Moulding Technology

by
BALRAJ TANWAR

Dated – 23 march 2019

INDIAN RUBBER INSTITUTE

DELHI BRANCH
 INTRODUCTION

 Moulding is a operation of shaping and vulcanization of

unvulcanised rubber compound by mean of heat & pressure in a
mould of appropriate shape.
 Type of Moulding –Fundamentally all process of moulding are
similar the only difference is the way of introducing material in to
the mould distinguish one technique from another.
Following type of Moulding
 1. Compression Moulding
 2. Transfer Moulding
 3. Injection Moulding
 4. Blow Moulding
 5. Reaction injection Moulding
 6. vacuum Compression / injection Moulding
 Compression Moulding
 Compression molding is the simplest form of Rubber molding in
which uncured rubber preformed, which is often shaped to the
approximate size & configuration of the desired finished part, is
placed directly in the mold cavity prior to mold closure. rubber is
compressed (squeezed) between the Top and Bottom plates then
Vulcanized (cured) utilizing both heat and pressure.
 The uncured pre-form must weigh max 10% more than the finished
part in order for air to be driven out of the mold cavity during mold
closure. If the preform weighs the same or less than the finished
part; voids, air traps or nonfills will appear on the finished product.
The excess rubber will flow into the overflow or flash groove. Two,
three or more mold plates may be used depending upon part
configuration and complexity.
Compression Moulding
 Three type of mould use in
compression Moulding
 Flash or straight compression moulding
 This is simplest mould it loaded by placing an excess
of the uncured compounding the cavity as the lid or
the top plate is closed under pressure , the compound
confirms to the shape of cavity and after it is filled , the
excess material is forced to outflow channels provide
in the mould .
 Positive or plunger type compression
moulding –The positive or plunger type of mould
ensures that full load of the press is applied directly
upon the rubber mix during moulding ,the absence of
overflow of flash groove in positive type moulds
requires that the volume of stock must be accurate .
This type of moulding generaly use in high hardness of
compound .
 Semi positive compression moulding –
the semipositive mould is designated to incorporate
some of the advantage .
 Transfer Moulding

 Transfer Molding Process in which uncured rubber compound is

not placed directly in the mold as did in compression molding ,
Instead of , it is placed in a Transfer Pot located above the cavity
area then pushed or transferred into the cavity with the help of
Piston through a Gate system , then vulcanized (cured) .
 Transfer molding is similar to Injection moulding as rubber enters
in to the cavity after closing mold .

 So it generally use in making complex products like engine mount

which low in production .
Transfer Moulding
 Transfer Moulding
ADVANTAGE
 Loading single large blank giving simplified blank preparation
 Shorter cure time
 Better rubber to metal bonded part manufacturing
 Low level of rejection
 Easy location of metal parts under bonding
 Stock grain effect reduced
 Mould cavities are less likely to damage by faulty seating at
parting line because they are closed prior to application of
pressure
 Less Maintenance cost of mould
DISADVANTAGE
 Higher mould cost than compression mould
 Extra weight due to transfer plate
 Longer cycle time
 Less cavities than compression or injection
 Frequent maintenance due to wearing of transfer ram or cavity
surface
 Bulky or high height and size of Mould
 Difference between Transfer &
Compression Moulding

