Injection Mold Design

Injection Mold Design Using Autodesk Inventor Tooling
Brian Sather Autodesk, Inc.
MA222-1
This class will walk attendees through the process of designing, analyzing, and validating a plastics injection mold using Autodesk Inventor Tooling. We will cover everything from automatic core and cavity generation to utilizing the built-in Moldflow simulation technology and standard libraries of mold components to quickly and effectively design a high-quality production mold.
About the Speaker:

Brian Sather is a Technical Evangelist for Autodesks Manufacturing Industry Group. During his time in this role, he has authored several articles on the use of plastics injection molding simulation software to improve the design and manufacture of plastic parts and injection molds. His exposure to the many stages of product development and awareness of emerging CAD/CAE technologies uniquely position him to present on the topic of design validation and optimization for plastic injection molding. He holds a bachelors degree in Engineering Graphics, and a masters degree in Manufacturing Engineering, both from Western Michigan University. brian.sather@autodesk.com
Contents
Creating a New Mold Design ................................................................. 4
Starting a New Mold Assembly ................................................................. 4 Importing the Plastic Part .......................................................................... 5 Adjusting the Orientation ........................................................................... 5 Setting the Material ................................................................................... 6
Analyzing the Manufacturability of the Plastic Part............................. 7

Gate Location ............................................................................................ 7 Part Process Settings ............................................................................... 9 Part Fill Analysis...................................................................................... 10 Part Shrinkage Analysis .......................................................................... 11
Creating the Mold Core and Cavity ..................................................... 12

Defining the Workpiece ........................................................................... 12 Patching Surfaces ................................................................................... 12 Runoff Surfaces ...................................................................................... 14 Parting Diagnostics ................................................................................. 14 Generating the Core and Cavity ............................................................. 15
Designing the Runner System ............................................................ 15

Creating the Runner ................................................................................ 15 Creating the Gate .................................................................................... 17 Adding the Cold Well .............................................................................. 17
Inserting the Mold Base....................................................................... 18

Inserting the Mold Base .......................................................................... 18 Inserting a Sprue Bushing ....................................................................... 19 Inserting a Locating Ring ........................................................................ 19
Designing the Cooling System ........................................................... 20

Using a Cooling Channel Sketch ............................................................ 20 Inserting a Cooling Channel.................................................................... 21 Inserting Cooling Components................................................................ 22
Inserting Ejection Components .......................................................... 23

Inserting Ejectors .................................................................................... 23
Creating a New Mold Design

The Mold Design Assembly file is the top assembly for the mold design. Special template files must be used to create the Mold Design Assembly file. In order to see the Mold Design environment and assembly templates you must first install Autodesk Inventor Tooling from www.autodesk.com/ait.
Starting a New Mold Assembly

1. Create a new mold assembly file using the Mold Design (mm).iam template file. 2. In the dialog box that appears, type in the Mold Design File Name and Location.
Importing the Plastic Part

1. In the Mold Layout tab on the ribbon, select Plastic Part to import the model into the Mold Design Assembly. 2. Navigate to the folder containing the Reciprocating Saw part file and open HANDLE_1.ipt.
Adjusting the Orientation

When the part is imported it maintains its original alignment and needs to be oriented to correspond to the opening direction (+Z axis) of the Mold Design assembly. The cavity side of the part should be facing up (+Z) and the core side facing down (-Z). 1. In the Mold Layout tab on the ribbon, select Adjust Orientation.
2. In the Adjust Orientation dialog box:

Change Method to Rotate around Axis X Axis of Rotation 90 deg Click the check mark
Before Adjusting Orientation
After Adjusting Orientation
Setting the Material

After a part has been placed into the mold assembly you can select the material that will be used to manufacture the part. In order to run an analysis (which will be done later) you must select a material. The material you want to use can be selected from a list of commonly used materials or from a list of materials after having selected the manufacturer. You can also conduct a search of the more than 7,700 plastic materials in the database. Prior to selecting the material you can also review the extensive property and manufacturing information of that particular grade of plastic.
For this example we will be using Cycolac G360, an ABS material from SABIC Innovative Plastics US, LLC designed to be used for automotive applications and power tools. 1. In the Mold Layout tab on the ribbon, click Select Material.
2. In the Select Material dialog box, click on the Manufacturer drop-down and choose SABIC Innovative Plastics US, LLC.
3. In the Trade name drop-down, select Cycolac G360.
Analyzing the Manufacturability of the Plastic Part

