressure. Little is to be
gained by lowering the lock pressure. If one wished to reduce wear in the toggle
linkages etc. 0hen producing castings, the tie bar nuts should be slackened.
For this purpose a plot of locking force against tie bar nut position is useful



( 
The use of two-stage injection with a slow first stage allows the gases more time
to escape from the cavity during the initial fill period of the nozzle and in some
cases of the run. Two-stage injection often also influences the cavity filling
speed. Depending on the injection system and where the changeover occurs, it
can either increase or decrease the filling speed.

 
(

~ Large diameter plungers and sleeves are used to increase the shot capacity.
Increasing plunger diameter also reduces the final force of the metal and tends to
reduce the plunger speed during injection. If the resistance to metal flow offered
by the die is low, the change injection speed can be very small which results in a
significant increase in metal velocity therefore reduced fill time. If the die offers a
large resistance it may be possible for plunger speed to be lowered so, such that
the metal velocity is also rescued thus increased the fill time.
~ A change in the plunger diameter also alters the injection change over position of
the
Increasing the plunger diameter makes the actual injection
changeover position (Position metal) occurs later.
~ In order to minimize time spent in changing shot sleeves, and also to reduce the
number spare parts required, it is often convenient to use the same size plunger
for the whole ran castings produced on a give machine. The size of the plunger
is the governed by the last shot weight from the given range of castings.


 (
 (
( 









  

  

 

Some machines have an overall cycle timer which in effect controls the die open
time. Usually the die open time is controlled by the opening and closing speed of
the machine and, in the case of semi-automatic machines, by the speed of the
operator. During the die open period the cavity surface and sub-surface have a
slower cooling rate than at any other time during the cycle (apart from the short
time interval between the die closing and injection). The injection timer and the
die cooling timer usually run consecutively, with the result that both influence the
solidification time of the casting. The fastest method of operating the die, from
the heat extraction point of view, is to have the die open time at a minimum. This
increase the temperature of the die fact at injection which is an advantage,
especially in the case of a thin section casting requiring a good surface finish.

( 
Correct lubrication of the die and of shot sleeve and plunger is very important
because it affects the slenderness and surface finish of the casting and the life of
the shot sleeve and plunger.








(

~ No one die temperature can be recommended for producing acceptable casting s
because not only does the correct temperature vary from die to die by also it
varies with time within the die both perpendicular to the surface and across the
surface.
~ Surface finish is largely controlled by the die face temperature at injection. The
casting dimensions are dependent on the temperature of the casting at ejection
and to a lesser extent by the die temperature. Too high an ejection temperature
can also cause blisters in the castings.
~ Correct die temperature distribution and cooling can increase soundness by
improving the freezing pattern, In some cases, is sounder castings are produced
during the warm up period than when the die is up to full working temperature.
This is because the extremities of the casting tend to freeze faster relative to the
feed area (the runner / gate area) during the early shots.
~ Die temperature is governed by the casting rate, cooling water flow and
temperature. The maximum heat extraction rate is obtained by having the
highest ratio possible of the time when the casting is in contact with the die
compared with the non-contact period, i.e. approximately, die closed time/die
open time should be maximum.
~ The die is cooled by the cooling water, radiation and conduction to the
surrounding machine and atmosphere. Generally the cooling effect of the die
lubricant is negligible. For example, in the case of a 2-impression zinc door
handle casting, the following heat input and extraction figures were recorded and
calculated on the assumption that the lubricant extracted the maximum amount of
heat, i.e. the lubricant was turned into dry steam:
~ Ratio heat extract by cooling water/heat input from castings = 0.84
~ Ratio heat extracted by die lubricant/heat input from castings=0.06
~ The die lubricant used was diluted 5:1 with water. Even in cases where
excessive lubricant is used, sometimes with the object of cooling the die, it is







  

  

 

surprising how little cooling is achieved by the water/lubricant because only a thin
layer on the die is cooled and then rapidly heated by the bulk of the sub-surface
material.

  (

Filling rate can be considered in terms of
~ Cavity fill time, u its seconds
~ Cavity filling rate or volume flow rate during fill, units: cm3/s or in 3/s
~ Gate velocity, units m/s or ft/s
~ For a given die, all three can be related by simple mathematical relationships.
None is the all-important factor for surface finish or soundness, but gate velocity
is important from the point of view of die wear, and soldering problems in the gate
area.


 



( 


 
 
 ( 
(


~ single impression,
~ multiple impression,
~ combination dies,
~ unit dies, and
~ Adjustable dies for different lengths and widths of
castings.
 
A single-impression die is probably the most
universal type used by all die casting plants.
Since it contains only one cavity which is
machined or hobbed in the mating halves, it is
basically the least simplex and easiest to build.
For small, simple castings, it is inexpensive and
therefore often is used when production
requirements are low; for medium-or large size
parts, it may be the only practical unit that can be
used because of the size limitation of the
machine. For all practical purposes it may be
considered as the standard die-casting die, all
the others being modification of it to achieve
faster and more economical production.

 

Combination dies and multiple dies both have
the same purpose: to permit the casting of two
or more parts simultaneously. Thus, both
contain two or more die cavities. The
difference between them is that the multiple
die is used for casting that are similar (i.e. for







  
P

  

 

the casting of several parts of the same shape), while the combination die is used
for castings that are different (i.e. for the casting of two or more parts of unlike
shape). Also, the no. of cavities in the combination dies often is limited, while a
greater no. is usually are employed in the multiple dies. Combination dies usually
are used for different parts of the same assembly whose production
requirements- either large or small- always are similar. Multiple dies, on the other
hand, are confined almost entirely too small parts that must be produced in
quantity, such as certain business- machine casting.