TRNASFER MOULDING
1. Loading single large blank giving simplified blank preparation
2. Shorter cure time because compound get heat during transfer
3. Better rubber to metal bonded part manufacturing
4. Low level of rejection
5. Easy location of metal parts under bonding
6. Stock grain effect reduced
7. Mould cavities are less likely to damage by faulty seating at parting line because they are closed prior
to application of pressure
8. Less Maintenance cost of mould
9. High mould manufacturing cost
10. Extra weight due to transfer plate
11. Limited no cavities
COMPRESSION MOULDING
1. More time required to make no of blank or barbell ( additional capital ) need to invest
2. Long curing cycle
3. Difficult of manufacture rubber metal bonded part
4. Due to manual blank placing ,chance of mistake is higher that lead to higher rejection level
5. Difficult to location of metal insert during mould closing
6. Stock grain effect observed
7 Chance of damage at parting line & cavities is high
8. More maintenance cost
9. Low mould cost than transfer mould
10 Less weight & height due to transfer plate
11. Higher No of cavities
 Injection Moulding
 Injection moulding consist of the
automatic feeding , heating and
plasticizing of a rubber mix , followed by
the high pressure injection of a measured
quantity of the hot , plasticized mix
through a narrow orifice in to tightly
closed mould in which vulcanization
taking place.
 The mix is almost at the mould
temperature when it reach the mould , so
cure time is very short .
 During Injection moulding compound
transfer by higher injection pressure &
temperature that lead to short injection &
cure time
 This process is most suited for high
production of good quality component .
 Although there are saving in processing
costs but the initial capital investment is
too high ,Moulds are also expensive
because they require extensive design
knowledge to make runner, gates and
made by high quality steel that can
withstand high pressure & temperature.
Injection Moulding
 Injection Moulding
 Ram Type injection moulding Machine – This is simplest type of injection
moulding in which compound injected by ram in to cavity of mould through nozzle as shown
in following diagram. It has very low cost .
 The main disadvantage of this type of machine is that the mix is heated slowly by thermal
conduction from the barrel of the machine end can not become hotter than barrel until it is
forced through the nozzle . It suitable for thin product .
 Screw type injection moulding machine – screw type injection moulding
machine in which compound transfer with the help of screw rather than ram.
 It consist of plasticize the compound along with screw then injected the compound through
the narrow nozzle or gate in to the cavity of mould .
 During transfer of compound heat generate that increase the temperature of compound so
curing time short as compare to ram type injection moulding.
 disadvantage is that screw in cylinder is less tight results during backpressure material push
back that lead to less volume delivered ( precise) .
 Injection Moulding
 Screw with separate Ram injection moulding Machine – This type
of machine have combined advantage of both screw & ram . The mix is
extruded by screw in to a separate chamber from which it is injected in to
mould by ram at a angle to the screw. The tight fitting , separate piston
gives accurate delivery of the mix and also allow more efficient application
of ram pressure
 Injection Moulding
ADVANTAGE
 Eliminate blank preparation & transportation ( Labor cost saving)
 High injection pressure reduce the long heat transfer time .high
mould temperature also reduced the cure time .
 No cutting , shaping and weighing of blank required.
 Low level of rejection
 During the plasticizing of compound in barrel lead to more
homogeneous stock
 Automatic control of cycle time gives more consistent product .
 Faster removal / ejection of component
 Higher no of cavities , higher production
 Less Maintenance cost of mould
 High productivity
 DISADVANTAGE
 Higher mould cost than compression / transfer mould
 Set time require more
 Mould design is complex & precision
 High investment cost for machine
 Only economical for high volume of production
 Difference between Injection and
Transfer Moulding
INJECTION MOULDING
1 No blank preparation required ( Labor cost saving)
2. Rubber absorbed heat during plasticizing & injection results Shorter cure time &
Cycle time
3. Injection molding require compound strip so placement of blank in to mould or
pot eliminated
4. Low level of rejection
5. Addition mixing taking place during plasticizing of compound in barrel lead to
more homogeneous products
6. Faster removal / Ejection of component
7. Higher no of cavities can be made So higher productivity
8. High Machine & mould cost ( high investment required )
TRANSFER MOULDING
1. Blank preparation require
2. Higher Cycle time
3. Rubber blank need to place in to pot of mould
4. No of cavities is less compare to injection so rejection is high
5. No additional mixing taking place so less compression product is less
homogeneous
6. More time required to removal of part from mould
7. Limited no of cavities made so low productivity
8. Low Machine & mould cost ( Low investment required )
 Reaction injection Moulding
 Reaction injection molding is a simple
concept As its name suggests, the process
is based on a chemical reaction ( curing
reaction ) occur with in mould .
 A reactive liquid mixture (usually polyol and
isocyanate) is injected or poured into a mold
then chemical reaction takes place then
moulded part taken off from mould .
 During chemical reaction pylol chemically
bonded with isocynate become
mechanically strong finished part .
 End product propertiess depend on the
proportion of chemicals , it may be foam or
solid, highly rigid or very flexible.

