Basic on injection Mould

Basic on injection Mould

Injection Molding Machine

Nozzle between
barrel and mold
(not shown)
Hopper
Heater
bands

Clamping
Unit Hydraulic
Unit

Barrel Screw
Mold cooling fed (Ram)
from external unit
Basic on injection Mould
THE INJECTION MOLDING PROCESS -INJECTION

• The tool closes and locking pressure is applied

• The injection unit moves forward and seats against the sprue bush
• The injection ram advances forcing the molten material into the cavity
Basic on injection Mould
Basic on injection Mould
Basic on injection Mould
A STANDARD MOLDBASE AND
ITS COMPONENTS
Basic on injection Mould
A STANDARD MOLDBASE AND
ITS COMPONENTS BACKPLATES
Basic on injection Mould
A STANDARD MOLDBASE AND
ITS COMPONENTS SUPPORT PLATE
Basic on injection Mould
A STANDARD MOLDBASE AND
ITS COMPONENTS CORE PLATE
Basic on injection Mould
A STANDARD MOLDBASE AND
ITS COMPONENTS CAVITY PLATE
Basic on injection Mould
A STANDARD MOLDBASE AND
ITS COMPONENTS CORE INSERT
Basic on injection Mould
A STANDARD MOLDBASE AND
ITS COMPONENTS CAVITY INSERT
Basic on injection Mould
A STANDARD MOLDBASE AND
ITS COMPONENTS PILLARS AND BUSHES
Basic on injection Mould
A STANDARD MOLDBASE AND
ITS COMPONENTS LINER / TUBULAR DOWEL
Basic on injection Mould
A STANDARD MOLDBASE AND
ITS COMPONENTS LOCATION RING
Basic on injection Mould
A STANDARD MOLDBASE AND
ITS COMPONENTS SPRUE BUSH
Basic on injection Mould
A STANDARD MOLDBASE AND
ITS COMPONENTS RUNNER
Basic on injection Mould
A STANDARD MOLDBASE AND
ITS COMPONENTS GATE

GATE
Basic on injection Mould
A STANDARD MOLDBASE AND
ITS COMPONENTS EJECTOR SET

EJECTOR PLATE

EJECTOR BACK PLATE

Basic on injection Mould
A STANDARD MOLDBASE AND
ITS COMPONENTS RETURN PINS
Basic on injection Mould
A STANDARD MOLDBASE AND
ITS COMPONENTS EJECTOR PINS
Basic on injection Mould
A STANDARD MOLDBASE AND
ITS COMPONENTS SUPPORT PILLAR
Basic on Typical Cooling layout
Cooling
• The Material Type
• The Number of Impressions
• The Size of the Press
• The Mold Configuration COOLING
Basic on injection Mould
MOLD DESIGN CONSIDERATIONS
• The Material Type
• The Number of Impressions
• The Size of the Press
• The Mold Configuration

SHRINKAGE - Each material has its own shrinkage value, shrinkage is differential and
is generally classified in terms of radial (with the flow of material) and axial (across
the flow of material).
Basic on injection Mould
MOLD DESIGN CONSIDERATIONS
• The Material Type
• The Number of Impressions
• The Size of the Press
• The Mold Configuration
SHRINKAGE

• DIMENSIONAL DIFFERENCE BETWEEN COLD MOULD AND MOULDING AT 23

DEGREE C, 24 TO 168 HOURS AFTER MOULDING
• MOULD SHRINKAGE
• AFTER SHRINKAGE
• PROCESS SHRINKAGE
• ISOTROPIC OR ANISOTROPIC
• VOLUMETRIC AND LINEAR SHRINKAGE
• SHRINKAGE ALLOWANCE
• ENHANCEMENT OF EVERY DIMENSION OF CORE AND CAVITY BY A PERCENTAGE OF
LINEAR SHRINKAGES
Basic on injection Mould
MOLD DESIGN CONSIDERATIONS
• The Material Type
• The Number of Impressions
• The Size of the Press
• The Mold Configuration
SHRINKAGE

SHRINKAGE DEPENDS ON

• PART DESIGN

• MATERIAL

• MOULD DESIGN

• MOULDING CONDITION

• EXPANSION OF MOULD
Basic on injection Mould
MOLD DESIGN CONSIDERATIONS
• The Material Type
• The Number of Impressions
• The Size of the Press
• The Mold Configuration
SHRINKAGE