~ For the die casting of moderately sized parts, especially when the desired
production is relatively low, the use of unit dies is of considerable advantage. The
difference between this and a multiple die is that in the later the impressions are
machined or hobbed in the die halves, while in the unit die the cavities are formed
in replaceable die units which then are set in machine location in the die, and to
which the charge of metal is
simultaneously delivered.
~

Each of the replaceable units

constitutes a separate part. It
may or may not differ from the
others in respect to the size and
shape of the casting impression,
but it must have similar outer
dimensions so that it can be
fitted into the locations in the
die. Thus, one unit die may be
used to die cast a number of
different parts for a number of
different products.

All unit dies have a common

supporting mechanism, termed as master holding die that contains the
machined locations for the unit blocks. The master holding die is permanently
fastened to the die casting machine, from which the units can be quickly and
easily interchanged without interrupting casting operation for more than several
minutes at a time.

The holding die is gated in order to distribute the casting alloy to each of the units
from a single gate opening, and each unit as an individual ejector mechanism that
is coupled with the ejector mechanism of the holding die.

Units are made in various sizes and may be of round, square or rectangular
shape. The master holding die may be constructed for multiples of two, four, six,
or eight units and thus may range in overall size from quite small to quite large.

The primary purpose if a combination dies is, of course, to reduce cost- to use on
the die block instead of two, and to produce two or more parts per casting cycle







  
3

  

 

instead of one. The precaution that must be observed is to balance the die
thermally.
The parts to be die-cast may vary considerably in shape and size. For this
reason it is sometimes quite; difficult to obtain a thermal balance in the die, but
when the die is designed the impressions should be disposed with the view of
obtaining the maximum uniformity of heat input.



( 

 

~ Multiple impression dies are used where large and rapid production of a part is
required. The number of impressions in such a die depends upon the size and
shape of the part and the rate of production needed. For some small simpleshaped parts the number of impressions may run as high as 32 or 48, such dies
usually are made for only one type of casting. They may be used, however, to
cast two parts that differ from each other only by slight change in orientation,
such as the casting of right-and lefthanded parts that go into one
assembly.
~

The
greater
the
number
of
impressions used in a die, the
greater the productivity in parts per
hour, and consequently the lower the
labour cost per piece. On the other
hand, the more impressions used,
the greater will be the die cost.

The impressions in a multiple die

should be arranged symmetrically
and uniformly each impression being
equidistant
from
the
other.
Impressions may be disposed in a
straight line of in circular form. If
arranged in a line, the total amount
of impressions should be of an even
number since it is desirable to have
the same number of impressions is necessary to obtain uniformity of heat
distribution in the die.

Sufficient space should always be provided between the edge of the impressions
and the outer edge of the Impressions and the outer edge of the die block. This
are, usually termed the metal seal, generally should measure not less than 3 in
(75mm). If less than this minimum, the molten metal may shot out through the
parting line, especially if the die blocks blow or part is slightly under the
pressure of the metal entering the die.









  

  

 







The various faults commonly encountered in die-castings can be classified into
three groups:

 (



(
~ Lack of fill
~ Cold shut
~ Severe chill
~ Chill
~ Flow lines

((



(
~ Soldering
~ Cracks
~ Broken part
~ Bend part
~ Heat marks or shrinkage pits

" 





(
~ Scale
~ Blisters
~ Porosity
~ Excessive flash
~ Mechanical defects
~ Ejector pin marks
0hen correcting faults during a casting run, it is important that the right corrective
action is taken as soon as possible. A fault correcting procedure, intended for
shop floor use is given below:


 
This condition has three basis causes. The first cause is inadequate metal in the
gooseneck or cold chamber. The metal level n the holding furnace of a hot
chamber machine ma=must be maintained above the gooseneck inlet pots. For
cold chamber machines, the correct size ladle must be used, and care must be
taken to insure that the ladle is full for each shot. 0hen a automatic ladle is
being used, it must be properly adjusted to ladle exactly the correct amount of
metal into the cold chamber. Secondly, this defect may be caused by cold metal,
cold die or both. The temperatures should be checked and adjusted ad
necessary. Finally, lack of fill may be the result of slow shot speed. The shot
control hydraulic valves should be opened the proper amount.

  (
Cold metal, slow shot or low die causes cold shut, like lack of fills, temperatures.
If air vents and/or overflows clogged with flash they may also contribute to the
problem. All these factors must be checked and correct as necessary.








  
{

  

 






 
Severe chill similar to cold shut. But it will cover a large surface of the casting
instead of being a single line. Excessive release material as well as cold, metal,
slow shot, low die temperature, or clogged air vents may be the cause. Severe
chill usually appears when shot are made into a cold die, but will rarely occur
during normal operation.

 
This defect has the same appearance and is cause by the same conditions as
severe chill, but is less noticeable. Slight or fain chill lines on the surface may not
be cause for rejection of certain types of castings. However, castings used for
ornamental parts will usually require a chill-free surface. Low die temperature,
low metal temperature, is low shot speed, or excessive die release materials are
al cause of chill.

 

Flow line defects are similar to chill and clod shut. Flow lines can usually be
reduced or eliminated by increasing the die temperature, metal temperature, or
both. Like chill, the defect may be corrected by higher shot speed or less die
release material.