the difference between RIM and plastic injection

molding
 Injection molding is the process of forcing
melted plastic into a mold while in reaction
injection molding, two liquid components
(isocyanate and polyol) are mixed in a high-
or low pressure mixing head and pumped
into a mold. The reaction occurs in the mold.
 RIM Operation
 in RIM operation, the raw materials are stored in tanks at controlled condition
before processing. temperature-controlled to the optimum processing
temperature as specified by the material supplier. This results in a consistent
manufacturing environment day in and day out, and will provide the desired
physical properties or cell structure. If the materials have other ingredients like
fillers or pigments that need to be evenly dispersed throughout the chemical
system, stirring devices or tank agitators are often incorporated into the tanks
to prevent settling or chemical separation.
 Recirculation
 The materials are continuously circulated at low pressure by the pumping
system and through the mixing head. When the materials reach the mixing
head, they are recirculated back to the day tanks and then through the same
path again back out to the mixing head. This low-pressure recirculation can be
used to maintain temperature, nucleation, and will help keep added ingredients
such as fillers or pigments evenly dispersed.
 Dispensing
 The two reactive materials, polyol and isocyanate, are kept separate until they
reach the mixing head. When it is time to dispense a shot or make a pour, the
machine automatically switches from recirculation to dispense mode. At this
point, the metering pumps precisely deliver the materials to the mixing head at
the required volume, ratio, flow rate and temperature. The chemicals are then
mixed by either high-pressure impingement (about 2500 psi) or in a high shear
dynamic mix chamber. The mixture is then injected into a closed mold or
poured into an open mold or cavity.
MOULDING VS RIM
 Benefits & Application of RIM
 1. Very large, lightweight parts
 The “flowability” of polyurethane components allows for even distribution of the
material within the mold. This lets you produce large parts, which is not
possible with injection molding. And because mold pressures are much lower,
large presses are not necessary.
 2. Low-cost molds
 Because of the low injection pressures of the RIM process, mold builders can
use a variety of less expensive mold materials including steel, aluminum,
Kirksite alloys, nickel, epoxy, silicone and fiberglass. The larger the mold, the
greater the savings.
 3. Freedom of design
 RIM lets you mold complex shapes or highly detailed parts with intricate design
features at relatively low tooling and capital equipment costs. Monolithic parts
or components with varying wall thicknesses can be designed into the same
molded part.
 4. Rapid prototyping
 Excellent working prototypes can be developed with lead times of 3-15 days, at
a cost much less than traditional injection molding. This also allows for
ergonomic or functionality testing prior to cutting actual high-pressure injection
molds. RIM is ideal for shorter production runs of less than 5,000.
 APPLICATION – RIM generally use for making flexible foam rigid foam , shoe
sole , automotive low density component
 Heating system in Moulding Machine

 Heating in moulding press is very important part of press. It provide energy

required for curing . Following media were use
 Steam heating –Steam pressure provide the temperature to platen. The
temperature of plate is directly related to steam pressure as shown in table
 Oil heating – Heated Oil supplied by thermal boiler provide the temperature
to platen
 Electric heating- Heater provide the temperature to platen and controlled by
temperature controller


Steam Pressure Temperature

PSI Kg/ sqcm Degree C Fahrenheit
20 1.41 125 258
30 2.11 134 274
40 2.81 141 287
50 3.51 148 298
100 7.03 170 337
Construction of Moulding
Press
Moulding press consist of
following unit
 Press column
 Press head
 Top plate having option for
heating
 Bottom plate having option
for heating
 Hydraulic unit which
generate the pressure

 Electric panel /Heating stem

 Manufacturing of Mould

The steel to be used generally is specified in mould design based on the stress, corrosion ,
abrasion requirement & machining limitation . The steel used in mould must be high
quality fined grained , free from dirt , porosity ,blow holes other defects. Most of moulds
for rubber product are manufactured by machine shops specialize in tool & die making .
A mould making shop required vertical & horizontal milling machine , Lathe ,shapers
,grinders planers drill presses , duplication & hobbing press

