Mold and Die

Mold and Die
Mechanical Engineering Department Kasetsart University
Standard 2-Plate Mold Components
Function of Mold Base Components

Top Clamping Plate
Supports the A cavity plate, locating ring, and sprue bushing.
Locating Ring
Its intended purpose is to properly situate the mold in relation to the injection nozzle of the machine.

A Cavity Plate
Contains and supports the cavity or cavities or the core insert, sprue bushing, and the runners for the parts to be molded. In some cases, the cavity may be cut directly into the solid steel plate, while in others the cavities can be constructed separately and inserted into pockets within the cavity plate.

B Cavity Plate (Core Plate)
Contains and supports a core section of the molded part and also contains the leader pin bushings. The plane between these two plates is the normal parting line (P/L) of the mold, which separates the two halves of the tool.

Support Plate
Is used to provide strength to the cavities to avoid deflection during melt injection inside the cavities.
Ejector Housing
The ejector housing parallel blocks are added to provide the height required for the movement of the ejector system.

Bottom Clamping Plate
Secures the movable half of the mold to the movable platen of the injection molding machine.
Ejector Retainer Plate

Mounted on top of the ejector plate, this plate retains the ejector head pins, ejector return pins, and sprue puller pin through counter bored holes.

Ejector Plate
Is bolted together with the ejector retainer plate to form a unit. It acts as a back support plate for the ejector pins, return pins, and the knockout bar.
Ejector Pins
Enter the cavity to make contact with the molded part.

Sprue Puller Pin
It is used to pull the solid sprue out of the bushing automatically when the mold opens and the molded parts and the runner system are ejected.
Return Pins
They contact the stationary cavity plate and prompt the movement of the ejector plates back to normal position prior to the next shot.

Leader Pins
Used to align the plates on the closing of the mold, are hardened and ground steel pins mounted into one of the mold halves.
Shoulder Bushings
Hardened and ground steel bushings are mounted into the other half of the mold, inline with the leader pins.
Injection Molding M/C Nozzle

The nozzle is a tabular shaped component of various lengths and inside diameters, long enough to reach the mold.
Injection Molding M/C Nozzle

It commonly consists of a one-piece unit or removable separate nozzle tip screwing into the main body of the nozzle.
Mold Cold Runner System

The cold runner system transfers the thermoplastic melt from the injection nozzle to the cavities. It consists of sprue, sprue puller, runner, cold slug pockets, and gates. It is desirable to keep the travelling distance of the material to a minimum to reduce pressure and heat losses.
Figure 1 Illustration of molded components in a complete shot

The purpose of the runner cold slug pockets is to catch the melt that has chilled at the front of the nozzle. The runner is a channel machined into the mold cavity plate surface (P/L) to connect the sprue with the entrance (gate) to the cavity.
Cold Runner Sprue

The sprue transfers polymer melt and heat from the molding M/C nozzle to either a runner system or directly to a cavity. The contact radius surface between the injection nozzle and the sprue bushing helps with alignment of the flow channels between these components.
Cold Runner Sprue

Fig 10-67
Figure 2 Contact radius surfaces between injection nozzle tip and sprue bushing
Cold Runner Sprue

The radius of the sprue bushing should be slightly larger than the injection nozzle tip to ensure sufficient sealing w/o flashing. If there were any misalignment, an undercut would be created and inhibit the sprue from being pulled from the bushing.
Cold Runner Sprue

Fig 10-68
Figure 3 Interface problems between injection nozzle and standard sprue bushing
Cold Runner Sprue

Guidelines when designing a sprue: The sprue must not freeze before the runner system and cavities. The sprue must be ejected easily and reliably. The sprue interfaces with the injection M/C nozzle must not have any flash to avoid sprue ejection problems.
Cold Runner Sprue

Guidelines when designing a sprue: At the base of the main runner, in line with the sprue, a sprue puller pocket should be provided to act as a cold slug well. The sprue bushing O diameter should be a minimum 0.031 in larger than the injection nozzle tip orifice diameter.
Cold Runner Sprue

Standard Sprue Bushings
Figure 4 Standard commercially available sprue bushing
Cold Runner Sprue

Performance Alloy Sprue Bushings
Figure 5 Performance alloy sprue bushing to improve temperature control
Cold Runner Sprue

TranziSprueTM
Figure 6 TranziSprue, a sprue bushing with temperature control
Cold Runner Sprue

