Objective

To understand the functions of the parts.

To learn the usage of a 2 plate mould that later on will be equivalent to my work
after study.
Give us knowledge of the safety when using 2 plate mould.
To understand how injection moulding works in 2 plate mould.
To understand the functions of the parts of 2 plate mould.
To understand the types of injection mould for 2 plate.

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 Introduction

Injection molding is a manufacturing process for producing parts by injecting material

into a mould. Injection moulding can be performed with a host of materials, including
metals, glasses, elastomers, confections, and most commonly thermoplastic and
thermosetting polymers. Material for the part is fed into a heated barrel, mixed, and
forced into a mould cavity where it cools and hardens to the configuration of the
cavity.Injection moulding is widely used for manufacturing a variety of parts, from the
smallest components to entire body panels of cars.

Parts to be injection moulded must be very carefully designed to facilitate the moulding
process. The material used for the part, the desired shape and features of the part, the
material of the mould, and the properties of the moulding machine must all be taken into
account. The versatility of injection moulding is facilitated by this breadth of design
considerations and possibilities.

Two plate mold is the mold with sprue, runners, gates, and cavities are all on the same
side of the mold divided by the parting line into moving half and fixed half.

The features for two plate mold are simple structure, easy to operate, and satisllietory to
have the plastic part to drop off freely. Minimal operational probIems, long lifespan,
shortened molding cycle, inexpensive mold cost, easier to choose gate shape and
location for the two pate mould.

Other than direct gates, gate location is limited to the side of the plastic part with certain
exceptions. After molding, there is need to cut off the gate from the part.

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 2 Plate Mould
Accessories

Top Clamping Plate

The function of the top clamping plate is to provide a means to attach the locating
ring to the mold base.

The top clamping plate also provides counterbored holes for the SHCS's that secure
the A retainer plate.

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 Locating Ring
The function of a Locating Ring is to align the Mold Base to the Stationary Platen side
of the Press. The Sprue Bushing is also located via a hole in the Locating Ring.

The Locating Ring is located and fastened into the Top Clamp Plate (TCP) via
counterbored hole.

Cavity Plate
It is used to attach core side of product, return pin, leader bush and slider core if
needed.

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 Guide Pin
The function of the Guide Pin is align both halves of the mold at the Parting Line. The
Guide Pin aligns with the Guide Bushing. It maintains proper alignment of two halves of
mould.

Core Plate
The core plate on the B side of the mold are identical in function to the A
side cavity steels, with one additional function, they typically have have
holes for Ejector Pins.

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 Return Spring
A method for disassembling and assembling a mold enables a return pin to be safely
attached or detached against an elastic force of the return spring.

Ejector Plate
The Ejector Plate provides a backer plate for retaining the ejector, return, and sprue
pins. The underside of the Ejector Plate is where the Knockout Rods from the Press
touch, and make the Ejector sub assembly move to eject the parts.

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 Return Pin
The function of a Return Pin is to return the entire Ejector Sub assambly to the home
position. If Return Pins were not utilized, the ejector sub assambly would be returned
via Ejector Pins, this is not acceptable, as it would damage the end of the ejector pins
and would alter the appearance the part.

Support Plate
The Support Plate has many functions. The primary function of the SP is to provide
support to the B side Cavity Steels. Proper support will reduce the possibility of flash
occurring at the Parting Line due to the B Cavity steel "bowing and flexing" under the
high pressures of Injecting Material into the Cavity.

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 Spacer Block
Mounted between the movable clamping plate (bottom plate) and the movable cavity
plate to give space and allow the ejector plate to move when ejecting the
part. The required length of spacer block depend on ejector stroke that needed to eject
product.

Allen Cap Screw

A long-threaded bolt, usually with a square head, used in fastening clamping plates.

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 Cavity Steels
The function of a Cavity Steel is to provide the negative image of the desired part that
will appear on the A side of the mold above the parting line. While not always the case,
the Cavity Steels MAY provide coolant lines for coolant. The Cavity Steels contain the
Gate, and usually a small portion of the Runner system.

Core Steels
The Cavity Steels on the B side of the mold are identical in function to the A side cavity
steels, with one additional function, they typically have holes for Ejector Pins.

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 Sprue Bush
The function of the Sprue Bush is to provide a seat at the spherical radius for the Nozzle
of the press. The Sprue Bushing provides a "path" for the material from the nozzle to
the runner system.

Stop Pin
The function of the Stop Pin is to provide a minimal contact area between the Ejector
Housing and the bottom of the Ejector Plate. The space provides an area for debris in
molds that are set in the vertical direction.

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 Ejector-retainer Plate
The function of the Ejector Retainer Plate is to retain the Ejector Pins, Sprue Puller
Pins, Guided Ejector Bushing and the Return Pins to the Ejector Plate.There are drilled
and counterbored holes for each of the components mentioned above.

Sprue Puller Pin

The function of the Sprue Puller Pin is to "pull" the material from the Sprue Bush at the
end of the Molding Cycle.