MATERIAL -Following Material being used to manufacture Mould for all type of Moulding
 For lost cost & Low productivity items – EN-8 or en24
 For medium cost & productivity – EN -31
For long life cycle & high cost – ( HCHC –high carbon high chromium)
For Rubber to metal items – Die steel
Dowel pins should made from high carbon steels and heat hardened for long life because of
high wear they receive . Bushing must be similar nature are recommended for lining
dowel holes
 Stage of mould manufacturing
 A. Design of Mould based on component design
 B. Plate resizing ,surface grinding & right angle
 C. Cavity making ( Machining )
 D. Cavity polishing & plating
 E. Mould matching & assembly
 F. Mould validation
 Moulding shrinkage

 Shrinkage is a term used to describe the deference in the dimension of

the mould and the article produced from it , when both measured at
ambient temperature .
 Determination –shrinkage factor must be determined for individual
compound if strict dimensional accuracy is required and can be
obtained by curing standard test specimen at production temperature
 The degree of shrinkage is primarily determined by difference of the
coefficient of expansion between vulcanization and the mould material
at given temperature
 The rubber part which fills the mould completely during vulcanization
shrink during cooling to room temperature more than the mould as it
has consider higher co efficient from latter .
 Thus degree of shrinkage increase with increasing difference between
the coefficient of expansion rubber material & mould material .
۞ The coefficient of expansion is higher if rubber content is higher
۞ The coefficient of expansion is higher if filler content is less or higher
the filler content lower the shrinkage
 Moulding shrinkage
calculation
☻shrinkage can be calculated by following formula
S = ∆T.∆A.K.∆F.∆H Where ∆T is difference between curing &
room temperature
∆ A is difference between co-efficient of expansion of rubber & mould mat.
K is the volume of rubber
∆ F is difference between co-efficient of expansion of filler & mould mat
∆H is difference between co-efficient of expansion of Acetone sol. Chemical and
that of elastomer
TABLE FOR LINEAR EXPENSION COEFFICIENT
Material Linear expansion coefficient
 NR 216 X 10¯6
 SBR 216 X 10¯ 6
 NBR 196 X 10 ¯6
 CR 200 X 10 ¯6
 IIR 194 X 10 ¯6
 STEEL 11 X 10 ¯6
 LIGHT METALS 22 X 10 ¯5
 FILLERS 5—10 X 10¯ 6
 Selection of Moulding Method

 The selection of moulding method is very important and being

finalize at the time product development stage ,it depend on the
following aspect .
 1.PRODUCT DESIGN & FLASH CRITICALTY
 2.PRODUCTION REQUIREMENT ( PER HRS )
 3.PRODUCT CONSTRUCTION (RUBBER TO METAL
BONDED)

 Low production requirement (but flash is not critical )- then we go

for compression moulding
 Low production requirement ( but flash is very critical )-then we
have to go for Transfer moulding .
 High production requirement but flash is not critical then we have to
choose either compression or transfer
 High production requirement but flash is very critical then we have
to go for injection moulding
 Fully automatic moulding – we have to go for only injection
 Rubber to metal bonding –transfer for low production & injection for
high production requirement
 Mould Release Agent

 Definition -
 Before loading a mould it is very important to treat the surface of the
cavities with a material which will facilitate release of vulcanization
from the cavity at the end of cycle . The material which prevent
sticking of rubber compound in the cavity are termed as release agent
.
 Chemistry of Mould release Agent – 1.Water solution of surface
active material such as Soap, wetting agent & synthetic detergent
 2.Silicone emulsion , aqueous dispersion of Mica, Talc, and fatty acids
also used as Mould release agent .
 3. Dry lubricant such as polyethylene
 Application – the amount of lubricant required is dependent on the
several factors such as mould complexity , type of release agent , type
of polymer & cavity surface e.g. Chrome plated mould cavities
required very less amount of release agent
 Mould Release Agent

Frequency Application –in majority cases it is necessary to apply

some release agent after each cycle .Unnecessary or frequent or
liberal application led to mould faults like crack, poor knitting flow
mark etc.
Disadvantage – The main disadvantage of use of release agent is the
build up of solid deposit on the surface of cavities .it is because of
constituent of release agent or mould release residue &
decomposition of mould release agent.

