Chapter single injection mold parting plane

First, the basic content of this chapter

This chapter includes the overall structure of the plastic injection

mold;Function singulation injection mold parting constituent bodies and

method of design;Plastic injection mold plastic parts position;Common gating

system design;Molding Parts Sizing;Simple design agency launched;Design

temperature regulating system;Mold design structural components;Design and

steps of the design method of a single injection mold parting surface.

Single injection mold parting surface composition and operation

Parting plane forms

Design Principles
Parting Surface
The number of cavities

Sprue Checking flow ratio

Shunt
Single injection mold parting plane Calculating the length of the flow path
Single parting surface of the mold

Runner
Gating system design Pouring system Ping Heng calculation
The

Cavity
balance

Core
Calculating the
Thread core
Forming part design Working
Threaded
Dimensions
ring
Rigidity strength
Putting an ejection mechanism
check
Push tube ejecting mechanism
The introduction of computing power
The introduction of mechanism design
Release mechanism pusher plate

Cooling circuit size calculation

Mold cooling system
Structure determined
Mold heating system
Electrical heating means calculates the total pow
Temperature Regulation System
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Second, learning objectives and requirements
In this chapter, the overall structure should have a single feed system and the parting

surface of the injection mold, the general design and method of introduction mechanism.

Third, the focus of this chapter, difficulties:

Single system design parting surface of the injection mold gating system and the

overall structure, the general design process ejector mechanism and method of

temperature regulation ,,.

1, form a single parting surface of the injection mold

Press institutions, a single injection mold parting surface of the cavity, molded parts,

gating system, guide means, the ejector means and a temperature regulation system

composed of structural components.

(1) The cavity

A mold cavity portion for forming a plastic article, since the part of the cavity is
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directly molded plastic parts, thus the shape of the cavity should be consistent with the

shape of the plastic parts of rot, mold cavity by a cavity in general, the core composition.

(2) forming part

Plastic parts constituting the mold cavity is referred to as molded components,

typically comprising a core (inner shape of molded plastic parts), the cavity (outer shape

molded plastic parts).

(3) the gating system

Directed by the plastic injection machine nozzle cavity gating system called runner,

sprue gating system points, runner, gate, cold-slug four parts by the sprue bush, and a rod

pulling materials stationary platen flow path components.

(4) guide means

To ensure accurate alignment of the movable die and the stationary die when the

guide member is provided mold clamping. Typically a guide post, a guide hole on the

stationary die or the movable die is provided at the inner and outer tapered surface

composed of each anastomosis, respectively.

(5) Release means

In the mold opening, means the introduction of plastic parts from the mold. Release

of the injection mold, some apparatus in order to avoid the introduction of the skew plate

ejection process, also has a guide member, so that the push plate held horizontally. By a

push rod, the push plate, the push rod fixed plate, the return lever, sprue pulling rod,

support the nail, the push plate and the push plate guide posts guide sleeve composition.

(6) and the exhaust system temperature control

In order to meet the process requirements of the injection mold temperature, the mold

is provided with cooling or heating systems, cooling systems generally defines the cooling

channels in the mold, the cooling water cooling system and nozzle components. Heating

the heating element is installed around or inside the mold, such as an electrical heating

element. In the injection molding process, in order to exclude the mold cavity gas, but is

often necessary to open the exhaust system.

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 (7) structural components

Means for mounting the fixed part of each part or support parts and the

above-described molding. Supporting parts assembled together, may constitute the basic

skeleton of the injection mold.

