Contents

Theory of moulds (Basics of mould construction)

1. Introduction 1 – 10
1.1 Thermoset plastic moulding methods
1.2 Thermoplastic moulding methods
1.3 Key words
1.4 Assignments
2. Compression moulds 11 – 36
2.1. Introduction
2.2. Working process
2.3. Working principle of compression moulding process.
2.4. Fundamentals of moulding.
2.5. Parts of moulding tool.
2.6. Types, construction, function, advantages, and dis–advantages of compression
moulds.
2.7. Split cavity moulds
2.8. Gang moulds
2.9. Loading chamber calculations.
2.10. Factors that influence on moulding process.
2.11. Heating of moulds.
2.12. Preforming.
2.13. Preheating methods of thermo plastic materials.
2.14. Compression moulding cycle
2.15. Common defects and remedies of moulded components.
2.16. Key words
2.17. Assignments.
3. Transfer moulds 37 –46
3.1 Introduction
3.2 Advantages of transfer moulding process
3.3 Dis-advantages Transfer moulding process
3.4 Types of transfer mould and their function.
3.5 Transfer moulding cycle.
3.6 Calculations of transfer chamber dimensions, gate and runner dimensions.
3.7 Perform and its considerations
3.8 Mould temperature

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3.9 Key words
3.10 Assignments
4. Injection moulds. 47 – 50
* Introduction
* Equipment
* Advantages
* Dis-advantages
* Types of injection moulds
5. Mould construction 51 – 66
5.1 Introduction
5.2 The various parts associated with working of injection mould
5.3 Function of Injection mould
5.4 Classification of Injection moulds
5.5 Construction of various parts of Injection mould
5.6 Key words
5.7 Assignments
6. Feed system 67 – 92
6.1. Introduction
6.2. Working principle of mould:
6.3. Runner system:
6.4. Determining sprue dimensions
6.5. Runner balancing
6.6. Gates, gate dimensions, types, design rules
6.7. Gate dimensions
6.8. Types of gates:
6.9. Design rules
6.10. Key words
6.11. Assignments
7. Parting surface 93 – 102
7.1 Introduction.
7.2 Classification of parting surface.
7.3 Balancing of mould surface
7.4 Relief of parting surfaces
7.5 Vents and venting
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7.6 Key words
7.7 Assignments
8. Temperature Control system of moulds 103 – 116
8.1 Introductions:
8.2 Factors influencing the cooling:
8.3 Cooling consideration:
8.4 Types of cooling system:
8.5 Thermal pins
8.6 Cooling slender cores
8.7 Water connectors
8.8 The important points to be observed in all cooling circuits are:
8.9 Design calculations:
8.10 Data for mould cooling calculations
8.11 Key words
8.12 Assignments
9.Ejection system 117 – 126
9.1 Introduction
9.2 The basic ejection techniques
9.3 Ejection from fixed half:
9.4 Sprue pullers:
9.5 Ejection force calculations:
9.6 Key words
9.7 Assignments:
10 Splits and side cores 127 – 140
10.1 Introduction
10.2 The major forms of split tools fall to the following categories;
10.3 Types of actuating splits
10.4 Splits locking method
10.5 Safety arrangement of splits:
10.6 Summary of splits
10.7 Moulding internal undercuts
10.8 Form pin:
10.9 Split cores:
10.10 Side cores
10.11 Stripping internal undercuts:
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10.12 Key words
10.13 Assignments
11. Three plate moulds 141 - 150
11.1 Introduction
11.2 Arrangement of parts in 3-plate mould
11.3 Underfeeding system
11.4 Working cycle of 3-plate mould
11.5 Designs features
11.6 Advantages of 3-plate mould
11.7 Dis-advantages
11.8 Limitations
11.9 Operating system
11.10 Keywords
11.11 Assignments:
12. Hot runner moulds 151 – 164
12.1 Introduction
12.2 Runner less moulds
12.3 Hot-Runner Unit Moulds
12.4 Design Features of the Hot-Runner Unit
12.5 Applications of the Hot-Runner Unit Type of Mould
12.6 Hot-Runner Unit
12.7 The manifold block
12.8 Nozzle:
12.9 Advantages of the Hot Runner Systems
12.10 Dis - advantages of Hot Runner Systems
12.11 Key words
12.12 Assignments
13. Injection moulding machines 165 – 182
13.1 Introduction:
13.2 Types of injection moulding machines:
* Hand Injection Molding Machine.
* Piston type Injection Molding Machine.
* Reciprocating screw type Injection Molding Machines.
Plasticising capacity:
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Injection pressure:
Factors that influence injection pressure requirements
Injection rate:
Injection capacity:
Swept volume:
Shot capacity:
13.3 Machine operating sequence
13.4 Key words
13.5 Assignments
14. Mould polishing 183 - 196
14.1 Introduction:
14.2 Need of polishing
14.3 Factors which affect polishability
14.5 Different surface conditions prior to polishing
14.6 Grinding and stoning of moulds (practical hints)
14.7 Polishing of moulds (practical hints)
14.8 Polishing sequences
14.9 Polishing technique
14.10 Polishing problems
14.11 Materials used for mould polishing.
14.12 Lubricants used in polishing
14.13 Hand tools used in polishing
14.14 Care of polished surface
14.15 Key words
14.16 Assignments
15. Injection moulding troubles and its remedies 197 – 228
15.1 Air traps.
15.2 Black Specks and black streaks.
15.3 Brittleness
15.4 Burn marks
15.5 Delamination
15.6 Dimensional variation
15.7 Discoloration
15.8 Fish eyes

