GENERAL MOULD CONSTRUCTION

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INJECTION MOULD

Injection mould is an assembly of parts containing within it an impression into which plastic material is injected and cooled.

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IMPRESSION

Impression is defined as the part of mould which imparts shape to the moulding.

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CORE & CAVITY

The impression is formed by two mould members: 1.Cavity : Which is the female portion of the mould, gives the moulding its external form. 2.Core: Which is the male portion of the mould, forms the internal shape of the moulding.
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CORE PLATE & CAVITY PLATE

The plate or assembly which contains the core is termed as core plate. The plate or assembly which contains the cavity is termed as cavity plate.

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CORE PLATE & CAVITY PLATE

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SPRUE BUSH
During the injection process plastic material is delivered to the nozzle of the machine as a melt; it is then transferred to the impression through a passage. This passage is a tapered hole within a bush. The material in this passage is termed as sprue and the bush is called sprue bush.
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SPRUE BUSH

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RUNNER AND GATE

Runner is a channel machined into the mould plate to connect the sprue with the entrance (gate) to the impression.

Gate is a channel or orifice connecting the runner with the impression.

Feed system is a flow way which connect the nozzle of the injection moulding machine to each impression.
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RUNNER AND GATE

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REGISTER RING
If the material is to pass without hindrance into the mould, the nozzle and sprue must be correctly aligned. This is achieved by Register Ring.

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GUIDE PILLARS & GUIDE BUSHES

To mould an even walled article it is necessary to ensure that the cavity and core are kept in alignment. This is done by incorporating guide pillars and guide bushes. Guide pillars on one mould plate which enters corresponding guide bushes in the other mould plate as the mould closes. Guide bush is incorporated in a mould to provide a suitable wear resisting surface for the guide pillar and to permit replacement in the event of wear and damage.
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FIX HALF & MOVING HALF

The half attached to the stationary platen of the machine is termed as fixed half. The other half of the mould attached to the moving platen of the machine is known as moving half.
Cavity is situated in fixed half and core is situated in moving half of the machine platen.
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REASON FOR KEEPING CORE IN MOVING HALF

When moulding cools, it will shrink on to the core and remain with it.
Ejector system to be provided to push the moulding from the mould is difficult to make in cavity side and can be easily provided in core side.

In case of single impression, under feed moulding, the cavity must be in the fixed half and the core in the moving half only.
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METHODS FOR INCORPORATING CAVITY & CORE

1.Integer method: Where the cavity and core can be machined in from steel plates which become part of the structural built up of the mould.
2.Bolster method: Where the cavity and core can be machined from small blocks of steel, termed inserts, and subsequently bolstered.
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INTEGER CAVITY & CORE

When the cavity or core is machined from a large plate or block of steel, or is cast in one piece, and used without bolstering as one of the mould plates, it is termed as integer cavity plate or integer core plate. This design is preferred for single impression moulds because of the strength, smaller size and lower cost characteristics. A 4 % Nickel-chromemolybdenum steel (BS 970-835 M30) is normally specified for integer mould plates.
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INTEGER CAVITY & CORE

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INTEGER CAVITY & CORE

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INTEGER CAVITY & CORE

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INSERT BOLSTER CAVITY & CORE

A recess or hole is made in the cavity or core plate to accommodate the insert which is then securely fitted into position. For moulds containing intricate impressions, for multi impression moulds, it is not preferred to machine cavity and core plates from single blocks of steel as with integer moulds.
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INSERT BOLSTER CAVITY & CORE

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INSERT BOLSTER CAVITY & CORE

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INSERT BOLSTER CAVITY & CORE

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INSERT BOLSTER CAVITY & CORE

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INSERT BOLSTER CAVITY & CORE

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INSERT BOLSTER CAVITY & CORE

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FOR AND AGAINST INTEGER AND INSERT-BOLSTER METHODS

1. Cost

2. Number of Impression
3. Multi-impression mould alignment

4. Mould size
5. Heat Treatment 6. Replacement of damaged parts 7. Cooling system 8. Conclusions.
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FUNDAMENTAL REQUIREMENTS OF A BOLSTER

1.It must provide a suitable pocket into which the insert can be fitted. 2.It must provide some means for securing the insert after it is fitted in position.