So these deposit must be removed frequently otherwise it will

leave the impact on the surface of products.
 Deflashing

 The extra material which present on parting line after moulding is

called flash and the process by which it removed is called deflashing
.so Unless Moulded articles have been manufactured by the flashless
moulding method ,the flash at parting line has to be removed . The
following method are generally used for removal of flash.
 1. Hand Trimming – by scissors, Knives.
 2. Machine Trimming- Roller trimming of oRings .
 3. Buffing – Buffing at parting line by Hard sand wheels, cloth or wire
brush.
 4.Punching – by hand single pcs die or by gang die for multicavity
removes flashes by mechanical press.
 5. Cryogenic Method-In this method the part are subjected to or
exposed to low temperature when thin portion of flash become brittle
then either by steel shot or plastic shot are used in tumbler which
break off the flash. ( Dry ice or Liquid Nitrogen is used for lowering the
temperature)
 Mould Cleaning
 The frequent mould cleaning is essential in the long run production to
ensure good appearance. This frequency depend upon the application
of components .
 The methods used for cleaning are manual scouring with steel wool
wire brush , sand blasting ,vapor blasting , electrolytic oxidation in
salt bath . & ultra sonic cleaning .
 First two methods are suitable for simple mould while other are
applicable to any size and configuration of mould
Ultrasonic mould cleaning method is latest development in cleaning ,
gives the following advantages:
 Short wash process leading to reduced time spent in cleaning
 No manual labour required. An operator is not
required when the machine is cleaning the mould.
 High levels of cleanliness give longer life in production.
 No abrasion of precise edges and surfaces gives longer mould life.
 No solvents needed because of aqueous process.
 Suitable for all moulds, large and small.
 Curing of Thick Article

 Laboratory specimen may be differ in thickness from production

part so adjustment must be made because of the slow transfer of
heat though elastomer composition .
 It is observed that at depth of one inch or greater , equilibrium reach
only after very long period . It impossible , therefore to obtain a
uniform state of cure through out the very thick section.
 For practical purpose a rule of thumb may be applied which state
that additional curing time of 5 minutes for each ¼ inch of depth to
the centre beyond the first quarter inch.
 For example if a compound developed an optimum cure in 30
minutes at 280 F as measured on astandards tensile sheet . A piece
of 2 inch thick would required 45 minutes at 280 F . This a common
generalisation because actual value may differ with the temperature
& heat conductivity of stock .
 The curing time of thick , large section may be reduced by electronic
preheating of blank by radio frequency genartor.
 Blooming

 The appearance on the surface of either a cured or uncured rubber

compound of one or more of the compounding ingredient or reaction
products thereof is referred to a blooming.
 It results from the migration of a material to the surface of elastomer
because it is present in excess of its solubility limits. They must have
some degree of solubility in the rubber in order to bloom. E.g. sulphur
will bloom if an excess is incorporated because it is soluble to some
extent .
 The Solubility of materials subject to blooming generally greater in
elastomer at mixing temperature than at room temperature .therefore
even through added amount soluble during mixing an ingredient may
bloom when the compound is cool at room temperature . Many
ingredient are are less soluble in cure component than in uncured
compound so blooming may occur only after curing.
 Solid & liquid both can bloom .
 Backrinding

 Rubber being a bad conductor of heat so it take time for heat to soak
through in to the central region ,If the compound cure on the out side
before the central area it get heated and expand thermally results
high pressure are developed in the central area ,This pressure may
overcome the moulding pressure and get release by tearing of the
vulcanized outer skin and throughing out the excess spew at the
parting line. If this does not occur during cure , at the time of opening
of press, the pressure gets release at parting line and the article has
torn edges at the parting line . This defect is known as Back Rinding .
Factor for back Rinding –1. High moulding temperature
 2. wrong mould design
 3. compound stock too fast
How to eliminate the Backrinding
 1. Preheating the stock by dielectric heating
 2. Use semiposetive mould s instead of straight mould
 3.Use delayed action accelerator like CBS, MOR
 4.Lower moulding temperature
 5. High heat conducting filler
 Moulding Defects

