ISE386 Integrated Design for Manufacture

Exercise 2: Plastics Injection Molding Part Design

Solution
Question 1

(a)
Let the diagonal of the plate be x
𝑥𝑥 = �2042 + 1782
= √73298
= 270.7𝑚𝑚𝑚𝑚
x/2 = 270.7/2 = 135.4 mm

The max flow length = (60 + 135.4 + 12) mm = 207.4 mm

The flow ratio =207.4/2=103.7
The projected surface area = 0.204 × 0.178 m2
= 0.0363 m2
From table, the factor of PC = 1.9
From table, 180 bar is chosen
The cavity pressure for molding PC = 1.9×180 = 342 bar
The required clamping force = 342×105×0.0363
= 1241.5 kN
The actual clamping force = (1+15%) × 1241.5 = 1427.7 kN
Refer to the handout section 2 slide 31, 1 ton = 9.9365 kN
The actual clamping force in tons = 1427.7 ÷9.9365 = 143.7 tons

The clamping capacity of injection molding machine suitable for molding the PC plate is at least
143.7 tons, therefore from Table 1, Model K180I with clamping force 180 tons is selected.

(b)
Injection Molding Process is used for producing the PC plate. A heat-softened thermoplastic (PC) is
forced from a cylinder into a cavity that fills the product with the desired shape in the mold.
The injection moulding process can be divided into 4 stages as follow:
Clamping
The injection unit is forward to the nozzle and sprue bushing making intimate contact, the mold
closes and clamping force is applied.
Injection
The screw advances forcing metered quantity of molten plastics resin into the cavity of the mold
through the barrel nozzle. The injection pressure is held until the material solidifies.
Cooling
The mold is circulated with water to cool the plastics rapidly for shorter cooling time. At the same
time, plasticating for melting plastic resin inside the barrel takes place, the screw rotates backward
and charges the barrel for the next cycle.
Ejection
Once the resins has cooled the mold opens, the ejector set moves forward to remove the part from
the core of the mold. A sketch of injection molding machine is shown as follows:

1
A 2-plate mold with single impression of direct gating system is adopted for producing the PC plate
which is thin walled part. A sketch of mold is shown as follows:

2
Question 2

The design guidelines can be summed up as follows (Any four):

 Keep walls as thin as possible.
 Use a uniform wall thickness.
 Use ribs and gussets to improve part stiffness.
 Without making the wall thicker, use generous radii at all corners.
 Design parts with draft to facilitate removal.
The design of box base missing radii (3, 4×external corners. 4, 4×internal corners. 5, 4×bosses base.
6, 4×internal edges and 7, 4×external edges)
Sharp corners are critical cause of part failure, stress concentration, poor flow patterns and
increased tool wear.
Corners of the molding part should be rounded to reduce stress concentration at the corner and
make removal easier. A rounded junction offers uniform strength properties.

The suggested improvements are (Any two) :

 Replace sharp angles of the part with radii of at least 0.5 × material thickness that minimize
heat and stress concentration. In cored parts, avoid designs without cooling surfaces.
 A fillet radius should be between 25 % to 60% the nominal wall thickness. The larger fillet
radius is suggested for load carrying features. A minimum inner radius of 0.5 mm is
suggested as well as to produce sharp edges with at least 0.2 mm radius.
 Corners should always be designed with a minimum fillet radius of 50% of wall thickness
and outer radius of 150% of thickness to maintain a constant wall thickness
 The outside corner radius should be equal to the inside radii plus the wall thickness (R=r+t).

The draft angle is missing (1, 4×bosses external wall. 2, 4×bosses hole. 8, 4×internal side wall and
9, 4×external side wall).
Draft angle is necessary for ejection of molding parts from the mold. The part is desired to remain
on the core side for ejection when mold opens. The draft on the cavity should be larger than that on
the core.

The suggested improvements are (Any two):

 The draft angle on the cavity is minimum 1½° and the draft on the core is minimum ¼°.
 Recommend draft angle at least l/4º on ribs and boss.
 Draft all surface parallel to the direction of mold separation at minimum ½° .
 Use standard draft angle of 2º per each 0.025mm depth of texture for sidewalls.
3
The ribs of the boss missing (5, 4×bosses)
 Ribs can improve stiffness and strength of the boss.
The suggested improvements are:
 Bosses should have a blended radius at the base.
 To prevent sink marks, keep the boss wall thickness to nominal wall thickness the same as
for ribs.

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