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 2 plate mould
Operations

Die casting
Die casting is a metal casting process that is characterized by forcing molten
metal under high pressure into a mold cavity. The mold cavity is created using two
hardened tool steel dies which have been machined into shape and work similarly to
an injection mold during the process. Most die castings are made from non-
ferrous metals,
specifically zinc, copper, aluminium, magnesium, lead, pewter and tin based alloys.
Depending on the type of metal being cast, a hot- or cold-chamber machine is used.

The main die casting alloys are zinc, aluminium, magnesium, copper, lead, and tin.
Although uncommon, ferrous die casting is also possible

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Equipments
There are two basic types of die casting machines: hot-chamber machines and cold-
chamber machines.

Hot-chamber machines

Hot-chamber machines, also known as gooseneck machines, rely upon a pool of molten
metal to feed the die. At the beginning of the cycle the piston of the machine is
retracted, which allows the molten metal to fill the "gooseneck".
The pneumatic or hydraulic powered piston then forces this metal out of the gooseneck
into the die.

Cold-chamber machines

These are used when the casting alloy cannot be used in hot-chamber machines; these include
aluminium, zinc alloys with a large composition of aluminium, magnesium and copper. The process for
these machines start with melting the metal in a separate furnace.

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 Metal injection moulding

Metal injection molding (MIM) is a metalworking process where finely-

powdered metal is mixed with a measured amount of binder material to comprise
a 'feedstock' capable of being handled by plastic processing equipment through a
process known as injection mold forming. The molding process allows complex
parts to be shaped in a single operation and in high volume. End products are
commonly component items used in various industries and applications.

The main metal injection moulding materials are Stainless Steel, Low Alloy Steels,
Titanium, Copper, Irons, Cobalt alloys, Copper alloys, Nickel alloys, Tungsten alloys
and Titanium alloys.

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Thin-wall injection moulding

Thin wall injection molding is a specialized form of conventional injection

molding that focuses on mass-producing plastic parts that are thin and light so
that material cost savings can be made and cycle times can be as short as
possible. Shorter cycle times means higher productivity and lower costs per
part.The definition of thin wall is really about the size of the part compared to its
wall thickness.

Thin wall parts have a wall thickness of less than 1mm. The size of the
part also plays a role in the definition since the bigger the part, the
more injection pressure is needed to fill the mould cavity.

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Injection moulding of liquid silicone rubber

Injection molding of liquid silicone rubber (LSR) is a process to produce pliable,

durable parts in high volume.
Liquid silicone rubber is a high purity platinum cured silicone with low compression set,
great stability and ability to resist extreme temperatures of heat and cold ideally suitable
for production of parts, where high quality is a must.
Due to the thermosetting nature of the material, liquid silicone injection molding requires
special treatment, such as intensive distributive mixing, while maintaining the material at
a low temperature before it is pushed into the heated cavity and vulcanized.

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Machines
Die Casting
Hot-chamber machines

Cold-chamber machines

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Metal injection moulding machine

A diagram of a typical injection-molding machine. Granular material (the plastic

resin) falls from the hopper into the barrel when the plunger is withdrawn. The
plunger then pushes the material into the heating zone, where it is heated and
softened (plasticized or plasticated). Rapid heating takes place due to spreading of
the polymer into a thin film around a torpedo. The already molten polymer displaced
by this new material is pushed forward through the nozzle, which is in intimate
contact with the mold. The molten polymer flows through the sprue opening in the
die, down the runner, past the gate, and into the mold cavity. The mold is held tightly
closed by the clamping action of the press platen. The molten polymer is thus forced
into all parts of the mold cavities, giving a perfect reproduction of the mold.

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 Thin-wall injection moulding machine

An Injection molding machine, also known as an injection press, is a machine for

manufacturing plastic products by the injection molding process. It consists of two main
parts, an injection unit and a clamping unit.

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Injection moulding of liquid silicone rubber

Injectors

Metering units

Nozzle

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 Maintenance
Cleaning Mould

Use bronze wool to remove the worst of the crud and wait until after casting. The
majority of the moulds you get have had some attempts at maintenance some time
in the past. Much of the crud may be old grease combined with rust. Fire up the pot
and run maybe 25 cast. Cast dummy bullets until the mould smokes all over and
then cast about 10 more. This will normally loosen most of the crud.

Then, let the mould cool and continue scrubbing with bronze wool. This removes
about 90% of the crud. If theres rust in the cavities, it should be loosened by now.
Use a bronze cleaning brush in the cavities with either a hand drill or an electric drill
at very slow speed.

Really stubborn deposits can be removed by using a brass or bronze countersunk

machine screw chucked in a Dremel tool. This allows you to get into the corners of
the grease grooves and remove built up deposits. Do this very carefully at low speed
and dont overdo the process.

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 Safety
Do not use the 2 plate mould unless a teacher has
instructed you in its safe use and operation and
has given permission.

Work place is properly secured

Safety glasses must be worn at all times in work areas

Keep the floor free from obstructions, or slip hazards.

Appropriate footwear with substantial uppers must be worn.

Close fitting/protective clothing must be worn

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 Rings and jewellery must not be worn

Handle the 2 plate mould with care

Summary
The aim of this report is to classify the 2 plate mould along with its objectives. The
accessories of the 2 plate mould are listed with its functions.

So are the 2 plate mould operations with its definitions. And lastly, there are list of safety
which are crucial for the host to remain safe.

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