There are many factors that play into the overall manufacturability of the plastic part itself. Using the built-in Moldflow functionality, analyses can be run to identify the optimal gate location and proper processing conditions that can then be used to perform a Fill analysis that helps identify problems in the part design that could lead to manufacturing defects.
Gate Location
There are two options for placing gates on the part: (1) manually place up to 10 gates on the part by selecting points, edges, or surfaces and then specifying an offset value or, (2) using the suggest tool to run an analysis that finds the optimal location for up to 10 gates at one time. Often, a combination of both options is used; the suggest option is used to get a general idea of the best location for the gate and the manual placement is used to place the gate in an area that may be easily accessible for the mold builder or in-line with the type of mold being designed. 1. Enter the Core/Cavity environment by clicking the button on the Mold Layout tab in the ribbon
2. Then click on the Gate Location button from the Core/Cavity tab in the ribbon
3. In the Gate Location dialog box, pick the Suggest tab. Leave the Number of Gate Locations at 1 and hit Start
4. The gate is automatically placed at the optimal location for manufacturability. However, we must also consider the design of the runner system
5. On the View tab in the ribbon, turn on the Center of Gravity and then orient to the Front view. Notice that the location where the Sprue will drop is offset just slightly from the gate. This can be fixed by placing the gate manually.
6. Reopen the Gate Location dialog box by clicking on Gate Location 1 in the history tree. Click on the surface indicated in the image to the right and change the U value to 0.175 and the V value to 0.850. This will align the gate perfectly with the center of the mold.
Part Process Settings

For the Part Fill Analysis to run, you must configure the part process settings. The settings that need to be set are: Mold Temperature and Material Melt Temperature Injection Pressure Injection Time Clamp Open Time
Similar to the Gate Location, you can either set them manually or use the Suggest tool to run quick analysis to find the optimal settings for the current part design and gate location. 1. Click on the Part Process Settings button inside the Core/Cavity tab on the ribbon.
2. In the Part Process Setting dialog box, go to the Suggest tab and check Low gloss and then hit Start. 3. Once the analysis is complete, click OK on the Summary dialog box to accept the suggested Process Settings. 4. You can review and/or adjust your process settings after closing the summary box by clicking on it from the history tree.
Part Fill Analysis

Now that the gate location is set and the process settings have been specified, a part Fill Analysis can be performed. This analysis simulates the plastic filling into the cavity and can provide a wealth of insight about the overall manufacturability of the part. 1. Click on the Part Fill Analysis button inside the Core/Cavity tab on the ribbon. 2. Click Start in the Part Fill Analysis dialog box that appears. 3. Once the analysis is complete, a list of results appears in the history tree. 4. Double click on the Fill time result. In the Tools panel, click on the arrow to expand the list and then click Animate Results. 5. Play the animation of the cavity filling with plastic. 6. Review the results for Quality prediction, Air traps, and Weld lines.
10
Part Shrinkage Analysis

An inherent property of plastic parts is that as they cool, they will shrink. If this shrinkage is not properly accounted for in sizing the core and cavity then the molded part will likely come out undersized and out-of-spec. Traditionally, a range of shrinkage values is given by the material supplier in the form of % or in/in (or mm/mm). The other option is to run a Moldflow Shrinkage analysis that will accurately predict anisotropic shrinkage values for the part. 1. Click on the Part Shrinkage button inside the Core/Cavity tab on the ribbon.
2. In the Part Shrinkage dialog box leave the Packing Profile at 10s and 80%. This can be adjusted later to minimize part shrinkage. Click Start.
3. Click OK when the Summary dialog appears to apply the Estimated Shrinkage values to the part.
11
Creating the Mold Core and Cavity

Autodesk Inventor Tooling includes a full set of tools for automatically creating the cavity and core of the mold. The process involves defining a workpiece that will encompass the entire part, defining patching (or shut-off) surfaces, creating runoff surfaces for the parting line, and then automatically generating the cavity and core.
Defining the Workpiece