2,Working principle of the single injection mold parting surface

Working principle of the single injection mold parting surface: when the mold is

closed, the lower guide of the guide post and guide sleeve is positioned, the movable mold

and the fixed mold is closed. The cavity by a cavity on the stationary platen and the fixed

core composition on the movable platen, by clamping force injection molding machine

mold clamping system to provide locking. Then the injection machine begins an injection,

the plastic melt through the mold gating system at a given into the cavity, the cavity filled

with the melt and through the packing, after cooling and setting up plastic mold. When the

mold by the injection machine mold clamping system driven movable backward, the

movable mold and the fixed split mold parting surfaces mold, plastic mold packages

retracted together with the movable core, while the pulling rod sprue gating system frozen

material drawn from the sprue bush. When the movable die is moved a certain distance,

the injector ram contacts the push plate, the push plate mechanism starts to operate, the

push rod and the pulling rod are plastic parts and condensate material feed system and out

of the core hole in the cold material, plastic member falls in the gating system condensate

fed together from the mold, thus completing an injection process. When mold clamping,

introduced by means of the reset lever to reset and ready for the next injection.

3, a single sub-surface injection mold gating system design

Composition (1) general casting system

Gating system means that the feed passage between the mold by the injection

machine nozzle to the mold cavity. Common gating system typically consists of four sprue,

runner, gate and cold slug composition. FIG 3.6a injection mold gating system is mounted

on a horizontal or vertical injection machine used, also referred to as a sprue gating system,

which is perpendicular to the sprue to the mold parting surface; FIG 3.6b mounted angular
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type injection injection mold gating system on the machine used, the primary channel

parallel to the parting surface.

Design principles (2) Injection System

Gating system design should follow the following basic principles:

① Learn molding properties of the plastic

② To avoid or minimize weld line

③ Conducive to the discharge of the gas in the cavity

④ Preventing displacement and deformation of the insert core

⑤ Try using a shorter process filled cavity

(3) check the flow ratio

Flow ratio from flow ratio referred to, when it refers to the longest distance of the

plastic melt flow in the mold, which is the same cross-sectional thickness of material

segments and each length of the flow channel sections of the mold cavity corresponding to

the sum of its cross-sectional thickness ratio, which is

n
  
Li
  (3-4)
i 1 ti

Where  - flow distance ratio;

L-- mold segments and each flow channel section cavity length, mm;

t-- mold segments and each flow channel cross-sectional thickness of the

mold cavity segment, mm;

  - compared with many plastic flow distance.

(4) sprue design

It refers sprue gating system starts from an injection machine nozzle

to the mold in contact with the shunt flow channel until the plastic melt.

Is the first sprue melt flowing through the mold part, its shape and size

of the plastic melt flow rate and filling time has a great influence,

therefore, necessary to minimize the temperature drop and pressure drop of

the melt.

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 ① Sprue size

The mold used in horizontal or vertical injection machine, the sprue

perpendicular to the parting plane. Since the sprueTo repeated contact with

the plastic melt temperature and an injection machine nozzle, so that only

small volume, only the primary channel machined directly on the injection

mold, most of the injection mold, the sprue is generally designed to be

removably replaceable sprue sprue bush. In order to make the sprue slug

smoothly pulled out from the sprue bush sprue designed conical, having a cone

angle  It is 2º ~ 6º.Small end diameterd nozzle diameter of 0.5 ~ 1 mm than

the injection molding machine. Due to the foregoing spherical small end, a

depth of 3 ~ 5 mm, injectionSpherical transmitter nozzle in this position

and contact with the die bonding, thus requiring spherical radius than the

nozzle sprue large spherical radius 1-2mm. Runner surface roughness value

Ra of 0.08 m .

② Sprue gate sets

FIG sprue 4 and the sprue bush is fixed in the form of

Sprue gate sets generally used carbon tool steel such as T8A, T10A and

other materials, heat treatment and quenching hardness 53-57HRC. Sprue and

sprue bush is fixed in the form shown in FIG.

(5) shunt design

It refers to shunt some of the plastic melt between the sprue and the

gate terminal flow channel. Shunt effect is to change the melt stream from,

so a steady state flow evenly distributed to each cavity. Note should be

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designed to minimize heat loss during the flow and the pressure loss.