Problem Cause Corrective Action

1.Deep cut in the mould cavity 1.Cavity need to repair
2.Wrong Mould Design 2. Design of mould need to be modify
Products
tear 3.Part sticking to cavity 3.Conc. Of release agent to increase
off 4.Low tear strength of compound 4. increase Tear strength of compound
during 5.Product over cure 5. correct the curing time
Removal
6. carelessness of operator 6. training need to be given to operator
7.Complex design of part 7. Fixtures to be used for demoulding
1. Under cure of product 1.cure time to be modify
Porosity 2. Less Moulding pressure 2. Correct the m/c pressure
in
3.High moisture content in stock 3. Remove the moisture from R,M.
Product
4.Less Curing time 4.Cure time as per lab report
1. Under cure of product 1.cure time to be modify
Sticking
of 2. Low con. Of release solution 2.Conc. Of release agent to increase
rubber in 3.Dirty mould 3. Mould need to clean
cavity 4.Low plasticity of compound 4.Too soft compound to be avoided
 Moulding Defects
Problem Cause Corrective Action
1.Compound scorch 1.Check compound scorch time
2. High con, of mould release sol 2.Dilute the release solution
3.Compound stock is too fast 3. Reduced acc. Dosage or add retarded
Cracking
4.High viscosity of compound 4.Reduced the viscosity of compound
5.Less moulding pressure or 5. Increase the m/c pressure or reduced
compound too stiff the viscosity of stock

Rough
surface

Tool mark
on
Product
 Moulding Defect

Problem Cause Corrective Action

1.exessively soft stock 1.Reduces mastication
2. insufficient stock in cavity 2.increase weight of blank
Air
3.Less moulding Pressure 3.Increase the pressure
Trapping
4.Inproper shape of blank 4.Use proper shape & size of blank
5.Bumping to fast 5.Bumping as per instruction
1. Loading method is not ok 1. Proper loading method

Unfilled/ 2.Low Machine Pressure 2. Increase the Machine pressure

short 3.Gauge of sheet is less 3. Thickness of sheet as WI
filled 4. Less wieght 4.increase the weight of blank
5.scorch sheet 5. check the Lab report

1. Improper dispersion of curatives 1. Remix the compound stock

2. Less steam pressure 2.check the pressure gauge
Under cure
3. Less cure time 3. check the cure time

4. Lower platen Temperature 5.check the temp. of platen

 Model Quastion for PGDIRI
What are the different method of molding rubber component . Discussed the relative advantage & disadvantage . Give the neat sketch
1 wherever necessary.

2 What are the different method of molding rubber component .Describe the advantage of Transfer molding

3 What is mould shringake .How to measured it

4 Mould shrinkage increase with increase of rubber content in compound ,comment

5 write a short note on Blooming

6 write a short note on backrinding

7 write a short note on injection moulding

8 write a short note on compression moulding

9 write a short note on transfer moulding

10 what is the different technique used in mould cleaning

11 sketch and label the principal feature of simple upstroke hydraulic press

12 cycle time of different molding

13 what is the relation between steam pressure & temperature

14 write a short note on RIM

15 what are the limitation & advantage of a compression molding machine as compare to transfer molding machine

16 Describe the process of transfer molding of rubber compound with neat sketch

17 Describe the with the neat sketch the principle of operation & design of different injection molding system

18 Compare transfer & compression molding with respect to process advantage & disadvantage

19 what is are the essential feature of an injection molding . How does it differ from RIM

20 Describe the three method of removal of flash for molding with example

21 What steps would you take care & cleaning of mould

22 a article can be made from rubber mix by compression , transfer, injection . Discussed the factor for deciding