To simplify the modeling process, the Workpiece Definition feature defines one piece that encompasses the entire part that is later split into the core and cavity halves in a separate process. 1. Click on the Define Workpiece Setting button inside the Core/Cavity tab on the ribbon.
2. Change the X_total value to 175mm and the Y_total value to 225mm in the Workpiece Setting dialog box and then press OK to create the workpiece.
Patching Surfaces
Patching surfaces are added to a product to close any openings in the product design for the mold tooling design. The patching surfaces define any location where the separation is required in the tooling. 1. To create the patching surfaces for the simple holes, click on the Create Patching Surfaces button.
12
2. The Create Patching Surface dialog box will appear listing all the patching surfaces to be created. Click OK to accept and create the surfaces.
3. To fill in the opening of the handle, use the Create Planar Patch tool and select all the edges of the opening on the bottom plane of the part.
4. To fill in the final opening, open the part model by right clicking HANDLE_1 in the history tree and selecting open. 5. Now use the Boundary Patch tool and select the perimeter of the opening to create a new surface. Close and save the file.
6. Back in the Mold Design Assembly, select Use Existing Surface. Make sure Patching Surfaces is chosen as the output, and then click on the surface that was just created. 13
Runoff Surfaces
The Runoff Surface is the parting surface between the eventual core and cavity in the mold. These surfaces extend from the outer edge of the plastic part to the edges of the Workpiece block. These are used in conjunction with the Workpiece and Patching Surfaces to automatically generate the core and cavity. 1. Click on the Create Runoff Surfaces button inside the Core/Cavity tab on the ribbon.
2. Click on all the edges and adjust the X/Y direction of each runoff surfaces until the entire boundary is selected. 3. Select OK once all edges are properly selected and aligned to create the Runoff Surfaces.
Parting Diagnostics
The Parting Diagnostics tool evaluates the runoff surfaces and determines if the final runoff surfaces can be used to split the workpiece. It will also color code the faces of the plastic part that is defined by the Core and Cavity and return the number of faces for each. 1. Click on the Parting Diagnostics button inside the Core/Cavity tab on the ribbon. 2. In the Parting Diagnostics dialog box, click on the Core and Cavity Faces option and then increase the Surface Separation. 3. Click Done in the dialog box when finished evaluating the Parting Diagnostics.
14
Generating the Core and Cavity

The Generate Core and Cavity tool splits the workpiece into separate core and cavity parts. The workpiece is automatically split based on the surfaces of the placed part, the added patched surfaces, and the runoff surfaces. 1. Click on the Generate Core and Cavity button inside the Core/Cavity tab on the ribbon.
2. The Core and Cavity are now created.
Designing the Runner System

The next step in the Mold Design process is to design the runner system. This process involves creating a sketch of the runner system centerlines and then defining the properties of the gate.
Creating the Runner

Creating the runner is a two step process. First, a sketch needs is created using the Auto Runner Sketch or by creating a sketch manually. Second, the Create Runner tool is used to define the cross section diameter and length and cold slug properties. 1. To start the runner sketch, Use the Auto Runner Sketch tool.
15
2. Select the corner of the workpiece where the Core and Cavity come together as the base point of the sketch. 3. Click OK to finish the Auto Runner Sketch dialog box to enter Sketch Mode.
4. In the Sketch, change the length of the line to 45mm.
5. Click on Runner in the ribbon to specify the runner properties.
6. In the Create Runner dialog box, change the diameter to 3mm and select only the side of the line going towards the gate. Then change the Cold Slug Position to Start and the Cold Slug Length to 0mm and hit OK to create the runner.
16
Creating the Gate

When you create gates, you have a wide variety of options to create the right shape and size for your design. Each of the eight gate types selected presents a table of parameters that you can edit to meet your design requirements. 1. Start the Gate creation tool by clicking on the Gate button in the ribbon.
2. In the Create Gate dialog box, use the following settings: Type: Submarine Placement: Two Points D: 1mm A2: 7.5 deg Ext1: 0mm
3. Select the Gate Location point and endpoint of the Runner Sketch and then click OK to create the gate.
Adding the Cold Well

When creating a cold well, there are several options available to create the proper size and shape for the feeding system of the mold design. A tapered or annular shaped cold well can be created and the diameter and length of the cold well can be controlled. 1. Select the Cold Well tool by clicking on the Cold Well button in the ribbon. 2. Once the Cold Well dialog is open, select the center point of the runner sketch as the placement. Change the profile to 3mm wide, 3mm high, and 5 deg taper and hit OK to create the Cold Well.
17
Inserting the Mold Base

Now that the core and cavity is complete and the runner is designed, a Mold Base can be inserted into the design. In addition to the mold bases, a library of Sprue Bushings and Locator Rings can also be accessed to directly insert these components into the design.
Inserting the Mold Base

Inventor Tooling has an extensive collection of standard Mold Bases that can be easily inserted into the mold assembly. Each component of the mold base can be easily customized to suit the needs of the particular application at hand. 1. In the Mold Assembly tab on the ribbon, click Mold Base to open up the Mold Base selector. 2. Using the Vendor and Type drop down list, choose the DME E mold base and change the size to 396mm x 446mm. 3. For the Placement Ref Point, select the corner point where the core and cavity touch.
4. Select OK to insert the mold base.
18
Inserting the Sprue Bushing