3.It must have sufficient strength to withstand the applied moulding forces.
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BOLSTER MATERIAL
Bolster is normally made from Mild Steel plate to the BS 970 040 A15 specification. A Medium carbon steel (BS 970 080 M40) can also be preferred.

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TYPES OF BOLSTER
1. Solid Bolster: Suitable for both Rectangular and Circular inserts. 2. Strip type bolster: Suitable only for Rectangular inserts. 3. Frame type bolster: Can be used for both type inserts. But particularly suited for circular inserts. 4. Chase bolster: This type is used in conjunction with splits.

5. Bolster plate: This is used in particular circumstances with both rectangular and circular inserts. CIPET

TYPES OF BOLSTER

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TYPES OF BOLSTER

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FITTING INSERT TO SOLID BOLSTER

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GUIDE PILLAR & GUIDE BUSH SPECIFICATION

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TYPES OF GUIDE PILLARS & GUIDE BUSHES

1.Leader Pin 2.Standard Guide pillar & Guide bush 3.Spigotted guide pillar & Guide bush 4.Surface fitting guide pillar & guide bush 5.Pull back type guide pillar & guide bush
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LEADER PIN

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STANDARD GUIDE PILLAR & GUIDE BUSH

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SPIGOTTED GUIDE PILLAR & GUIDE BUSH

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SURFACE FITTING GUIDE PILLAR & GUIDE BUSH

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PULL BACK TYPE GUIDE PILLAR & GUIDE BUSH

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SIZE OF GUIDE PILLARS AND GUIDE BUSH BASED ON MOULD SIZE

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LOCATION OF GUIDE PILLARS AND GUIDE BUSH ON MOULD

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MATERIAL FOR GUIDE PILLARS AND GUIDE BUSH

The surface of the guide pillar and guide bush must be hard and wear resisting. This is achieved by machining the component from low carbon steel (BS 970-080 M15) which is subsequently case hardened. This process gives a surface which resists pickup and scoring as the guide pillar continuously enters and leaves. If the guide pillar is likely to be subjected to bending forces, the use of a carburizing nickelchrome steel (BS 970-835 M15) is to be preferred.
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MOULD ALIGNMENT
Any misalignment in the mold will have one wall thinner than the other. In addition to this material entering the mould will take the easiest route and flow down the thicker section first. This will tend to move the core further out of alignment, and result in un acceptable mouldings.

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MOULD ALIGNMENT

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TAPER LOCATION
For most small moulds the guide pillars are normally able to maintain alignment of the two halves within reasonable close tolerance irrespective of the force applied during injection. However, moulds for thinwalled articles require special treatment as even a slight misalignment can not be tolerated. With some very large moldings the size of pillar necessary to maintain alignment becomes excessively large. In either case the designer must consider means of maintaining alignment without relying entirely on guide pillars. A satisfactory way of achieving this is by the incorporation of a tapered location, normally in addition to the guide pillars. CIPET

TAPER LOCATION

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SPECIFICATION OF TAPER LOCATION

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SPRUE BUSH
Is a connection member between the machine nozzle and the mould face, and provides a suitable aperture through which the material can travel on its way to the impression or to the start of the runner system. Sprue bushes are made from 1 % Nickel Chrome steel (BS 970-817 M40) and should always be hardened. The internal aperture of the sprue bush has between 2 to 4 included taper, which facilitates the removal of the sprue from the mould at the end of the moulding cycle. .
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TYPES OF SPRUE BUSH

1.Sperical seating

2.Flat seating

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TYPES OF SPRUE BUSH

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SPRUE BUSH & NOZZLE SEATING

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REGISTER RING

Register ring also called locating ring or location ring is a circular member fitted on to the front face of the mould. Its purpose is to register or locate the mould in its position on the injection machine.

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REGISTER RING TYPES

1.Reduced Diameter type

2.Constant diameter type

3.Increased diameter type

4.Increased depth type

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REGISTER RING TYPES

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LOCATING MOULD WITH MACHINE PLATEN BY REGISTER RING

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METHODS OF SECURING SPRUE BUSH WITH LOCATING RING

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MOULD PLATE FASTENINIG

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MOULD PLATE FASTENINIG

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ATTACHMENT OF MOULD TO MACHINE PLATEN

Two methods of attachment of mould with machine platen are;

1.Direct bolting method

2.Indirect bolting method

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DIRECT BOLTING METHOD

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INDIRECT BOLTING METHOD

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THANK YOU
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