① Shape and size of the shunt

Moving up the shunt, or both on either side of the stationary die parting

plane, which sectional shape should be so small specific surface area

(surface area than the flow channel to its volume). Conventional split

channel forms a circular cross section, a trapezoid, u-shaped, semicircular

and rectangular, etc., shown in Figure 3.9. U-shaped cross-section and

trapezoidal shunt easier processing, and the heat loss and pressure loss is

not large, it is commonly used forms.

② The length of the shunt

The arrangement of cavities in the case of the parting line, can be

divided into a shunt shunt, twice or even three times runner runner. Shunt

length as short as possible, and less bent, in order to reduce heat loss and

pressure loss, the plastic raw materials and energy savings.

③ BypassRoadSurface roughness

Since the outer plastic shunt in contact with the mold is rapidly cooled,

the melt flow only inside the ideal state, so runner surface roughness value

can not be too small, and generally about 0.16 μm, which may increase the

flow of the outer layer of the plastic melt resistance. Skin cooling so that

the fixed outer plastic, insulating layer is formed.

④ Shunt arrangement

Shunt arrangement commonly used balanced and unbalanced two, which is

a multi-cavity unbalanced and balanced arrangement is consistent.

(6) gate design

① The concept of the gate

Also known as the feed port gate, runner and the cavity is connected

to a melt channel. Design and selection of appropriate gate position is

directly related to the plastic parts can be intact, high-quality injection

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molding.

② The role of the gate

Limiting gate and the gate can be divided into two types of non-limiting

gate. Non-limiting sprue gating system in the whole portion of the maximum

cross-sectional dimension, which is mainly from the pressure acting on the

large cylinder type, shell type plastic parts and the feed material

introduced cavity. Restriction site of the gate is the minimum

cross-sectional size of the entire casting system, and its role as follows:

a) Gate by a sudden change in cross-sectional area of the shunt fed plastic melt to

increase the injection pressure of the plastic melt has a mutation increasing the flow

rate through the flexible port, improving the shear rate of the plastic melt, reduce the

viscosity, it ideal flow conditions, so as to fill the cavity rapidly balanced. For

multi-cavity mold, adjusting the size of the gate, so that the cavity may also be

arranged in a non-Ping Heng feed purposes simultaneously.

b) Gate also acts earlier solidified melt cavity to prevent the reverse flow effect.

c) Typically the smallest cross section gate pouring system, which facilitates the

separation of Houjia Ding plastic parts and plastic parts sprue slug.

③ Single injection mold parting surface gate type

Single injection mold parting surface of the gate can direct gate,

central gate, the side gate, the gate ring, spoke gate and gate claw.

a) direct gate

Direct gate sprue called fork type gate, which gate is non-limiting.

This form of gating is only suitable for single-cavity mold, in the form of

direct gate shown in Figure 5.

Characterized by: the flow resistance is small, long and short flow paths

feeding time; help eliminate the drawbacks of the deep pockets of the exhaust

gas is not easy; minimal plastic parts and pouring systems, compact projected

area mold parting surface, injection machine uniform force; warpage of

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plastic parts, the large cross-section gate, the gate difficult to remove,

after removal of the gate mark would have a larger, affecting the appearance

of plastic parts.

b) Center gate

Direct gate 5 in FIG. 6 FIG central gate

When the bottom of the central cylinder type or plastic parts of

crustaceans or close to the center portion of a through hole opened in the

gate of the hole, while the divider cone disposed at the center of the gate

as center gate, a direct gate a special form, as shown in FIG. It has a number

of advantages of the direct gate, and overcomes the deficiencies of shrinkage

or deformation is easy to produce a direct gate.

c) side gate

Generally defines a side gate at the parting surface of the plastic melt

from the mold cavity is filled inside or the outside, which is a

multi-sectional shape% (flat groove), limiting the gate. Side gate widely

used in a single multi-cavity injection mold parting plane, in the form of

side gate as shown in FIG.