 
~ This condition is the result of the cast metal bonding to the die surface. Upon
ejection the casting tears away, leaving a layer that has bonded to the die. 0hen
soldering occurs, it may create additional problems such as cracking or bending
of the casting, out-of-tolerance dimensions depressed ejector pin marks in the
casting and/or porosity within the casting.
~

Soldering may be cause by excessive metal temperature, incorrect die

temperature (too hot or too clod) or insufficient die release material. If the
condition is severe or when other methods fail to remove the solder, it must be
cleaned from the die. Caustic solutions provided for this purpose may be use, or
the material may be polished out of the die. It is recommended that a die maker
or other person with special training polish the die cavity. If the polishing is not
done properly, a rough die surface may be created that will increase the soldering
condition. Care must also be exercised when increasing the amount of die
release material applied to the soldering area. Excessive amounts of this
material may create other defects such as porosity, chill, or blisters. 0hen
adjustments to the above conditions do not eliminate the soldering condition, it is
likely that the problem may have been cause by the metal alloy being cast or it
may result from the die construction.

 
Shallow smooth depressions on the castings surface are called sink marks.
Such marks usually appear on the casting surface opposite any heavy section
such as rib or boss and are caused by uneven shrinkage of the casting. Reduced







  

  

 

die temperature in; the area of the sink mark, reduced metal temperature, and
sometimes increasing the temperature of the other die half will minimize these
defects. Sometimes increased injection (shot) pressure coupled within higher die
temperatures between the defect and the gate will help to reduce sink marks.




Build-up of die release materials (or their oxides) on the die results in an irregular
rough surface on the casting. The material must be removed with a caustic
solution or by polishing the die. The same care is needed as described for
soldering. After cleaning the die, the amount of release material applied for each
shot must be reduced. Sometimes it may be desirable to change the type or
release material and/or the ratio of release ;material to solvent(or water)

 (

Bubble-like bumps on the casting surface are caused by air or other gases
trapped inside the casting. Slower shot speed, clean vents, reduced die
temperature, or less die release material will usually eliminate blisters.

 (
Large holes in the casting are called porosity. Low die temperature (particularly in
the runner and gate area), low shot pressure, clogged vents, or excessive release
material can cause porosity. Porosity is also often related to lack of fill, cold shut,
heat marks, and blisters. 0hen such a relationship exists, the correction for the
related defect will often improve or eliminate the porosity.



 
 
Excessive flash results from material such as flash sticking to the die faces and
holding the die open, excessive injection pressure or speed, or insufficient
clamping force. The first problem is corrected by cleaning the die faces. Flash
that has become embedded into the die face must be scraped off. Corrections to
injection speed and pressure must be made by adjusting the appropriate
hydraulic valves. The clamping force is increased by adjusting the tie-bar nuts.
Very slight adjustments to these nuts are usually al that is required. Flash
indicates that an extra thick casting is being made. Extra thickness causes extra
thickness causes extra heat input to the die, and may result in additional
problems.



~ Castings may crack from internal stress or from abnormal pressure during
ejection. The first cause, internal stress, is created from excessive metal or dies
temperatures. If the condition persists after several temperature adjustments
have been made, it may be necessary to increase the shot or machine timer
settings. The timers should be adjusted only after everything else has failed.
~

Cracks from abnormal ejection pressure may be indirectly the result of soldering.
The operator should carefully inspect the casting for signs of soldering. If
soldering exists, the appropriate corrective measure should be taken. Insufficient
draft or a rough cavity finish in the die can also cause abnormal ejection







  

  

 

pressure. Additional die release material may help, but will not correct this
situation. In severe instances, die repair may be necessary


(
A portion of the casting may stick in the die during ejection and the rest of the
casting break away and eject normally. The cause I the same condition as
described for cracks: excessive metal or die temperature, insufficient die release
material, or soldering.


((
Castings may bend instead of breaking when part of the casting sticks in the die.
This is a different result from the same conditions that cause a broken part.


(
~ Have the appearance of surface pits and are causes by excessive di3
temperature or excessive metal temperature. Depressed areas in the casting
and sharp inside corners are the most susceptible to this defect. Sometimes die
temperature balance can be adjusted to eliminate heat marks. For example, the
flow of cooling water to the area affected may be increase, and decreased to the
other die half in the same area.
~ Clogged vents or excessive die release may cause large volumes of gas to
become entrapped in the die. Such gases will increase the size of heat marks
and may cause the pits to become rounded & smooth on the inside.




Irregular lines or slight steps on otherwise smooth casting surfaces are usually
caused by excessive die temperature in the area of the defect. Increasing the
flow of die cooling water of increasing the water (or solvent) dilution of the die
release material will reduce such defects.







(
The operator should be aware of all moving and fragile parts of the die cavity,
which are subject to wear, breakage, or other failures that could cause defective
castings. Small cores or thin blades of the die forming deep narrow holes or slots
in the casting can bee easily broken or bent. Ejector pins and moving cores can
wear, break, or not seat properly. In any of these situations, the die will not make
the part to the correct shape.