Extension Nozzle Sprue Bushings
They are used to reduce length of the sprue, reduce pressure drop, and lower injection pressure required for the molding process.
Figure 7 Extension nozzle sprue bushing and short sprue mold
Guidelines for dimensioning sprues
Sprue Puller
During mold opening, the cold sprue is pulled from the sprue bushing by an undercut in the sprue puller pocket.
Figure 8 Ejection sequence of the cold sprue and runner system
Sprue Puller
Figure 9 Recommended sprue puller designs
Sprue Puller
Reverse taper: It is the most common design used for molding both high and low melt temperature materials, unreinforced, impact modified, fiber glass, and mineral reinforced resins.
Sprue Puller
Z type sprue puller:
It is used in similar applications as the reverse taper. It is not recommended with brittle materials.
Sprue Puller
Annual ring: This design is recommended only for unreinforced resins.
Designing the Cold Runner System

Important considerations for designing the cold runner system: Cold runner system layout Cold runner cross section geometry Cold runner dimensions
Cold Runner System Layout

The layout of the runner system will depend on the following factors: The number of cavities The geometry of the molded parts The type of mold The type, geometry, and size of the gates.
Cold Runner Cross Section Geometries
nn
Figure 9 Typical cold runner cross section geometries

The half round runner design is the most insufficient in delivering a melt, because its ratio of pressure loss to runner unit volume is very high. The parabolic runner best approximation of circular cross-section, simpler machining in one mold half only.

The trapezoidal runner alternative to parabolic crosssection, more heat loses and scrap than parabolic cross-section.

A full round runner slowest cooling rate, low heat and frictional losses, center of channel freezes last therefore effective holding pressure, machining into both mold halves is difficult and expensive.

The runner should provide a maximum cross section area from the standpoint of pressure transfer and minimum contact on the periphery from the standpoint of heat transfer.
Cold Runner Dimensions

Considerations required for specifying the cold runner dimensions: The wall thickness and volume of the molded part The distance of the cavity from the main runner or sprue
The mold cooling system for the runner and gates

Considerations required for specifying the cold runner dimensions: (cont.) Type of cold runner cross section design The thermoplastic melt flow rate The thermoplastic viscosity and shear rate characteristics

The runner length should always be kept to a minimum to reduce pressure losses and the cold runner system should be balanced. Runner balancing means that the distance, the volume, and heat transfer characteristics should be identical for each channel.
Cold Runner Layout
Figure 10 Difference between balanced and unbalanced runners
Cold Runner Layout
Figure 11 Three different balanced runner configurations
Cold Runner Layout

Circular Layout
Equal flow length to all cavities, Easy demolding especially of parts requiring unscrewing devices, Only limited number of cavities can be accommodated.
Cold Runner Layout

Series Layout
Space for more cavities than with circular layout, Unequal flow lengths to individual cavities, Uniform filling possible only with corrected channel diameters.
Cold Runner Layout

Symmetrical Layout
Equal flow length to all cavities without gate correction, Large runner volume, Much scrap, Rapid cooling of melt (Remedy: hot manifold or insulated runner).
Mold Cavity Gating

The gate is always the narrowest point in the gating system (except the sprue gate) which encounters a resistance to flow. This is a desirable effect because
The melt entering the cavity becomes more fluid and reproduces the cavity better, The surrounding metal is heated up and the gate remains open longer for the holding pressure.
Mold Cavity Gating

The gate size is important for the following reasons: The correct type of gate allows for simple gate separation from the molded product and automatic molding process. After de-gating, only a small witness mark remains on the molded part. Uniform quality control of multi-cavity molds can be achieved.
Mold Cavity Gating

The optimum type, geometry, dimension, and location of the gate are determined by the following factors: The viscosity and shear rate characteristics of the resin to be molded. The shot size or volume of material to be injected. The melt and mold processing temperatures.
Mold Cavity Gating

The crystallinity rate or time required to freeze the melt in the mold cavity
The size, complexity, and wall thickness of the molded part.

Molded product requirements (flatness, roundness, tolerances, strength, toughness) Type of injection molding process (runnerless, 2- or 3- plate)
Types of Mold Cavity Gates

Sprue Gate The molded part is injected directly from a sprue, the feed section is called a sprue gate. The main disadvantage is that it leaves a large gate mark on the molded part, requires manual sprue removal, and single cavity molds.

Rectangular Edge Gate The cross section geometry is simple and cheap to machine (only in one mold plate). Close accuracy in the gate dimensions can be achieved. The gate dimensions can be easily and quickly modified.

Rectangular Edge Gate One disadvantage is that after gate removal, a witness mark is left on a visible surface of the molded part.
W should be between D and H

Overlap Edge Gate This gate, being attached to the molding surface, does require more careful removal and finishing than for edge gate.