Characteristic due to the small cross-sectional gate, the gating system

to reduce the consumption of plastic, while the gate is removed easily,

without leaving obvious traces.

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 FIG side gate 7

Variation of the two forms is fan gate side gate peace slit gate.

A fan gate in the gate width direction gradually increases, decreasing

the thickness of the fan-shaped side gate, gate, also known as sheet seam

gate, a large gate width and small thickness. Primarily for shaping smaller

area, the size of a large flat plastic parts, plastic parts can be reduced

warpage deformation of the plate, but is more difficult to remove than the

fan gate gate, gate trace on the plastic parts and more obvious.

d) ring gate

Filling of the cavity using the feed in the form of an annular ring gate,

said gate, shown in Figure 8. Ring gate is characterized by a uniform feed.

Around the circumferential velocity substantially equal, good melt flow

state. Air is easily discharged cavity, weld line may be substantially

avoided, but feed consumption gating system are more difficult to remove

sprue.

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 FIG 8 ring gate spoke gate 9 of FIG.

e) spoke gate

Spoke gate is improved on the basis of the ring gate, the original number

of small pieces to feed the circumferential arc feed, in the form shown in

Figure 9 spoke gate. This form of gating feed consumption is much less than

the ring gate. And easy removal of the gate. Such gates are widely used in

the production ratio of ring gate. Used for a large hole at the bottom of

the cylindrical member or casing shaping. Gate spokes disadvantage is the

increased weld line, may affect the strength of plastic parts.

f) gate claw

Claw gate processing more difficult, typically forming EDM. Core can

be used as the divider cone, its head with the main passage has a

self-centering action, so as to avoid bending the plastic parts forming

defects or poor concentricity. Disadvantage claw spoke gate and gate

Similarly, mainly suitable for forming a small hole and a high concentricity

requirements elongated tubular plastic parts.

④ RunnerpositionofSelect principle

a) Try to shorten the flow distance

b) To avoid melt fracture phenomena caused by defects of the plastic parts

c) Gates should be opened at the thick plastic parts

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 d) Consider the impact of molecular orientation

e) Reducing the weld line, the weld strength improved

(7) the gating system designed to Ping Heng

① The concept of Ping Heng gating system

In order to increase productivity, reduce cost, small (including

medium-sized portion) tend to adopt a multi-cavity plastic in a mold

configuration should be used in the form of a cavity Yu balanced arrangement.

The gating system, if a need to be designed molding cavity unbalanced

arrangement, by adjusting the gate size is required, the flow rate of the

gate forming process and the same condition is reached, this is Ping Heng

casting system, also known as gate Ping Heng .

② Ping Heng calculation method for pouring system

Thinking Ping Heng calculation is performed by pouring BGV (Balanced

Gate Value) value is calculated for each gate to determine multi-cavity mold

or calculated. When the gate Ping Heng, BGV value should meet the following

requirements: the same plastic multi-cavity mold, each gate BGV calculated

value must be equal; multi-cavity mold of different plastic parts, each gate

must be calculated value BGV filling volume is proportional to its plastic

cavity.

4, a single injection-molding parting surface parts

A mold generally dozens of parts, in order to ensure the normal operation of the mold,

between the mold parts, plastic parts and between the parts, have strict dimensional

relationships. Part of this study was to understand the cooperating relationship between the

function of each part in the mold, the parts of the structure and parts.

(1) Design

① Cavity design

Cavity forming parts are the main parts of the outer surface of the

plastic member. According to the structure can be divided into

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 Monolithic cavity structure

The cavity is machined from a unitary piece made of metal, which is

characterized by strong, easily deformed, it does not make the plastic parts

produced splice line marks. However, due to difficulties in monolithic cavity

machining, heat treatment inconvenient, so commonly used in the simple shape,

a small mold.

The combined cavity structure

Combined cavity structure refers to the cavity is a combination of two

or more components formed. According to different combinations, the modular

structure can be divided integrally embedded cavity, topical mosaic, mosaic

and sidewall walls split the like.