( 
High and low ejector pin marks. Ejector pins may push into the casting when
solder and/or a rough cavity surface result in the casting sticking in the cavity.
High casting temperature at the time of ejection also can let the pins push in to
the part. Increases flow of cooling water or more liberal application of release
material will sometimes reduce low ejector pin marks.











  
x

  

 






1. 0hat do you mean by casting?
2. 0hat are the types of die casting?
3. In .. method molten metal is poured from the top.
4. In . Method molten metal is injected i9nto the mould under pressure.
5. 0hat is die casting alloys.
6. Name some die casting alloys.










































  

  

 
























































  

  

 





 

  
Functions of alignment injection of moulds are mounted onto the platens of the clamping
unit of the injection. Moulding machine. The clamping unit opens and closes them during
the course of the molding cycle. The molds have to be guided in such a way that all
inserts are accurately aligned and the mold halves are tightly closed. 0ithout proper
alignment moldings would exhibits deviations in wall thickness; they would not have the
required dimensions because guiding moulds with the clamping unit alone is generally
not sufficient. Injection moulds also need a so-called internal alignment. It aligns both
mold halves with the necessary precision and prevents their convolute joining.
 
( ( (
 (
(
(  (
Precise alignment is mandatory here otherwise the nozzle could interrupt operation.
Therefore alignments concentric with the sprue bushing are used almost exclusively. For
this purpose the mold is equipped with a flange-like locating ring, which keeps the sprue
bushing in the mold and matches the corresponding opening in the machine platen.
Locating rings are either machined into the mold clamping plates or most of the time, a
separate part mounted onto the mold. They are readily available from producers of mold
standards and are machined from case-hardening steel or water-quenched unalloyed
tool steel.
Of course, a mould has usually only one locating ring. If both mold halves a re equipped
with locating rings, then a loose fit is needs on the movable side to better align both
sides. This is only a help for setting up the mold.
The locating ring is slightly press- fitted into the mold plate and fit the machine platen
with a close sliding fit the figure. 505 shows a two piece locating ring. This design is
particularly useful for adding an insulating sheet to the mold, this is done for processing
thermosets or thermoplastics if a high mold temperature is needed for molding parts.
(
 
(  (

 
The mold halves themselves have to be guided internally, besides by the tie bars of the
machine, to obtain the needed accuracy. In small molds this is done with leader pins.
They are pins which protrude from one mold half of the opened mold and slide into
precisely fitting bushing in the other mold half during mold closing. This ensures a
constant and accurate alignment of both surfaces of flat moulds without shifting during
injection and production of moldings.
In molds with deep cavities, especially those with long and slender cores, a shifting of
the core can occur during injection in spite of exact alignment with leader pins this has







  

  

 

already been discussed in chapter 11. " shifting of core" . design examples for such
molds were presented with figure . 405
Figure shown an example of positioning and mounting a leader pin and the appropriate
bushing. Four leader " units" ( pin and bushing) are usually required for proper alignment
.to facilitate the assembly and to make sure that the mold is always correctly put
together, one leader pin is offset or made in different dimension. The latter method may
cause fewer difficulties. If two leader pins, one diagonally opposite the other, are made
longer. It is easier to slide the two halves together while placing the mold into the
machine or during assembly. The leader pins are positioned as close to the edge as
possible to gain space for the cavity and an adequate number of cooling lines.
Effective alignments is possible only if close tolerances are kept between leader pins
and corresponding holes. This however, causes considerable wear. Therefore it is not
prudent to let the pins slide directly into the respective holes of the mold plates. As a
matter of principle, leader bushings should be used to counteract wear and to enable
worn out parts to be exchanged easily. Leader bushings. Like leader pins are made of
case hardened steel with a hardness of 60 to 62 Rc. They are commercially available in
various sizes and shapes. 0ear can furthermore be reduced by lubricating the pins with
molybdenum disulfide. For this purpose pins or bushings have oil grooves, leader pins
without lubrication (fig.510) should only be used for rather small molds or special
application in sliders or with ball bushing.(fig.512)
Leader pins and bushing are commercially available in various designs . attention
should be paid to the recommended fits . the length of leader pins depends on the depth
of the cavity.
Leading has to begin before the mold halves are engaged. Therefore a sufficient length
must be selected. Shoulder leader pin can at the same time. Pin mold plates together.
Commercial availability is treated in chapter 17.
The length of leader bushings depends on their diameter. It should be 1.5 to 3 times the
inside diameter. the corresponding holes in the mold plate have to be drilled according
to instructions. Figure 510 and 511 demonstrate the assembly leader pins and bushing
[1].
Fig.510 shows the system with shoulder leader pins. Bores for pin and bushing can be
drilled in a single operation. ( equal diameters).
The system of fig. 512 is not used very often . it is carefree and ensures a precise and
low-friction movement but at additional expenses.
0ith a leader sleeve, mold plates can be aligned and connected with one another which
would otherwise not be engaged by leader pin or bushing . The diameter of the sleeve is
kept the same as that of the bushing or the shoulder of a shoulder leader pin. Therefore
all holes can be machined in one pass. The internal diameter is adequately large to
permit unrestricted entering of pins.







