Basic Calculation of Injection Mold

Basic Calculation of Injection Mold
List of Content
1. Material For Injection Mold.

2. Basic Calculation.
2.1 Calculation of Clamping force for the Mold.
2.1.1 Viscosity Factor (Flow Factor) Material in the Mold.
2.1.2 Maximun Flow path - Wall thickness of the Mold.
2.2 Mold Cooling.
2.2.1 Enthalphy Curves for Various thermoplastics
2.2.2 Calculation of Cooling time for the Mold.
2.2.3 Cooling Time Diagram.
2.3 Calculation of Mold Heating.
2.4 Cycle Time Calculation for the Mold.
2.5 Shot weight Calculation for Machine.
4. Design of Moldings.
4.1 Compensating for Different Wall Thickness.
4.2 Transitions.
4.3 Design of Ribs.
4.4 Camouflage of Sinkmark at Rib Transitions.
4.5 Distortion Resulting from Ribs Present on One Side
for Various Rib Wall Thicnkess.
4.6 Distortion from Wall Thickness Different and Special
Thickness of Material.
5. Mold Design.
5.1 Basic Mold Design.
5.2 Sprue and Runners.
5.4 Venting the Mold.
5.5 Mold cooling and Cooling Channel.
5.6 Mold Temperatures.
5.7 Ejector System.
6. Mold Manufactures.
7. Mold Operation.
8. Basic Information of Injection Molding.
9. Plastics Resin.
10. Sample Mold Assembling drawing of Product in the Market.
11. Literatur.
1) Shot Weight Calculation for Machine.
The maximum shot weight depends on :
- material being used.
- volume of barrel (cm3).
Different material - different gravity under temperature.
How to calculate max. shot weight :
= volume . factor
(cm3) . (g/cm3)
For example :
Volume of KM achine 120-460 with screw diameter = 275 cm3

Max. shot weight for ABS = 275 . 0.90 = 247 g
This means max. use of screw stroke !

As a recommendation from KM machine : do not use the screw stroke more than 85 - 95%.
2) Cycle Time Calculation for the mold Process.

t close
t E : injection time
t N : hold on pressure time
t K : cooling time
tv. pl. : delayed start of plasticising
t pl. : plasticising time
t open :
t C : "cores in" "cores out"
t A : ejection time
t p : pause time
3) Calculation of Mold Heating.

As you can see in the list of mold temperatures, due to different materials, you need to set
different mold temperatures.
How to calculate the right mold heating unit :
P = heat capacity (kw)

m = weght of mold (kg)
c = specific heat (kJ/kgK)
steel C = 0.49
Alumunium = 0.88
delta V = Vb - Va (celcius)

Vb = mold temperature during production
Va = start up temperature of mold
t = heating up time
s = safety factor 1.1 - 1.3 for loss by radiation
1 m . c deltaV . s

P = ------ . -------------------- kw
3600 t
Example : 200 kg steel mold from 20 celcius (c) to 60 celcius (c) in 0.5 hour.
1 200 . 0.49 . 40 . 1.3

P = ------ . ---------------------- kw
3600 0.5

= 0.000278 . 10192
= 2.83 kw
= 3 kw
4) Cooling Time Diagram.
Now use the cooling time diagram :

- make a line from "a" to "s".
- make a line from crossing point line 1 to line T and read out the cooling time on line t in
secons, in our case approx. 9.5 to 10 sec., for example no.1.
The same for example no.2 : cooling time approx. 32 to 35 sec.
5) Calculation of Mold Cooling Time for the Mold.
Use diagram cooling time calculation.
T = normal demolding temperatur of article.

T^ = maximal demolding temperatur of article.
Vm = melt temperatur.
Vw = mold temperatur.
Ve = demolding temperatur of article.
s = wall thickness.
for example :
No.1
No.2

-----------------------------------------------
-4
-4
Thermoplast PS a = 8.5 - 10 8.3 -
10
Melt temperatur Vm 250 C 250 C
Mold temperatur Vw 25 C 25 C
Demolding temperatur Ve 50 C 60 C
Wall thickness s 2 mm 4
mm
No.1 T = Vm - Vw = 250 - 25
---------- ----------- = 9
Ve - Vw 50 - 25
No.2 T = Vm - Vw = 250 - 25