② Core Design

Shaping into the inner surface of said core part, there are a main core,

the small core and the like. For simple containers, such as shells, plastic

cover or the like, forming part of the inner surface of the main parts of

said main core, and the other aperture forming core is referred to as

puncturing or small shaped core rod.

Core structure design

According to the structure of the main core can be divided into two kinds

of integral and modular. Main unitary core structure, which is solid

structure but inconvenient processing, multi-die steel consumption. The main

process for experiments or simply on a small core mold. Modular structure

of the main core after the core is processed separately, and then insert the

human template.

Structure design of small core

Small core is used as a shaping orifice or groove member. After making

small cores separately, and then embedded in the template.

 Several small circular core fixing method

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 Small circular corecanuseFixed several ways. AvailableShoulder fixed,

below padThe pressing plate; orThick fixing plate can be reduced in

length with the fixing plate, andTheA core made of fine step;Small

plate is fixed core thickTimeAfter the core insert al cushion pad at

a lower end with a flat cylindrical; fixed thickness, no plateTime,

The lower end of the fastening core plug; insert person after the

core,At the other end is fixed using caulking.

 Several small shaped core fixing method

For shaped core, for ease of manufacture, often designed as two cores.

Connecting the fixed core section formed in a circularShoulder and

template connection; May be secured by a nut.

 Small core fixed close to each othermethod

A plurality of small cores close to each other, if the fixed shoulder,

the shoulder interference overlap, the table may beTouching the

shoulder side rubbed off, and processing the stepped hole larger than

the core fixing plate or circular stepped bore waist long circular

stepped hole, and then insert the core people.

③ And screw threaded ring core design

Threaded core and are threaded ring is used to shape the insert metal

inner and outer threads of the member. Further, screw-type is split threaded

ring and the apertures can be used to insert the fixing screw threaded. After

forming, there are detachable a threaded core and the threaded ring is two,

one is automatically detachable mold, the other is a mode to the manual

detachment, Here only mode to the manual detachment structure of screw-type

core and the screw-ring and fixing method.

Thread core

By zoning the thread core shaping member directly into the threaded hole

and the fixing nut insert two kinds, two core threads in principle there is

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no difference in structure. For shaping the core into a threaded member

threaded holes should be considered in the design of shrinkage, it should

normally O.5 degree draft angle. Start and end by threaded plastic threads

structural requirements designed to prevent unscrewing from the plastic

parts, plastic threads nap. Qu threaded female fixed core designed without

considering shrinkage can be manufactured by the common thread. Threaded core

mounted on a mold, to reliable positioning of the molding, the mold can not

be moved by vibration or stations stream impact, one should be able to remove

the mold with the plastic parts and ease of handling.

Threaded ring

Common Thread ring structures are monolithic threaded ring, the ring

with the template feature H8 / f8, with segment length 3 ~ 5 mm, in order

to facilitate installation, a system other than the mating segments 3-5

degree inclination, ring may be milled into the lower end of the square, so

as to tighten with a wrench from the plastic parts; modular ring, the split

ring is made from two half flaps, two intermediate guide pin is positioned.

After molding, the mold can be used unloading wedge-shaped wedged-ring

grooves on both sides of the wedge pry the mouth, separated from the threaded

ring, this method is faster and effort, but this method is difficult to leave

the trimmed plastic threads formed on the outer Flatten marks.

(2) Job size calculation

Shaped part configured to direct the work size refers to the size of

the plastic profile, for example, radial dimension of the cavity and core,

and the depthHeight dimension,Distance between fL size, pore size, or

distance from the boss to a forming surface, the radial dimension of the

thread screw and molded partsFrom the size and so on.