  
P

  

 

Among the multitude of leader pin systems, those shown in figure 514 and 515 should
also be mentioned . both are based on components already described: leader pin,
bushing and leave. The system of Fig. 514 has pins and bushings with threaded holes
and tightening crews, which are propped on the opposite side by head supports. Plates
not engaged by pin and bushing are lead by sleeves. This design is more expensive,
however, than the one shown in fig 506 but has some decisive advantages. The
assembly of the individual plates is not done with screws, and additional drilling of holes
is unnecessary. The plates are kept together with the tightening screws. At the same
time the mold plate can be utilized better for accommodating cavity and cooling lines.
The system the system in fig 515 shows a very different design a leader bushing and
sleeves and their assembly in mold. The bushings consist of three parts : the bushing
proper , a retainer ring and a ring nut. There are two locating for the retainer ring. The
bushings can be mounted flush with the plate surface or protruding by 5 mm and
tightened with the nut. In the protruding position any number of plates cab be connected
to one another. This kind of bushings can take over the job of bushing with or without
retainer ring and can also be used as leader sleeve. In this case no ring nut is used. The
nut connects the bushings reliably to the mold plates. This could save additional plates.
0hich are needed in other systems for supporting the bushings . the height of the mold
is lower. This may compensate the cost for the more elaborate design.
To ensure proper operation no lateral forces should act upon the leader system, if there
is no lateral load, the required cross-section of the leader pins does not have to be
computed. For oblique pins, especially those acting on slides. The necessary cross
section should be calculated.
 
(
 
Occasionally no leader pins are used in a large and deep molds such as those for
buckers and boxes. Guiding is left to the tie bars of the molding machine during opening
and closing until short of complete engagement. Since this accuracy is insufficient for
proper alignment , special arrangements become necessary . they are all characterized
by the fact that the alignment does not begin sooner that shortly before the mold is
closed. Both mold halves brace one another when closed.
Of special advantage is the "pot" design( fig.516) and its variations and because it also
reacts against forces from cavity expansion. The inserted ledges in the variations are
easily replaceable after they are worn-out. More variation re presented with Fig 519.
Frequently bolts are used as aligning interlocks fitted into both mold halves their center
line is not in the plane of the parting line. Thus, both mold halves are braced against one
another after clamping. Fig.521 shows such a mold. Instead of cylindrical alignment
bolts rectangular interlock made of shock-resistant tool steel can be employed.
Alignment of molds by such interlocks calls for high accuracy of machining, because
later corrections are not practical. Frequently, tapered interlocks according to fig. 522
are finally used.







  
3

  

 

   
(



 (
(

Injections molds are usually mounted to the machine platens by mechanical clamping
devices( conventional mold clamps with bolts) and connected to power- and watersupply lines. To of this the mold is either horizontally or vertically brought into the
machine by lifting device. Depending on size and weight of he mold and the number of
connections this leads to shutdown times. 0hich may last from an hour to several days(
Fig 523) such secondary times affect the productivity and better economics lead by
necessity to systems for a quick mold change. In spite of this , such systems have
hardly prevailed so far. There are two reasons for this. One is the lack of compatibility
among the various systems on the market today[7,8]. The second one is the need for a
change of almost all molds used in a machined and associated high cost.
A quick change system consists of several components which allow to change injection
molds either fully automatically or semi-automatically, controlled by an operator. Such
components serves the function of
- detaching and fastening the mold at he machine platens.
- disconnecting and connecting the supply lines.
- bringing the mold into the clamping it or taking it out.
From this follows the need for these means of quick-change system:
-quick-clamping devices.
-quick-connection couplings
- changing equipments.
Besides this some more components are required for an automation of mold changing,
which have to be combined to one system. Only the combined action of all component
permits flexible and automated injection molding[7].
Mold design is mostly affected only by quick-connection couplings. Two solutions for
quick clamping devices have prevailed on t eh market. One can distinguished between
adaptive and integrated clamping systems, which are usually actuated hydraulically.
They can easily be inserted into a concept of flexible automation.
The adaptive clamping system has hydraulically actuated locking cylinders or ledges
with integrated collects[6] mounted to the clamping platens of the machine, into which
the precisely machined clamping plate of the mold is inserted. They are mostly
chamfered or provided with a groove( fig. 525 &526)
During clamping , piston or ledge, which is also chamfered, is moved against a
corresponding counter chamfer of the mold( fig.525 &526). The counter chamfer is
about 5V. This angle causes self-locking ( as long as oil has dripped on it). For reasons
of safety, clamping elements are therefore equipped with a proximity switch as a
standard[11].







  

  

 

The integrated clamping system has a hydraulic locking device integrated into the
clamping platens, which hydraulically locks a bolt mounted in the base plate of he mold.
The equipment to automate the mold change is so multifarious today, that not everything can be presented here. The references [12 to 18] should be consulted.
All systems presented so far operate basically with the same locking mechanism. As
soon as they are mounted to the clamping platen of he machine, they have to be looked
at as rigid system, which determines the size of he mold plate independent of the mold
size. Thus, the base plates of small molds may become disproportionately large and for
large molds one eventually has to witch to a machine with greater clamping force.
The solutions presented so far assume a rectangular clamping plate of the mold. Fig
528 present a design with hydraulic clamping sides acting on locating rings and integrated into the clamping platens of the machine. This system is suited for rectangular as
well as for circular molds[19].
A manually operated quick-clamping device is on the market as a supplement
composed of standards[8].
The quick-clamping systems for changing molds already results in a considerable
shortening of the setup time but it doesn't yet ensure a fully automatic change of molds.
This is only made possible by employing quick-coupling systems for energy supply
and for sensors. Required are the following connections for
 ejectors
 heat-exchange medium( oil, water)
 hydraulic connections for heating (hot runners)
 connections for thermocouples and pressure sensors.
Coupling systems are designed as modular systems and consist, depending on size. Of
individual couplings for energy supply and sensor connections, guide pins. Lock and
docking cylinders. Thus the system cab be assembled as demanded by the application.
They are supplied as standards for manual and automatic operation. Accurate assembly
of these systems is mandatory for their trouble free function. A small inexactness during
assembly can lead to inadmissible displacement, which results in leakage and
premature wear. Therefore coupling elements are floating in the carrier plates in order to
eventually allow an adjustment. Thermal expansions cab also be captured this way
especially in large molds[ 6,7].
A mold-change equipment affects mold design, if at all, only insignificantly. They are
accessories, which change molds and, depending on make-up, can accept the function
of a mold- conveying system. . they are illustrated in even more detail in numerous
publications [ 6 to 8,10,13 to 17, 20 to 26]. The complete mold is always exchanged.
Depending on the standard of the equipment , molds are immediately ready for
operation and are already brought up to working temperature during the change
procedure.