Fan Edge Gate

Fan Edge Gate A width of the gate at the cavity is relatively wide and, because of this, a large volume of material can be injected in a short cycle time. This gate can be used for large area, thin-walled molded part. The fan shape appears to spread the flow of the melt uniformly.

Tab Edge Gate This gate prevents the undesirable jetting, leaves large witness marks, and is developed for high viscosity amorphous resins.

Sprue Diaphragm Gate This gate is used for single-cavity tubular shaped injection molded part.

External Ring Gate This gate is used for tubular type molded parts when more than one cavity is required in a simple 2-plate mold.

Internal Ring Gate This gate is used for molding small tubular molded parts.

Spider Gate

Film Edge Gate

Film Edge Gate This gate is used for injection molding large, thin-walled, good surface finishing thermoplastic component to help in the production of warpfree products.
The gate normally extends across the complete width of the molded part.

Pin Point Gate

Standard Tunnel Gate
Figure 14 Tunnel gate, sequence of ejection

Standard Tunnel Gate It is a circular or oval gate that submerges and feeds into the cavity below the P/L of the mold. The gate is sheared off from the cavity automatically during ejection.

Standard Tunnel Gate The standard tunnel gates are found in two varieties: short tunnel and long tunnel gates.

Standard Tunnel Gate When a long tunnel is used, the angle between the part and the tunnel should not exceed 30 to ensure gate shearing.
The steel safety margin must be at least 0.078 in or greater.

Banana or Cashew Gate It is a variation of a tunnel gate and can provide gating into the lower base of the molded component.
Gate Molding Effects

Ideally, the gate should be positioned to allow an even flow of the melt into the cavity, so that fills uniformly and the advancing melt front spreads out and reaches the various cavity extremities simultaneously.
The location and the type of gates used in the molds affect the geometry and dimensional size of the molded part.
Figure 15 Molding effects caused Figure 16 Effects caused by two by a single external edge gate external runners and edge gates
Figure 17 Effects caused by two internal spider runners and gates
Figure 18 Effects caused by four internal spiders and gates
Figure 19 Molding effects caused by the type of gate and location
Figure 22 Effects caused by type, number, and location of gates
Mold Venting Systems

The openings through which gases trapped inside the cavity escape are known as vents.
The ideal vent would be one that will allow gases to expel freely from the cavity while completely blocking the escape of molten polymer, which would cause flashing.

Consequences of inadequate mold venting:
For the molded part Burn marks due to diesel effect For the mold For injection molding Abrasion through combustion Irregular processes residues in the combustion gas through blockage of venting channels diesel effect
Structural defects/surface defects through detachment of the polymer from a structured mold wall
Overpacking due to injection pressure set too high when vents clogged
Corrosion by aggressive gases diesel effect
Longer cycle times due to increased back pressure in the cavity
Mold coated by combustion residues in the combustion gas diesel effect
Short service life of machine due to higher loading

Consequences of inadequate mold venting:
For the molded part Displacement if weld lines due to changes in vents Entrapped air (voids) For the mold Mold exposed to direct heat due to strong air heating during compression hardening of outer layer Increased cleaning of venting elements For injection molding Escaping gases during the process may be harmful to health, depending on material Longer setup time through higher scrap rate Greater need for pressure due to increased back pressure in the cavity Injection molding machine has higher energy requirements
Incomplete mold filling Higher repair and maintenance costs Reduction in strength especially at weld lines

Lack of proper venting will cause excessive use of injection pressure for the molding process, which will cause a high degree of internal stresses. Relief edge vents have to be small enough to prevent the polymer melt from entering the venting channels.
Product Design for Venting

Several product design geometries can lead to venting problems: A thermoplastic injection molded product designed with thin-walled sections connected and surrounded by thick sections should be avoided.
Figure 23 Venting problems, outer heavy/middle thin wall section

Blind, deep hole in the cavity should be avoided.
Figure 24 Venting problems with a cavity/center deep blind hole

Avoid any geometry that could cause a preferential filling along the P/L or around core pins, where the unvented section of the cavity is last to fill.
Figure 25 Venting problems of thick upper/thin base taper core
Venting Characteristics of Thermoplastic Polymers

There are two characteristics of thermoplastics that lead to venting problems:
Thermoplastic that release large quantities of vapor when heated require more mold venting than materials that do not. Thermoplastic that have sharp melting points, fast melt flow rates; for a fast injection, the mold must be well vented.
Mold Venting Process Problems

