Injection molding

Mohak Patel

4th November, 2011 9003045

Aim
To study moulding design by analysing an injection moulded product and prepare a mould design for the same.

Background
Injection molding is a manufacturing process for producing parts from both thermoplastic and thermosetting plastic materials. Material is fed into a heated barrel, mixed, and forced into a mold cavity where it cools and hardens to the configuration of the cavity. Molds are made from metal, usually either steel or aluminium, and precision-machined to form the features of the desired part. Injection molding is widely used for manufacturing a variety of parts, from the smallest component to entire body panels of cars.

Theory
Injection moulding is used for producing large number of complex parts. A major part of the work is to conceive a mold. The quality of the product and productivity of the machine are very much influenced by the development of mold. Injection molding cycle The sequence of events during the injection mold of a plastic part is called the injection molding cycle. The cycle begins when the mold closes, followed by the injection of the polymer into the mold cavity. Once the cavity is filled, a holding pressure is maintained to compensate for material shrinkage. In the next step, the screw turns, feeding the next shot to the front screw.This causes the screw to retract as the next shot is prepared. Once the part is sufficiently cool, the mold opens and the part is ejected. Mould Design The mold basically consists of two parts: a stationary half (cavity plate), on the side where molten polymer is injected, and a moving half (core plate) on the closing or ejector side of the injection molding equipment. The separating line between the two mold halves is called the parting line. The injected material is transferred through a central feed channel, called the sprue. The sprue is located on the sprue bushing and is tapered to facilitate release of the sprue material from the mold during mold opening.

Open Mould The core plate holds the main core. The purpose of the main core is to establish the inside configuration of the part. The core plate has a backup or support plate. The support plate in turn is supported by pillars against structure known as the ejector housing, which consists of the rear clamping plate and spacer blocks. This structure, which is bolted to the core plate, provides the space for the ejection stroke also known as the stripper stroke. During solidification the part shrinks around the main core so that when the mold opens, part and sprue are carried along with the moving mold half. Subsequently, the central ejector is activated, causing the ejector plates to move forward so that the ejector pins can push the part off the core. Both mold halves are provided with cooling channels through which cooled water is circulated to absorb the heat delivered to the mold. The mold cavities also incorporate fine vents to ensure that no air is trapped during filling.

Closed mould

Procedure
Study the given component and concieve and sketch a mold with dimensions, giving the follwing details: Parting Line and Mold Halves Location of the Cores Segmentation of the Mould Volume of the Component Location of the Gating Location of the Ejector Pins

Analysis
The following is the picture of the given components showing: Possible location of gates and parting line:

Possible location of ejector pins and Ribs: Figure shows few ejector pins but there are 14 ejector pins used in the object. Similarly 6 ribs are used. The more the number of ribs more is the strength and rigidity is provided to the molded component.

Mold Design Below are the suggested mold designs for the given product generated by using Autodesk Inventor software. The given product is constructed by using two dies. The holes in the product do not require any core as the mold itself can be such that it can create those holes. Enough material must be poured so that a uniform thickness develops around the holes. The 3-d designs clearly specify the Left and Right die used to make the given object.

The designed molds used in the injection molding object given to us are shown along with the gate used to inject the material inside the mold cavity.

Sources of error
1. The molds dimensions dont meet the shrinkage criteria. 2. Sufficient amount of material must be feed into the mold such that the liquid material reaches to all the extremities of the mold. 3. Number of ribs should be sufficient to provide strength and rigidity to the object.

Suggestion
The mold has too many curved surface making its manufacturing difficult. Cooled molds should be used for faster rate of cooling.