  
{

  

 

Starting with a special mold concept[27], which only provides for an exchange of shapeproviding mold insets, an exchange device was developed[ fig. 530]. It is machinebound and attached to the mould inserts are located above the clamping unit. An
exchange mechanism feeds the inserts can be locked by the already described quickclamping devices and connected to supply lines by quick-connectors.
This system can not be transferred to all types of molds, but offers significant cost
advantages for small lots and with simple molds.
Suitable mold bases are offered in the US and Japan as standards [29].


(  


( 


(  


( 


Mould prices and delivery deadlines are always the critical points in production planning
and sales negotiations.
The price of the mold has a major effect on the unit price of the part to be produced.
Other factors having a decisive effect on successful sales are exact calculation and
rapid launching of the new products onto the market. These requirements put the mold
maker under constant pressure. For quotation purposes high-precision molds must be
exactly calculated and then manufactured at short notice.
The mold maker is forced to limit his activities to the essential, i.e., to the machining of
cores and cavities. Everything else is a necessary evil and must be achieved in the
simplest manner possible. The most economical way is to use standard elements.
Standard elements are standardized mold part, which are available ex-stock. Even
during the stages of mold calculation and planning. Standard elements at fixed prices
can be widely considered. Today standard elements are used to a large extend as
bases for molds and dies, as well as for connections to machines and other equipment







  

  

 

and for special purposes. The use of standard elements helps to keep within the bounds
of production capacities. To minimize the calculation and production risk and to simplify
the procurement of spare parts. The possibility of buying standardized elements at short
notice considerably reduces stock keeping and shut down times of production
capacities.
The first standard elements for molds were known in the U.S. even before 0orld 0ar II.
In Germany, too, the first step in this direction was made at a very early stage: "turnwald
standardization" of mold bases for compression molds can be regarded as the first
positive result. In the late 1950's standardized mold bases were introduced on the
German market for the first time, thus completing the range of standardized mold
component which had already been available for a considerable time.
Mold making today is moving towards more specialization. Various machine operators
on milling, lathe, EDM or jig grinding machines manufacture parts of the finished mold
separately at the final stage all these parts are brought together and assembled by the
mold maker. He has the overall responsibility for the functioning of the mold, which is
also a result of teamwork. Standard elements are designed exactly for this type of
manufacturing process.
Figure shows a selection of standard elements available from the catalogue for
economical and efficient mold making and production.
In principle almost all molds consist of the same basic elements: mold plate for the
inserts, intermediate plates for supporting the cores and insets in the mold plate on the
ejector side, risers to limit the working distance of the ejector plates, and clamping plates
to clamp the mold to the machine.
Comprehensive studies have shown that the total hour required for mold making can be
split up as shown in fig. 2. at least 25% of the required capacity can be saved by using
standard elements. In addition, special machining requirements can also be handled by
the manufacturer of standard elements. In total this adds up to some 40% of the
capacity required for the production of a mold.
Thus in the example shown some 25% of the machine capacity is required for rough
machining. Only partial utilization is possible, since the contour parts require more time
on small special-purpose machines.
A mold making shop that replaces rough machining capacity by specialized machining
capacity for the production of counterparts utilizes manpower and machines more
efficiently. Calculations can be made with lower hourly rates, since the rate or utilization
is better.
Mass production of standard elements for molds on large, highly efficient special
machinery guarantees high quality and purchase without risk because of fixed prices
and reliable delivery dates.
(  


( 
(
( 







  

  

 

Basically two types are available as standard elements: assembled mold bases, referred
to a basic mold, and the modular systems for individual combinations.


 
Basic molds as shown in Fig.3 are assembled as ready-made mold bases, available in a
relatively small range only. Their application is far more limited because the designer is
confined by being kept to the assembled mold base.
Modular systems
Modular standard elements consist of individual places. 0hich allows the designer and
mold maker the flexibility to build molds to their own individual versions.
1. ready to use interchangeable jig-bored plates , so-called standard elements" with
holes for guide pins, bushes and screws
2. Unbored plates, all surfaces machined, so called "P standard elements" in the
same dimension and steel grades as K standard elements.
These tow versions of modular elements can be combined in any way to solve every
mold construction problem.