Inadequate venting causes many injection molding problems:
Flashing problems
Figure 26 Poor mold venting causes flashing problems

Short shot
Figure 27 Poor mold venting causes incomplete molded parts

Internal gas voids
Figure 28 Micro structural analysis showing internal gas voids

Poor weld lines
Figure 29 Micro structural analyses showing the weld lines

Burn marks
Figure 30 Burn mark problem of a thermoplastic molded part

Core insert corrosion
Figure 31 Core insert corrosion caused by poor mold venting

Poor surface finishing: caused by the inability to fill the mold cavity quickly.
Figure 32 Two molded bushings showing poor surface finishing

Mold deposit spots
Figure 33 Molded cup showing mold deposit problems
Mold Venting Design

P/L Cavity Venting
Figure 34 Mold base plates and cavity insert mount clearances
Mold Venting Design

P/L Cavity Venting
Figure 35 In-line P/L cavity venting (in)
Mold Venting Design

P/L Cavity Venting
Figure 36 P/L cavity venting to the ring groove vent (in)
Mold Venting Design

Table 2 Cavity relief edge vent depth for common types of resins
Mold Venting Design

P/L Cavity Venting
Figure 37 P/L cavity venting systems
Mold Venting Design

Mold Cavity Insert Parting Surface Venting
Figure 37 Different mold cavity insert parting face venting systems
Mold Venting Design

Figure 37 Different mold cavity insert parting face venting systems
Mold Venting Design

Figure 38 Horizontal parting face insert cavity venting (in)
Mold Venting Design

Figure 39 Vertical parting face insert cavity venting (in)
Mold Venting Design

Ejector Ring Venting System
Figure 40 Ejector ring and P/L cavity venting system
Mold Venting Design

Core or Ejector Pin Ring Groove Venting
Figure 41 Core or ejector pins ring groove venting details (in)
Mold Venting Design

Figure 42 Core or ejector pins ring groove vent projection view
Mold Venting Design

Figure 43 Two screw bosses using cores with ring groove vents
Mold Venting Design

Ring groove vents for sprue puller pins, runner/gate ejector pip vents, and 3-plate mold runner venting systems.
Figure 44 Additional cold runner system locations for venting
Mold Venting Design
Mold Venting Design
Mold Venting Design

Using Sintered Porous Insert Plugs
Figure 45 Sintered porous insert plug mold venting
Figure 46 Sintered vent plug insert mold venting application

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Mechanical Engineering Department Kasetsart University

Standard 2-Plate Mold Components

Function of Mold Base Components

Function of Mold Base Components

Function of Mold Base Components

Function of Mold Base Components

Function of Mold Base Components

Ejector Retainer Plate

Function of Mold Base Components

Function of Mold Base Components

Function of Mold Base Components

Injection Molding M/C Nozzle

Injection Molding M/C Nozzle

Mold Cold Runner System

Mold Cold Runner System

Figure 1 Illustration of molded components in a complete shot

Mold Cold Runner System

Cold Runner Sprue

Cold Runner Sprue

Cold Runner Sprue

Cold Runner Sprue

Cold Runner Sprue

Cold Runner Sprue

Cold Runner Sprue

Figure 4 Standard commercially available sprue bushing

Cold Runner Sprue

Figure 5 Performance alloy sprue bushing to improve temperature control

Cold Runner Sprue

Figure 6 TranziSprue, a sprue bushing with temperature control

Cold Runner Sprue

Figure 7 Extension nozzle sprue bushing and short sprue mold

Guidelines for dimensioning sprues

Figure 8 Ejection sequence of the cold sprue and runner system

Figure 9 Recommended sprue puller designs

Designing the Cold Runner System

Cold Runner System Layout

Cold Runner Cross Section Geometries

Figure 9 Typical cold runner cross section geometries

Cold Runner Cross Section Geometries

Cold Runner Cross Section Geometries

Cold Runner Cross Section Geometries

Cold Runner Cross Section Geometries

Cold Runner Dimensions

The mold cooling system for the runner and gates

Cold Runner Dimensions

Cold Runner Dimensions

Cold Runner Layout

Figure 10 Difference between balanced and unbalanced runners

Cold Runner Layout

Figure 11 Three different balanced runner configurations

Cold Runner Layout

Cold Runner Layout

Cold Runner Layout

Mold Cavity Gating

Mold Cavity Gating

Mold Cavity Gating

Mold Cavity Gating

The size, complexity, and wall thickness of the molded part.

Types of Mold Cavity Gates

Types of Mold Cavity Gates

Types of Mold Cavity Gates