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INJECTION MOLD
DESIGN
BDD 40903 Prepared by : Mohd Hilmi Othman
CHAPTER 1
Introduction(2 hours)
Mold type
Standard Molds
The standard mold is the most simple design, basically
divided in two side :
a) Cavity side
Cavity side is the side that construct to flowing plastic
material from nozzle to cavity parts, basically they consist
of sprue, runner.
b) Core side
Core side construct to make shape for core, de-molding
system and ejection system, at this side it the ejection
system will be designed.
Standard mold have one parting line, and have one
opening direction. This type of mold use in all kinds of
plastic parts that doesn't have undercut, inner and outer
screw.
BDD 40903 Prepared by : Mohd Hilmi Othman
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Mold Material
The plastic part is when a plastic material is
heated until it becomes soft enough to be injected
into a closed mold.
The finished part is ejected out once it has cooled
enough to solidify and is completely formed.
It is possible to create a part with intricate
features, although the more complex the part the
more complex the mold, and ultimately more
expensive it is.
There are six materials that are commonly used
for creating mold, which are Aluminum, Copper
Alloy, Plaster, Polymers, Steel and Wood.
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http://injectionmold.cc/mold-design-and-manufacturing-process
BDD 40903 Prepared by : Mohd Hilmi Othman
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zinc alloy
bismuth-tin alloy
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Electrical Discharge
Machining (EDM)
Machine
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Surface Treatment
Why strive for a high surface finish?
The increased use of plastic products has created a
higher demand for mirror finish of molding tools. The
highest demands for surface finish are in the optical
lens mold whereby an extreme requirement on
polishability is desired.
However, in general there are other advantages for
high surface finish, including:
a) Easier ejection of the plastic parts from the
molding tool
b) Reduced risk of local corrosion
c) Reduced risk of fracture or cracking due to
temporary overloading or pure fatigue.
www.acerosuddeholm.com/spanish/files/polishing-english.pdf
BDD 40903 Prepared by : Mohd Hilmi Othman
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Develop preliminary
mold design and
quote
Project OK?
Ejector System
Design
Cooling System
Design
Layout Design
Structural System
Design
Machining, Polishing,
Assembly and Trials
Initial
Design
Moldings
OK?
Close
Project
Source: David O. Kazmer, Injection Mold Design Engineering, Carl Hanser Verlag, 2007. (Page 14)
BDD 40903 Prepared by : Mohd Hilmi Othman
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Shrinkage
When plastic material is injected into a cavity, it starts to
cool down, whereby its volume decreases. A measure for
this volume decrease is given by the difference between
melt density and solid density. As cooling rates in the
cavity are very high and non-uniform, the frozen material
will also incorporate internal stresses. These stresses may
relieve after ejection from the cavity, which process can be
accelerated by keeping the part at elevated temperatures.
Shrinkage can be defined by the following formula:
S = (D - d) / D ( 100%).
D = dimension of mould cavity.
d = dimension of moulded part.
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Shrinkage (2)
Shrinkage to be distinguished are:
shrinkage in flow direction ;
shrinkage normal to flow;
shrinkage in thickness direction.
3 Dimension pVT-diagrams
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Shrinkage (3)
Shrinkage Factors
Injection pressure higher pressures force more material
into mold cavity to reduce shrinkage