Product Analysis for mold design

Group no 7 Prashant Patel 09003029

Objective: For a given product/sample, suggest a mold design which can be used in Injection
Molding for mass production.

Method Description:
Do complete inspection of given product. First find out parting line of a given product. Look for no of dies that is going to be used and how orientation of dies can anyone have to manufacture product. Given product is shown below:

Sample is use as a valve for allowing liquid to pass through it. On rotating upper part, one can match the circular hole of upper part with the cylindrical opening of lower part. And on further rotating upper cap, cylindrical opening can be blocked. In this fashion, flow of liquid can be controlled. It consists of two different parts as shown.

Figure 1: (a) Upper part (b) Lower part of the sample

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Upper Part: It has parting line passing through middle of upper handle. Cylindrical shape do not have parting line which indicates that it is manufactured using single die consist of core as shown in figure.

Figure 1: Die for cylindrical shape of upper part with core (red colour) for making two side holes .

Upper portion consist of handle, is produced using two dies. Position of gate was unable to find as the product was not new and it got some scratches. Ejector pin is placed at the top surface of above die. After placing all three dies and core at the required position, melt plastic is allowed to fill the cavity through gates and allowed to cool. After cooling, all the dies are removed to get required product. The diagram show two dies for producing handle part:

Figure 2: Two dies for producing handle portion of upper part.

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Diagramatic flow of overall process is shown below:

. Left Die

Upper Part

Right Die

Die for Cylindrical part Direction of die

Lower Part: Parting line is passing through middle of lower part. It is possible to manufacture lower part using two dies and two cores. Right die take care of cylindrical opening as shown in figure. To have hollow structure in the middle, a core has to be move in. Diagram indicates the clear picture of arrangement:

Figure 3: Arrangements of dies and core for producing lower part.

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Diagramatic flow of overall process is shown here: . Left Die Right Die with core

Lower Part
Cylindrical core

Direction of die

Note: Volume of given sample could not be calculated as the beaker given to measure displaced water volume was broken by some student. Location of Gating was found for lower part as it was clearly visible but it was not possible for upper part to locate gating position.

Suggestions for reducing effective cost:

If instead of curved design at the bottom of handle of upper part of sample (Easily visible in above figure), we made flat rectangular handle then upper part can be easily produce using two dies only instead of three dies. In this case, one bottom die will cover cylindrical portion (as it was in previous one) and one die will take care of whole handle. In present design, whole handle of upper part cannot be produce in a single die as curved part of handle will block die to come out after solidification of liquid plastic. Using new design, we can reduce effective cost of product.

Conclusion: The two half of given sample can be easily manufacture by Injection molding
using design of dies as suggested above. Large no of products can be manufacture by making large no of cavity in each die.

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