The K standard elements are based on a patented modular system. Figure 6/A shown
the guide and doweling elements of this system. They fit in uniform holes passing
through all plates, guiding and doweling all the plates of the mold. The guide pins(l) ,
guide bushes(2) and centering sleeves(3) can be arranged as required , depending on
the combination of plates used. In addition , P standard elements can be used to
advantage for the construction of jigs, special machinery and also as mold inserts if
made of suitable steel grades. The round K standard plates are available with either
four, three or two guide bores.
Guide elements as shown in fig.6/B can be used for simpler molds where not all of the
plates need to be guided through the guide system. They do not have a spigot at the
rear and are particularly suitable when no clamping plate is used on the stationary mold
half. This illustration also shows the possibility of combining K and P standard elements.
The guide pin shown in Fig 6/C is designed for special applications. It has tow
differently tolerance fits, ensuring that one side of the pin has a press fit in the H7
bores of the cavity plates , while the other side has a slide fit in the H7 bores of the
guide bushes. The location holes for the guide and centering elements( diameter 1) are
identical for all plates. The only exception are the bore of the K 25 cavity plates. In order
to eliminate problems arising from distortion during heat treatment of machining , these
plates have grinding allowances in the locating holes ( fig. 7).







  
x

  

 

Reworking these holes form dia 2 to dia 1 ensures interchangeability. This is of importance for stock keeping and replacing the guide elements. The guide dia( dia 3) of the
pins and bushes are different in order to prevent incorrect assembly of the stationary
and moving half.
Apart from the finished guide bores , the K 20 cavity plates have all side faces ground to
close tolerances. They can be used as reference faces. Unlike assembled mold bases,
which are ground in this state, these plates can be interchanged at any time.
The so-called "Euro- system" was developed for special-purpose mold designs. The
individual plates are not screwed together separately. The guide elements are specially
designed also for holding the plates together, and more space for cavities is available.
These standard elements are also designed on the basis of he modular system, and
they can be combined and interchanged as required. If guide bolts or bushes of this
system are fitted in one plate only with out holding other mold elements together, a split
clamp ring such as that shown in fig. 8/B is used the counter sunk socket head screw,(l),
is used to press the tapered ring.(2) into the split clamp, ring(3), thus fastening the guide
element in the hole.
The sizes of modular standard plates are steeped on a 50 mm scale, and such plated
are available ranging in size form about 95 x 95 mm to about 800 x 1000 mm. the round
dimensions range form a diameter of about 95 to 400 mm.
Molds can be designed in various ways using modular standard elements. Figure 9
shows a variety of possible combinations (l) using only K standard elements(2)using a
combination of K and P standard elements and (3) using only P standard elements.
Thus what is offered is not a ready-made solution but a set of possibilities for individual
use and maximum flexibility of design.
If premachining is required on standard plates, e.g. for slide guides or inserts, the
supplier of the standard elements should at least carry out the rough machining
according to the mold maker's specification. This will avoid any distortion , which could
otherwise have a negative effect on the function of the guide elements.







  

  

 

 
 


 
 


mbol

BS


Polymer



Predrying
Temp.
C

Acrylontrle

Moulding

Hour Temp c
70-80

24

220

cellulose Acetate

70

OM

Polyacetal

110

23

260
170250
195245

Polyacetal

70

220-

MA

PO

ButadienceStyrene

Methacrylate
Polyphenylene

100

Oxide

250-

Polyamide 6

80

24

6/6

Polyamide 6 6

80

24

Polycarbonate

120

ES

Ployether Sulfone

150

BT

Polybutylene

120

34

240-

PS

Polyphenylene

150

340-

terephthalate

Polyester (linear)