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15.9 Flash
15.10 Flow marks
15.11 Hesitation
15.12 Jetting
15.13 Ripples
15.14 Short shot
15.15 Silver streaks
15.16 Sink marks and voids
15.17 Weld and meld lines
15.18 Key words
15.19 Assignments
16. Shrinkage 229 – 238
16.1 Introduction
16.2 Why do shrinkage occur?
16.3 Shrinkage
16.4 Problems caused by part shrinkage
16.5 Injection variables & shrinkage:
16.6 Causes of excessive part shrinkage
16.7 Warpage
16.8 Warpage due to differential shrinkage
16.9 Differences in filled and unfilled materials
16.10 Cavity dimension calculations:
16.11 Table shows shrinkage factor for different plastic material
16.12 Effect of processing parameters on shrinkage
16.13 Important notes on shrinkage:
16.14 Key words
16.15 Assignments
17. Thermo plastic resin data 239 – 264
17.1 PE-HD (High Density Polyethylene)
17.2 PE-LD (Low Density Polyethylene )
17.3 PA – 12 (Polyamide – 12 )
17.4 PA – 6 (Polyamide – 6)
17.5 PA – 66 (Polyamide – 66)
17.6 PBT (Polybutylene Terephthalate)
17.7 PC (Polycarbonate)
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17.8 PEI (Polyetherimide)
17.9 PET (Polyethylene Terephthalate)
17.10 PETG (Glycol-modified PET; Co polyesters)
17.11 PMMA (Polymethyl methacrylate)
17.12 POM (Polyacetal or Polyoxymethylene)
17.13 PP (Polypropylene)
17.14 PS (Polystyrene)
17.15 PVC (Poly vinyle chloride)
17.16 SAN (Styrene acrylonitrile)
17.17 PC/ABS (Polycarbonate-Acrylonitrile-Butadiene-Styrene Blend)
17.18 ABS (Acrylonitrile-Butadiene-Styrene)
18. Thermoset plastics 267 – 284
18.1 Phenol – formaldehyde
18.2 Amino Plastics
* Urea -formaldehyde (UF)
* Melamine -formaldehyde (MF
18.3 Epoxy Resins
18.4 Unsaturated Polyester Resins
18.5 Polyurethane
18.6 Silicones
18.7 Reinforced Thermosets
* Dough moulding compound (DMC).
* Sheet moulding compound (SMC).
19. Materials for mould making 285 - 300
19.1 Introduction
19.2 Steels used in mould making
19.3 Different types of steel commonly used in mould making are
19.4 Typical usage of various tool steels
19.5 World standards and its designations
19.6 Specification of tool steels
19.7 Specification and equivalents of tool steels
19.8 Tool steels and approximate equivalents
19.9 Application & characters of moulding steels

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19.10 Composition, heat treatment temperatures of bs-970 en series steels
19.11 General engineering steels and composition
20. Reference data 301 – 312
20.1 Preliminary analysis for mould
20.2 Check list for mould, moulding and machine
20.3 Preventive care of moulds when processing on Injection moulding machine
20.4 Abbreviations of different plastics
20.5 Few commercial engineering polymer blends and alloys
20.6 Examples of mould functions
20.7 Relate errors to mould processing
20.8 Temperature data for different thermo plastic resins
Bibliography 314
Index

Theory of moulds VIII

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Theory of moulds IX