① Calculating dimensions of elements forming part of work to be

considered

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 a) Shrinkage fluctuation of plastic parts

b) Mold forming part manufacturing error

c) Die forming worn parts

d) Mating mold mounting error

e) Total error of plastic parts

f) Consider the principle of size and accuracy of plastic parts

② Forming parts working sizeCompute

(3) Rigidity check

When the strength calculation StiffnessFactors to consider

① Plastic deformation?

② broken?

③ Expanded cavity size?

④ Flash phenomenon occur?

5, the introduction of mechanism design

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 Structure ejector mechanism (1) Composition

Concept: In each cycle the injection molding of the plastic article and

the gating system condensate material coming out from the die mechanism

referred towel ejection mechanism, also known as a release mechanism or

ejection mechanism. Release mechanism of action by the piston is typically

mounted on the injection machine mechanical jack or a hydraulic cylinder to

complete.

Structure: Release of reset and the guide parts.

(2) Structural Classification

① Manual launch,

② Motor launch,

③ Hydraulic or pneumatic launch

(3) structural design requirements

① Plastic parts remain in the movable mold

② Plastic parts do not deform during launch, no damage

③ Without damaging the appearance quality of plastic parts

④ Release clamping mechanism so that when properly reset

⑤ Reliable action

(4) Design

① Putting an ejection mechanism

Putting the entire organization launched ejection mechanisms simplest

and most common form. The degree of freedom since the push rodLarge, circular

cross-section and most push rod, the push rod is easy to achieve with

precision holes in the push rod and the template or core. Release movement

of the push rod when resistance is small, flexible and reliable introduced,

is also easy to replace if damaged, it is widely used in production. But since

the launch of putting the general area is relatively small, it can lead to

greaterLocal stress through the top plastic parts or plastic parts deform,

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so rarely used in large release resistance small draft angle and tube type

or box type plastic parts.

② Push tube ejecting mechanism

Release mechanism is used to push tube Release cylindrical shaping

member ring structure or a particular piece of plastic with a hole, which

the plunger and release the same motion. Since the hollow plunger is a push

tube, so that the entire Zhou Bian contact plastic parts, plastic parts

Release uniform strength, easily deformed plastic parts, and will not leave

visible traces of the launch.

③ Release mechanism pusher plate

Any thin-walled containers, shell shaping member and the surface does

not allow the introduction of traces of plastics, pusher plate can be

introduced. Release pusher plate, said top plate means sense the ejection

mechanism, and which consists of a core with a certain accuracy the

composition and the push rod cooperating templates.

Characteristics: Release pusher plate ejection force is characterized

by a uniform, smooth movement, and the introduction of a large force. But

relatively difficult for non-circular cross-section plastic parts, which fit

partially processed.

④ Events insert and the die pushThe agency

Some plastic parts due to the shape and structure of the relationship

between the material used, can not use the push rod, the push tube, the

introduction of a simple pusher plate release mechanism, it can be used or

the insert pocket formed out of plastic parts.

6, the temperature control system design

Temperature adjustment (die temperature regulation is to cool or heat

the mold) both related to the quality (dimensional accuracy of plastic parts,

plastic parts of the mechanical properties and surface quality of plastic

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parts) of plastic parts, but also related to productivity. Accordingly, the

mold temperature must be controlled within a reasonable range depending on

the requirements to obtain a high-quality plastic parts and high

productivity.

(1) Cooling System

① Basic Principles cooling water circuit arrangement

a) Cooling water should be as much as possible, should be as large cross-sectional

dimension

b) Cooling water from the surface of the cavity to the appropriate

c) Cooling water should be free from obstruction

d) Cooling water should avoid easy to produce plastic parts weld marks

② Common structure

(2) heating the mold system design

When the injection molding process requires at a temperature above the county die

80 ℃, large preheated mold or hot runner mold, the mold must be provided heating means.

Electrically heating method of heating a mold, the cooling water may be passed through

the hot water, hot oil, steam preheated medium. Yi can be classified into electrically heated

resistance wire heating and electric heating rods.

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