Polystyrene

Polystyrene HI

PE

70

10

13

High Density

Polypropylene

VC

Hard Polyvny

250275
170190
180-

AN

Choirode
Styrene
Acrylonitrile

70

13

200
240270

PU

Thermoplastic

80
23

180275

Polyurethane

100




rpm

Screw
Pressure
Bar

Back
Structure

150

180

210

222

30-80

High

750-1500 Low<100

< 250

230

40

140 185

280
185
200
195
215

Low

300 - 1500 low

<150

0.10.7

180 200

280
165
200
190
200

40-120

30-40

180
135
165
150
180

40-120

High 750 - 1500 Low<100

<200

50-60

135

185

200

200

Low 1050 -1750 Low

<400

2
0.40.8

180

200

250

250

40-120

60-80

190

230

250

240

80- 100

High

<35

0.40.7

270

60

240
200
230

290
250
280

275
240
270
270
280
315
360
420

40

240 260

285 315

60-80

265
235
270
320
390

350 410

280
285
315
360
430

60-80

220

250

260

255

260

270

275

270

60-80

290

300

310

305

320

20-30

310
205
220
150
180
150
200

180 230

360
230
250
210
230
210
260

320
230
250
210
230
220
280

20-30

160

200

220

260

20-30

230
150
210

210 250

280
240
290

30-40

135

165

160

180

40

125

40

150
150
200

70-80

60-80
20-30

Choirode
Soft Polyvny

Injection

35-40

Polyethylene

VC

130

370
260280
220280
220270
220280

Nozzle Temp c

Mould Injection
Pressure
Speed Bar

0.40.7

276

Sufflone

ET

Barrel Temperatures C
Feed
zone Rear Middle
Front

260

290
230290
290300
260310
330400

A6

40

280

100- 1500 Low<100

AMO

AMO
SEMI.CRYS
AMO

SEMI.CRYS

high Torque
60-90

High

60-120

High

750 -1500 Low<100

<150

0.82.5
0.82.5
0.70.8

SEMI.CRYS

<150

80-120

300 -1500 Low<100

Low<
High 1200 -2000 100Torque

130-200

High 1200 -2000 Low<60

<400

70-140

Low 1200 -2000 Low<100

<400

0.6
12.2

25-200

High 1000 -1500 Low<100

<50

90-140

Low 1200 - 1500 Low

<50

30-80

High

800 -2000 High

<150

30-50

High

800-1500 High

<150

210

20-60

High 1200-1820 High

<200

270
240
300

20-80

High 1500-1800 High

<200

180

180

20-60

Low

1000-1700 Low<80

<50

1.22.2
0.50.02

205

210

150

160

150

20-60

High

800-1200

<250

1.2

AMO

175
200 250

200
210
260

200
210
250

30-80

High

750 -1000 Low

<150

AMO

150

170

180

190

15- 65

Low

750-1200 Low<100

<15

0.5
11.5

190

200

210

220

220 240
180 230




  
x

<300

1.31.5
0.4.06
0.40.6
1.52

SEMI.CRYS
AMO
AMO
SEMI.CRYS
SEMI.CRYS

SEMI.CRYS
AMO
AMO
SEMI.CRYS

SEMI.CRYS
AMO

High

  

 

SEMI.CRYS

*
*

*
*
*

*
*
*

*
*

*
*

*
*

*
*
*

*
*

Voids i.e. air bubbles in moulded parts.

*
*

0orm lines in the moulded part

0avy condition of the surface

Streak limbos and material in

*
*

Material temperature too high (burning)

Brittleness of the moulded parts

Discolouration at the sprue

0arping of the Moulded parts

Tearing off the sprue

Moulded parts sticking in cavities

Flaking

Inferior surface finish (gloss)

Flash on moulded parts

Moulded parts show matt areas

Burning in the moulded parts.

Sink marks in moulded

Screw does not return

The mould has not been completely filled.

*

Flow scerns

Increase injection pressure

Decrease Injection pressure
Increase cylinder temperature
Decrease cylinder temperature
Increase holding pressure time
Decrease Holding pressure time
Increase nozzle temperature
Nozzle seal or nozzle blocked
Nozzle seal is jammed
Increase screw rotation speed
Decrease screw rotation speed
Nozzle seal or nozzle loose
0rong type of nozzle seal
Inject with rotating screw
Increase moulding locking force
Injection pressure starts
too early
Decrease Injection speed
Increase injection speed
Increase screw back pressure
Decrease screw back pressure

Material dribbles out between sourse and nozzle

POSSIBLE REMEDIES

*
*
*

*
*
*

*
*

*
*

*
*
*

*
*

*
*

*
*

Decrease mould temperature

Polish mould and




*
*




  
x

*
*

*
*

  

 

round off edges

Moulds requires maintenance
Polish sprues runners
and channels
Sprues and runners
should be increased
Introduce mould venting
Introduce cold slog pocket
Pre-dry material
Materials is contaminated
Hopper is empty or
throat blocked
Metering is insufficient
Use mould release agent
Check on nozzle setting
Check on nozzle/
sprue bush radiuses
Temperature too high
increase nozzle contact time
Decrease cylinder temp. at intake zone
(except nylon)
Bridging in hopper/
vent attachment
Check for equal fitting
(multi cavity tools)
Introduce air ejector
Increase cooling and
pause times
Decrease cooling and
pause times

*
*

* *

*
*

*
*

*
*

*
*

*
*

*
*


-

-

-




























-



-


-











-








-




-



  
  

5material
density
shrinkage
accuracy
quantity
shape and size
- Material- Material with which the component is to be moulded
- Shrinkage- After cooling how much mm. per mm length will shrink

4


 (
##


 
 ( 
(

(

()
High Impact
0.005 - 0.007
1.01 - 1.04
Heat resistance
0.004 - 0.005
1.06 - 1.08
Medium impact
0.005
1.04 - 1.07
 

(


0.020 - 0.035
1.42
Easy flow
0.002 - 0.007
1.09 - 1.14
General purpose
0.002 - 0.009
1.11 - 1.18
Heat resistant
0.003 - 0.010
1.09 - 1.14
High Impact
0.004 - 0.008
1.09
 



((

Hard/medium/soft
0.002 - 0.005
1.22 - 1.34
 



((
((
0.002 - 0.005
1.15 - 1.22
 
Type-6.6
0.010 - 0.025
1.08 - 1.14
Type-6
0.007 - 0.016
1.12 - 1.14
Type-6.1
0.010 - 0.025
1.07
Type-11
0.010 - 0.025
1.04 - 1.05







  
xP

  

 

Type-12
0.008 - 0.020
Transparent
0.004 - 0.006
Glass filled
0.005 - 0.010
 
( 


Low Density
0.015 - 0.035
High Density
0.015 - 0.030
 


0.010 - 0.030
 (


General purpose
0.002 - 0.008
Heat resistant
0.002 - 0.008
Toughened
0.003 - 0.006
 (
(
( 


0.050 - 0.100.
#

  

#
Un plasticized
0.002 - 0.004
Rigid
0.002 - 0.004
Semi rigid
0.005 - 0.025
Flexible
0.015 - 0.030
 (

4
 ( 
#0.002 - 0.006
 
(
#
0.006 - 0.007

1.01 - 1.02
1.23
1.34 - 1.42
0.92 - 0.925
0.941 - 0.965
0.860 - 0.906
1.040 - 1.100
1.04 - 1.10
1.04 - 1.10

1.35 - 1.45
1.16 - 1.35
1.00
1.075 - 1.100
1.20

( ( As per requirement


 ( Depends upon resin used(To be decided from table 1)



 As per components used
 
  
4 To be studied from component







  
x3