The sprue bushing channels the material into the runner system or directly into the mold cavity, depending on the mold design. It can be positioned so that it aligns with the main runner system using two edges of the mold, or by aligning it with the center point of the primary runner. 1. Click on the Sprue Bushing tool in the Mold Assembly tab in the ribbon.
2. Select Sprue Type DME R76 and specify a -16mm offset. 3. Apply these Parameters: D: 18mm L: 96mm
4. Click on the center point of the runner system to locate the Sprue Bushing in the center of the mold and then hit OK to insert it into the assembly.
Inserting the Locating Ring

The locating ring retains the sprue bushing and aligns it with the injection nozzle. When the Locating Ring is inserted into the assembly, it is automatically constrained concentric to the sprue bushing. 1. Click on the Locating Ring tool in the Mold Assembly tab in the ribbon.
2. Choose Type DME R DMEStandard(R 95 SERIE) and specify a -3mm offset. Also change the d_ parameter to 38mm. 3. Click OK to insert the Locating Ring.
19
Designing the Cooling System

The rate at which the injected plastic cools in the mold has a direct impact on the quality of the final product and the manufacturing cycle time. To achieve the quality and productivity required, you need to be able to add the features and components that can help control the temperature of the mold.
Using a Cooling Channel Sketch

The quickest way to design the cooling channels is to create a sketch of the overall layout. This works very well when all the cooling lines are on the same plane. 1. Create a plane parallel to the parting line with a -18mm offset. 2. Open the Manual Sketch tool from the Mold Layout tab on the ribbon and select Cooling Sketch as the type, and then select the plane that was just created. 3. Create the sketch below.
20
4. Select the Cooling Channel tool from the Mold Layout tab in the ribbon. 5. Change the following settings in the Cooling Channel dialog box: Placement: From Sketch Drilled Hole: 11.2mm Diameter Add 25x20mm Counterbore
6. Select the first of the two parallel lines and hit Apply. Do the same for the other. 7. Remove the counterbore and then select the third (horizontal) line. Click OK.
Inserting a Cooling Channel

When a single cooling channel needs to be created, you can use the same Cooling Channel tool, but use Linear Placement to avoid the need to create a Cooling Channel Sketch. 1. Select the Cooling Channel tool from the Mold Layout tab on the ribbon. 2. Change the Drilled Hole Diameter to 11.2mm and select the bottom of the Core plate as the Face. 3. Choose two edges of the mold as the Linear Edges 1 & 2 and use the dimensions in the image to the right. 65mm
182.5mm
145mm
21
Inserting Cooling Components

Standard cooling components like baffles, bubblers, O Rings, connectors, and plugs are all housed within the Content Center and can be accessed using the Cooling Component tool inside the Mold Assembly tab. 1. Select the Cooling Component tool from the Mold Assembly tab.
2. In the Type drop down, select the DME BB Baffle and then change the R parameter to BSP and use 60mm as the trim value. 3. Use the Concentric Placement option and pick the bottom of the Core plate as the Face and the vertical cooling channel as the Concentric Reference. 4. Select OK to insert the baffle.
5. Reopen the Cooling Component tool. 6. Using the default Connector Plug change the size to BSPT. 7. Apply the Connector Plugs to the two Cooling Channels with counterbores.
8. Reopen the Cooling Component tool. 9. Select the DME AN Pipe Plug and change the size to BSPT. 10. Apply the Pipe Plug to the opening of the third Cooling Channel.
22
Inserting Ejection Components

The Ejection Components of the mold include Ejectors, Sliders, and Lifter. Each of these three components has specific tools inside of Inventor Tooling for customization and placement within the mold assembly.
Inserting Ejectors
There are two main types of ejectors that you can add: ejector pins and ejector sleeves. Depending on the selected ejector type, there are different parameters available for setting the diameter and length of the ejector. 1. Select the Ejector tool from the Mold Assembly tab.
2. Select the location of each ejector pin on the part. 3. Set the Diameter parameter (d1) to 4mm and the Length (L) to 160mm. Click the Anti-rotation check box. 4. Click OK to insert the ejector pins.
23

Injection Mold Design

Uploaded by

Document Information

Original Description:

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Injection Mold Design

Uploaded by

Copyright:

Available Formats

Injection Mold Design Using Autodesk Inventor Tooling

Brian Sather Autodesk, Inc.

About the Speaker: