Tutorials on Injection Mould Designing

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Tutorials on Injection Mould Designing

Otherengineering mechanical mould mold educational basicsourbhBy Sourbh on 29 Jul 05:30 28 answers 14030 views 16 comments

Basics Part and W o r king Features of Molding Assembly

Rest of Slides you were found out here in My Library:-" Tutorials on Injection Mould Designing "Moulding Products:-"ALL-OUT Fuel Container, Injection blow moulding part ""Container-Injection blow moulding part""Grabby Torch""Hexagonal Torch " Requested Design"""Baby Girl Hair Clip ""Something More than RC ""Table Lamp""Table LAMP-II"
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http://grabcad.com/questions/tutorials-on-injection-mould-designing 2

And also much more in my library..!!

28 answers

Sourbh over 1 year ago

Than after this one.......Learn much first than design it.

1. Step 1

5.

2. Step 2

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3. Step 3

7.

4. Step 4

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5. Step 5

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6. Step 6

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7. Step 7

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8. Step 8

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than this

1. Step 1

13

2. Step 2
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14

3. Step 3

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4. Step 4

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5. Step 5

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7. Step 7

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11. Step 11

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13. Step 13

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1.Mehran Zaryoun over 1 year ago

Perfect man, Thx
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2.Sourbh over 1 year ago

you're welcome dear Mehran

3.huuhoa 12 months ago

sorry i dont understand "day light" what is this mean

4.Sourbh 11 months ago

day light means the min./max. opening of mould halves after filling of materialin injection mould for part ejection.


Go through this Presentation, you will Clear all your Doubts!!

Enjoy

1. Step 1

This one first...1.
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2. Step 2

2.

3. Step 3

3.


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4. Step 4

4.


Dear Bobys Here is your Shrinkage Data Sheet

1. Step 1
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All Data about Shrinkage Value of Different Plastic Materials..

thanks and Enjoy..!!

2. Step 2

2

1.BoByS over 1 year ago
http://grabcad.com/bobys-1http://grabcad.com/bobys-1https://d2t1xqejof9utc.cloudfront.net/pictures/files/24536/large.JPG?1375881878https://d2t1xqejof9utc.cloudfront.net/pictures/files/24535/large.JPG?1375881876


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Amazing...just amazing!


Thanks dear Bobys


Here is the working System and Different Zone's in Injection Molding Machine

1. Step 1

The Injection molding Machine

2. Step 2

Purging


Ya Of-course am in Way of Writing the book,this Slides only the 0.1% of My Notes, which I prepared During My AcademicSession.
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am did Lots of Research in Different types of Moulding Technique or Process.and also Designed and Manufactured it.Due to Low Internet Speed am Just Uploading the Less Amount of My works.If You Have any type of Doubts and Question than Sourbh kumar is Ready to GiveAnswer With Suitable Examples.

Thanks


The next Part of this Tutorials is Here"Tutorials on Injection Mould Designing:-Design Steps"

Sourbh about 1 year ago

Today the topic is "FLOW SYSTEM"

No slide just Theory only, I will upload the slide soon.

Thanks and Enjoy..!!

1. Step 1

Flow system: The design of a flow system to inject molten alloy in to a die

cavity greatly influences the success of a die. The failure of many dies can betraced to faulty design of the flow system. By applying the basic principles of hydraulics a proper molten metal flow system can be developed.The system aims at an efficient controlled delivery of through the flow systemto the die-casting with mixing of molten alloy and air.Machine suitability:Choice of suitable machine is important aspect of die designing. Two mainconsideration determine suitability:Clamping force.Injection capability.

2. Step 2

Clamping force can be calculated by multiplying the projected area of theimpression including runners,gate overflow by the injection pressure.The resultshould be less than the clamping force of the machine. The injection capabilityor metal pumping capacity of the machine must be determined from the pQ2diagram.The flow system comprises of a series of passage of varying lengths anddiameters which carry molten alloy at varying high velocities from the underside of the injection plunger to the gate.
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The flow system should be properly designed and manufactured to minimize theenergy losses.The flow system should converge from gooseneck to gate, sharp corners should

be avoided and the surface of the flow path should smooth and well finished.

3. Step 3

The sprue:

The sprue has two basic functions:1. To provide a smooth flow path between nozzle and runner..2.To provide a means of rapidly solidifying molten metal alloy at the entranceof the die after the cavity has filled and the flow has stopped.

3.Runner type sprues have been developed to achieve a smooth flow path withuniform cross section, minimum change of direction and smooth transmissionfrom nozzle to sprue and sprue to runner.

4. Step 4

The runner system from sprue to gate:Main runner:

The main runner join the sprue to the final tapered tangential runners feeding thegate. They should be as shot as possible and must have a constant crosssectional area.

Tapered tangential runners:Tapered tangential runners provide the final flow path from main runners to

gate. They provide an efficient flow path based on simple geometry and permitthe use of the very thin gates (from 0.15-0.3mm).

5. Step 5

Runner cross section:

Circular sections give best flow efficiency and minimize thermal losses, but arethe least practical cross section from the tool makers view.

For tapered tangential runners modified square or trapezoidal shapes are used.Area calculations are based on square sections and are converted intotrapezoidal shapes.

Pairs of tapered tangential runners can be used to feed a long gate into a singlecavity.A thin delta shaped region between the paired runners is found.

6. Step 6

Shock Absorbers:


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The small ends of tapered tangential runners terminates in simple disk shapedshock absorbers. The control the very high transient velocities which may occurat the small ends of the runner. Shock absorbers also protect the die when thedoes not flow completely as in the case of a cold die during setup,when veryhigh velocities can be reached.Fan Gate:Correct design and dimensions of gates is essential to achieve high castingquality and efficiency. The fan gate has been largely superceded by by the

tapered tangential runner. To increase its efficiency the inlet should be largerthan the gate.

7. Step 7

Gate PositioningGeneral guidelines for gate positioning:Center gating: Center gating offers the best feeding configuration. It permits theuse of short direct feed system. It achieves an ideal flow path across the diecavity.

Edge gating susing tapered tangential runners:The following are the recommendations :The longest uninterrupted length of casting available for casting should bechoose but it must satisfy the shortest and smoothest flow path across the cavity.The direction of metal flow in the cavity sho9uld be chosen such that at leastone side or corner be open during fill time to allow for venting.

8. Step 8

Gate area:The total gate area must always be smaller than nozzle exit area. But its should

not be less than 40% of nozzle exit area.Gate velocity:The velocity of molten alloy through the gate depends on :The energy of machineThe pressure losses in the total flow system in the gate.The type of runner.True velocity through gates fed by tapered tangential runners is higher than thefigure arrived at using the formula:Velocity(v) = volume flow rate(Q)gate area(A)

9. Step 9

Air vents:The use of converging flow system with correctly designed runners ensures thatair in the feed system is pushed out a head of the molten alloy flow and expelledthrough the cavity trough the air vents.Depth greater than 0.075mm will lead to flashing problem.Overflows: No over flows need be cut prior to the first casting trial unless theiruse is specified for ejection purpose. On trial if the castings exhibit poor finishor blister the following conditions must be checked first:


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Machine operations and performance

Feed system design and performance.This will establish both machine and die are operating at the design parameters.

10. Step 10

Thanks..!!!


Mould Steels

1. Step 1

1

Prabhakar Purushothamman about 1 year ago

Design of Three Plate Mold an Introduction

1. Step 1

Type of gate and type of ejection used in Three Plate Mould
http://grabcad.com/sourbhhttp://grabcad.com/prabhakar.purushothamman-1http://grabcad.com/prabhakar.purushothamman-1https://d2t1xqejof9utc.cloudfront.net/pictures/files/25249/large.jpg?1377159283http://grabcad.com/sourbh


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2. Step 2

Three plate Mold Closed condition

3. Step 3

Three plate Mold Open condition


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4. Step 4

THREE PLATE MOLD - Elements

5. Step 5

MOULD OPENS AT FIRST PARTING SURFACE


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6. Step 6

Second Parting Surface Opens

7. Step 7

Stripper Ejection


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8. Step 8

3 plate mould

1.Sourbh about 1 year ago

Nice Contribution.

Thanks to share this.
https://d2t1xqejof9utc.cloudfront.net/pictures/files/25261/large.JPG?1377182136https://d2t1xqejof9utc.cloudfront.net/pictures/files/25262/large.JPG?1377182139http://grabcad.com/sourbhhttp://grabcad.com/sourbh


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Ok Today I will Tell you about Shrinkage, Completely

1. Step 1

Shrinkage and its Applications.

2. Step 2

Shrinkage
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3. Step 3

Shrinkage of common plastics

4. Step 4

Application of Shrinkage, An Example


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5. Step 5

Component drawing with shrinkage added

6. Step 6

core Insert


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7. Step 7

Cavity Insert


Welcome dear..!!
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2.george avgerinakis about 1 year ago

Thanx!

Zakir Qureshi over 1 year ago

awesome job!!!


Thanks Zakir


When a basic mould consisting of two parts, is open there is only one space ordaylight between the two mould halves. This is called a single-daylight mould. In astripper plate mould which consists of a fixed mould plate, the moving mould plateand the stripper plate there are two daylights when opened. This is called a double-

daylight, stripper plate mould. Another type of mould which also consists of threemain parts a feed plate, a floating cavity plate and a moving mould plate, has twodaylights and is termed as double-daylight underfeed mould or three plate moulds.This design permits a particular feed technique known as underfeeding.A combination of stripper plate and underfeeding results in a triple-daylight mould.


Types of Injection moulding machine

1. Step 1

1
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BoByS over 1 year ago

Can you tell us what is the scale factor for the cavities because of the shrinkage whenthe detail cools (for different polymers)? I don't see this in the slides. :(Thanks for this amazing tutorial!


Now the File is there download it, Shrinkage.pdf


ya ofcourse Dear I will Upload the next tutorials for Plastics were mouldedthrough.And its combination of total Details Necessary for moulding..

3.BoByS over 1 year ago

I can't wait! :)
http://grabcad.com/bobys-1http://grabcad.com/bobys-1http://grabcad.com/bobys-1http://grabcad.com/sourbhhttp://grabcad.com/sourbhhttps://d2t1xqejof9utc.cloudfront.net/pictures/files/25736/large.jpg?1378702145http://grabcad.com/bobys-1http://grabcad.com/sourbhhttp://grabcad.com/sourbh


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Today the Topic is Runner's

1. Step 1

Cold Runner

In a cold runner mold, the runner is cooled and ejected with the part. Everycycle, a part and a runner are produced. The obvious disadvantage of this systemis the waste plastic generated. The runners are either disposed of, or regroundand reprocessed with the original material. This adds a step in the manufacturing

process. Also, regrind will increase variation in the injection molding process,and could decrease the plastic's mechanical properties.Despite these disadvantages, there are many significant advantages to using acold runner mold. The mold design is very simple, and much cheaper than a hotrunner system. The mold requires less maintenance and less skill to set up andoperate. Color changes are also very easy, since all of the plastic in the mold isejected with each cycle.

2. Step 2

Hot Runner

In a hot runner mold, the runner is situated internally in the mold and kept atemperature above the melting point of the plastic. Runner scrap is reduced or

eliminated. The major disadvantages of a hot runner is that it is much moreexpensive than a cold runner, it requires costly maintenance, and requires moreskill to operate. Color changes with hot runner molds can be difficult, since it isvirtually impossible to remove all of the plastic from an internal runner system.Hot runners have many advantages. They can completely eliminate runnerscrap, so there are no runners to sort from the parts, and no runners to throwaway or regrind and remix into the original material. Hot runners are popular inhigh production parts, especially with a lot of cavities.

3. Step 3

Types of Cold Runner Molds

There are two major types of cold runner molds: two plate and three plate.A two plate cold runner mold is the simplest type of mold. It is called a two

plate mold because there is one parting plane, and the mold splits into twohalves. The runner system must be located on this parting plane thus the partcan only be gated on its perimeter.

4. Step 4
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A three plate mold differs from a two plate in that it has two parting planes, andthe mold splits into three sections every time the part is ejected. Since the moldhas two parting planes, the runner system can be located on one, and the part onthe other. Three plate molds are used because of their flexibility in gating

location. A part can be gated virtually anywhere along its surface.

5. Step 5

A two plate Cold Runner mould

6. Step 6

A Three Plate Cold Runner mould
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Today Topic is Vacuum Forming, Let take a look on it.

1. Step 1

Vacuum Forming Process

1. The process involves heating a plasticsheet until soft.2. The softened sheet is draped over amould.3. A vacuum sucks the sheet into / ontothe mould.4. The newly shaped sheet is taken offthe mould.

2. Step 2

Typical PLASTICS used in thevacuum forming process

PSAcrylonitrile Butadiene StyreneABSPOLYSTYRENEPOLYCARBONATEPCPOLYPROPYLENE


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3. Step 3

Further PLASTICS used in thevacuum forming processPOLYVINYL CHLORIDEPVCPMMAAcrylic

PEPOLYETHYLENE (woven sheet)

4. Step 4

a). Plastics are man made chemicals extracted mainly from petroleum.b). They are basically composed of hydrocarbons: groups of linked hydrogen

and carbon atoms.(Imagine them as a small train and carriage!)c). Most plastics are made up of long chains of hydrocarbons.

(Identical small trains joined together to form one very long train.)

What are Plastics ?

What are Plastics? continuedd). More than 50,000 molecules (long trains) may be joined in chains to produce

polyethylene (or polythene).e). Very long straight or branched chains. are present in thermoplastics:

eg. polyethylene and polystyrene.f). Thermoplastics always soften when heated and harden when cooled down.g). This makes these plastics ideal for the vacuum forming process.

5. Step 5

Advantages ofthe Vacuum Forming Process

Vacuum forming uses low pressures so only relatively low cost equipment /

components are required.

Low pressures mean that moulds can be made of inexpensive materials and ina short time.

Prototypes, small and medium quantity runs become economical.

6. Step 6

Disadvantages of


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the Vacuum Forming Process More complicated machines and moulds are needed for automatic orcontinuous production of high volume items,eg. disposable cups and sandwich packs. The vacuum forming process starts with a flat plastic sheet and there may be aneed for a second process to trim the moulded end product. This means moreexpense to obtain additional equipment.

NB. The trimmed waste, however, can be re-ground and recycled!

7. Step 7

The process requires heat, suction, and (thermo)plastic sheets.

Hot air is required to soften the plastic sheet and allow it to conform easily tothe shape of the mould.

Vacuum is then used to suck theplastic to the mould.

Vacuum Forming is one of themost common methods ofproducing low-high volumes of

moulded useful forms that play amajor role in our lives.


Requested by Ganesh, Lifter's and slider's

1. Step 1

Aha You asking Lifters and Slider in Terms of mould Design,

Dear Ganesh, First I wish to tell you that We not able to compare the lifter's andslider's because They are Different from each other, Area wherever itsEmployed..!!

I already Stated in my tutorials that A simple mould In which outer side of

Component having Undercut in Periphery, Needs the CAM Actuation that isSlider Mechanism working there for Actuating the side and after Ejector's wereEmployed to Eject the Components,

But at the same time Inner side also having the Undercut means we Employ theLifter's mechanism,

In Simple Language, Lifter's are the Clever modification of the normal Ejectionsystem that Allows undercut feature in the core to be ejected from the mold. ALifter's is an ejector pin set into the core at an angle. Attached to the end of theejector pin is a block of steel that contains the undercutting feature. as the
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Ejector plate move forward the ejector moves forward and slide waysimultaneously, due to the angle on the lifter pin. this slide way motion motioneventually frees the hook(undercut) on the vent .The Lifter maintain the contact with the part during the Entire Ejection phaseand actually assists the other ejectors in pushing the part off the core. for thisreason, parts that have a large number of lifters often need little or no regularejection.

Finally the Conclusion is the Lifter's and sliders are two Different thingEmployed for Undercut, One is for Internal Undercut (Core side) and second isfor Outer Undercut( also called CAM actuated mechanism).

You able to Employ both of it in same Mould, or use any one of them withrespect to Easy Ejection of parts without rupture.Product Safety is Must.

BestSourbh KumarIndia


Here is the some example part for injection blow moulding

1. Step 1

fuel container`


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2. Step 2

Jar

Kianoush about 1 year ago

Very useful
http://grabcad.com/kianoush-2http://grabcad.com/kianoush-2https://d2t1xqejof9utc.cloudfront.net/pictures/files/27351/large.jpg?1382643556https://d2t1xqejof9utc.cloudfront.net/pictures/files/27352/large.jpg?1382643559


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Thanks dear Kianough, Please let me know if you need any answer related toany moulding technique.

am ready to help you enerytime.


So Request is here for the Lifter's and slider's.

Today am gonna show you and to explain you that how is the Slider works and howwe calculate the angle of its with respect to our moulding part.

1. Step 1

Split:- The mould designer is frequently comforted with a component designthat in corporate a recess or projection which prevents the simple removal of themoulding from the Mould.

The component designer, while endeavoring to produce in line of drawcomponent designs, has often to include a recess or a projection to perform a

particular function or to satisfy on artistic requirement.

"A moulding which has recess or a projection is termed as undercut moulding" .The mould design for this type of component is inevitably more complex thanfor the in line of draw component, as it necessitates the removal of that part of the impression which forms the undercut prior to ejection.

2. Step 2

I will upload the remaining tutors soon..!!

Wait for it

Sourbh 11 months ago

Requested by Sam

1. Step 1

Details 2D-Requested
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Sourbh 9 months ago

The mold flow express Tutorials here.

1. Step 1

" https://grabcad.com/questions/mould-flow-training "

BoByS over 1 year ago

I think that you need to write a book with your knowledge! Thanks for sharing thisinformation!

suresh.s about 1 year ago

Sourbh Please share some knowledge about lifters & sliders ..............and how to findthe angle of lifter?

huuhoa 12 months ago
https://grabcad.com/questions/mould-flow-traininghttp://grabcad.com/bobys-1http://grabcad.com/suresh.s-3http://grabcad.com/sourbhhttp://grabcad.com/huuhoa-1http://grabcad.com/sourbhhttp://grabcad.com/huuhoa-1http://grabcad.com/suresh.s-3http://grabcad.com/bobys-1https://d2t1xqejof9utc.cloudfront.net/pictures/files/30696/large.jpg?1387284831


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thank you share

1.Sourbh 12 months ago

welcome dear

Sourbh 9 months ago

Mold calculator is in downloads:-

If you have any doubt than feel free to ask..!!

1. Step 1

1 " Tutorials on Injection Mould Designing "

Prince Neo 8 months ago

Great Tutorial work..!!

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