---------- ----------- = 6.43
Ve - Vw 60 - 25
6) Calculation of Clamping force for the Mold.
How to use the diagram :
1. Ascertain the projected injection surface. Ascertain the flow path/ wall thickness ratio.
2. On the diagram, draw a vertical line upwards from the value of the wall thickness on the
horizontal axis until the line intersects the curve for the flow path/ wall thickness ratio : at
the point of intersection, draw a line horizontally to the left and read off the value of the
specific internal pressure (in bars).
3. The locking force in Mp is then calculated from :
Specific internal pressure from the diagram X locking surface.
Example:
Projected injection surface : 200 cm2
Flow path about 90 mm
Wall thickness 1.25 mm
Resin of plastic :: PS, PE, PP
The diagram shows a spesific internal pressure of about 175 bars.
Clamping force = 200 x 175 = 35,000 kP = 350 kN = 35 Mp
The diagram is drawn up for the materials of good flow and for simple moldings. In the case
of molding with numerous webs and changes in direction of material flow, and in the case of
material with less good flow, the spesific internal pressure are higher.
7) Maximum Flow path - Wall thickness of the Mold.

Ratio with different wall thickness :
Symbols for Plastics (extract from DIN 7728 )

8) Viscosity Factors (Flow Factors) in the Mold.
PE, PS, PP = 1
PA = 1.2 - 1.4
CA = 1.3 - 1.5
ABS = 1.3 - 1.4
PMAA = 1.5 - 1.7
PC = 1.7 - 2.0
The factors are guide values for the previously mentioned clamping force calculation tables
whereby the following factors naturally must be taken into account :
 shape of part.
 type of injection.
 feed position melt temperature.
 various other factor
Example no 2 :
- projected injection surface = 200 cm2
- flow path (max lenght) = 90 mm Ratio = 70:1
- wall thickness = 1.25 mm
- material = PC
The diagram shows a spesific internal mold pressure of approx 175 kp/cm2.
Clamping force for this case :
200 x 175 = 35,000 kp x 1.7 - 2 = 70,000 kp

= 700 kN = 70 Mp
9) Enthalphy Curves For Various Thermoplastics

Enthalpy curve for various thermoplastics diagram.
How to use :
Read out on the corect material curve the enthalpy in Kcal/kg and multiply this with the
used material quantity in kg/h, you get the:
(Kcal/ kg)/(kg/h) = Kcal/h
Which are needed to cool down the melt material in the mold during production.
For example :
- material : PS
- shot weight : 100 g 100 shot/h
- demolding temperature : ca. 30 C
- 210 C = 85 Kcal/kg
- 30 C = 5 Kcal/kg ==> 85 - 5 = 80 Kcal/kg
Enthalpy = (80 Kcal/kg) . (0.1 kg/h) . 100 = 800 Kcal/h
For summer temperature in Northern Europe, you must add up approx 25 - 30 % to have
enough capacity at your cooling equipment. A mold with hot runner needs an extra cooling
of approx. 25 - 30%.

Basic Calculation of Injection Mold

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Basic Calculation of Injection Mold

1. Material For Injection Mold.

Different material - different gravity under temperature.

How to calculate max. shot weight :

Volume of KM achine 120-460 with screw diameter = 275 cm3

This means max. use of screw stroke !

2) Cycle Time Calculation for the mold Process.

3) Calculation of Mold Heating.

How to calculate the right mold heating unit :

P = heat capacity (kw)

delta V = Vb - Va (celcius)

1 m . c deltaV . s

1 200 . 0.49 . 40 . 1.3

4) Cooling Time Diagram.

Now use the cooling time diagram :

The same for example no.2 : cooling time approx. 32 to 35 sec.

5) Calculation of Mold Cooling Time for the Mold.

Use diagram cooling time calculation.

T = normal demolding temperatur of article.

No.2 T = Vm - Vw = 250 - 25

6) Calculation of Clamping force for the Mold.

How to use the diagram :

3. The locking force in Mp is then calculated from :

Specific internal pressure from the diagram X locking surface.

Flow path about 90 mm

Wall thickness 1.25 mm

Resin of plastic :: PS, PE, PP

The diagram shows a spesific internal pressure of about 175 bars.

Clamping force = 200 x 175 = 35,000 kP = 350 kN = 35 Mp

7) Maximum Flow path - Wall thickness of the Mold.

Symbols for Plastics (extract from DIN 7728 )

Clamping force for this case :

200 x 175 = 35,000 kp x 1.7 - 2 = 70,000 kp

9) Enthalphy Curves For Various Thermoplastics

(Kcal/ kg)/(kg/h) = Kcal/h

Enthalpy = (80 Kcal/kg) . (0.1 kg/h) . 100 = 800 Kcal/h

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