TO CONTROL SHRINKAGE
• REDUCE WALL THICKNESS
• INCREASE INJECTION PRESSURE
• INCREASE INJN. FORWARD TIME
• INCREASE CYCLE TIME.
• INCREASE METL.TEMP.
• LOWER MOULD TEMP.
• INCREASE GATE SIZE
• DECREASE FLOW LENGTH
Basic on injection Mould

• The Material Type

• The Number of Impressions
• The Size of the Press
• The Mold Configuration

FlOW PROPERTIES - Each material has its own specific type of flow properties which
determine characteristics such as the length of flow and the type of gating used.
Basic on injection Mould
MOLD DESIGN CONSIDERATIONS
• The Material Type
• The Number of Impressions
• The Size of the Press
• The Mold Configuration

DRAFT – The draft required is determined by a combination of surface finish and the
material used, generally a draft angle between 1 and 2 degrees is used but the higher
the shrinkage rate of the material and the coarser the surface finish the harder the part
is to remove.
Basic on injection Mould
MOLD DESIGN CONSIDERATIONS
• The Material Type
• The Number of Impressions
• The Size of the Press
• The Mold Configuration
Basic on injection Mould
MOLD DESIGN CONSIDERATIONS
• The Material Type
• The Number of Impressions
• The Size of the Press
• The Mold Configuration

The size of the required press is established by a combination of the physical size of
the mold, the number of impressions and the clamping pressure required.
Basic on Mould and its types
MOLD DESIGN CONSIDERATIONS
• The Material Type
• The Number of Impressions
• The Size of the Press
• The Mold Configuration

THE STANDARD 2 PLATE MOLD

Basic on Mould and its types
MOLD DESIGN CONSIDERATIONS
Two Plate Mould

Mould Construction with Wedge Lock and its importance

1. To allow ease of assembly and disassembly, Draft required for the Wedge lock is min 5° (it
depends on mould on mould size, as the size of the mould increases we need to increase
the Wedge lock Angle
2. To decrease the moulds Parting line were out in Shut Off Areas
3. To withstand injection pressure in fast and large Production Without Cracks in the mould
4. In some special cases Shut off pads can be used (because of less Shut off angle in part A
surface)
5. It decrease miss balance and miss alignment of the Mould
Basic on Mould and its types
MOLD DESIGN CONSIDERATIONS
• The Material Type
• The Number of Impressions
• The Size of the Press
• The Mold Configuration

THE COLD RUNNER MOLD

Cold runner:

Brings the melted plastic into the cavity mold, but after cooling stays solidified in the parting line.

This volume must be added to the injected volume and could be recycled.

Has to be ejected at the same time as the part.

Is situated in the parting line either on the core or cavity side; or 50/50 between both of them.

Since the cold runner goes to the scrap, the size of it should be optimized for reducing scrap. It must be also
cooled before ejection.
Basic on Mould and its types
MOLD DESIGN CONSIDERATIONS
• The Material Type
• The Number of Impressions
• The Size of the Press
• The Mold Configuration

THE HOT RUNNER MOLD

Hot runner system:

It’s an extension of machine injection system.

Enables to bring material into the different areas of the tool thanks to heating of the runner.

Reduces scrap, which would otherwise have to be regrind.

It’s necessary for big and complex parts.

Basic on Mould and its types
MOLD DESIGN CONSIDERATIONS
• The Material Type
• The Number of Impressions
• The Size of the Press
• The Mold Configuration

THE HOT RUNNER MOLD

Basic on Mould and its types
MOLD DESIGN CONSIDERATIONS
• The Material Type
• The Number of Impressions
• The Size of the Press
• The Mold Configuration

HOT RUNNER
Basic on Mould and its types
MOLD DESIGN CONSIDERATIONS
• The Material Type
• The Number of Impressions
• The Size of the Press
• The Mold Configuration

THE 3 PLATE MOLD

Basic on Mould and its types
MOLD DESIGN CONSIDERATIONS

THE 3 PLATE MOLD

Basic on Mould and its types
MOLD DESIGN CONSIDERATIONS

THE 3 PLATE MOLD

Disadvantages of 3 plate mould

1. Slow production rate when compared with 2 plate mould

2. More expensive than two plate mould
3. Less complexity of parts are only feasible
4. More material wastage for runner and Sprue
5. More machining work for manufacturing the mould
Basic on Mould and its types
MOLD DESIGN CONSIDERATIONS

SPLIT MOLD
Basic on Mould and its types
MOLD DESIGN CONSIDERATIONS

MULTI STAGE MOLD

Basic on injection Mould
CAVITY AND CORE SPLITS
• Basic Configurations
• Lands and Shut Outs