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MouldsMOLDDESIGN

MOLDDESIGN
PostedbyadminonJuly22nd,2012
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Keytotheinjectionmoldingprocess,theinjectionmoldformsthemoltenplasticintothedesiredshape,providesthesurface
texture,anddeterminesthedimensionsofthefinishedmoldedarticle.Infacilitatingmoldcavityfillingandcooling,themold
alsoinfluencesthemoldingcycleandefficiencyaswellastheinternalstresslevelsandenduseperformanceofthemolded
part.Thesuccessofanymoldingjobdependsheavilyontheskillsemployedinthedesignandconstructionofthemold.
Aninjectionmoldisaprecisioninstrumentyetmustberuggedenoughtowithstand
hundredsofthousandsofhighpressuremoldingcycles.Theaddedexpenseforawellengineeredandconstructedmold
canberepaidmanytimesoverinmoldingefficiency,reduceddowntimeandscrap,andimprovedpartquality.
MOLDBASICS
Atthemostbasiclevel,moldsconsistoftwomainparts:thecavityandcore.Thecoreformsthemaininternalsurfacesofthe
part.Thecavityformsthemajorexternalsurfaces.Typically,thecoreandcavityseparateasthemoldopens,sothatthepartcan
beremoved.Thismoldseparationoccursalongtheinterfaceknownasthepartingline.Thepartinglinecanlieinone
planecorrespondingtoamajorgeometricfeaturesuchastheparttop,bottomorcenterline,oritcanbesteppedorangledto
accommodateirregularpartfeatures.

Choosethepartinglinelocationtominimizeundercutsthatwouldhinderorpreventeasypartremoval.
Undercutsthatcannotbeavoidedviareasonableadjustmentsinthepartinglinerequiremechanismsinthemoldtodisengage
theundercutpriortoejection.
TYPESOFMOLDS
Thetwoplatemold,themostcommonmoldconfiguration,consistsoftwomoldhalvesthatopenalongonepartingline(see
figure71).Materialcanenterthemoldcavitydirectlyviaaspruegate,orindirectlythrougharunnersystemthatdeliversthe
materialtothedesiredlocationsalongthepartingline.Themovablemoldhalfusuallycontainsapartejectionmechanism
linkedtoahydrauliccylinderoperatedfromthemainpresscontroller.

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Thethreeplatemoldconfigurationopensattwomajorlocationsinsteadofone.

Figures72Athrough72Cshowthemoldopeningsequenceforatypicalthreeplatemold.Typically,alinkagesystem
betweenthethreemajormoldplatescontrolsthemoldopeningsequence.Themoldfirstopensattheprimarypartingline
breakingthepinpointgatesandseparatingthepartsfromthecavitysideofthemold.Next,themoldseparatesattherunner
platetofacilitateremovaloftherunnersystem.Finally,aplatestripstherunnerfromtheretainingpins,andpartsand
runnerejectfromthemold.
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Unlikeconventionaltwoplatemolds,threeplatemoldscangatedirectlyintoinnersurfaceareasawayfromtheouter
edgeofparts:anadvantageforcentergatedpartssuchascupsorforlargepartsthatrequiremultiplegatesacrossasurface.
Disadvantagesincludeaddedmoldcomplexityandlargerunnersthatcangenerateexcessiveregrind.Also,
thesmallpinpointgatesrequiredforcleanautomaticdegatingcangeneratehighshearandleadtomaterialdegradation,gate
blemish,andpackingproblems.Becauseofthehighshearratesgeneratedinthetaperedrunnerdropsandpinpointgates,three
platemoldsarenotrecommendedforshearsensitivematerialssuchasCadonSMAandmaterialswithshearsensitive
colorantsorflameretardants.

Anotherconfiguration,thestackmold,reducestheclampforcerequiredbymulticavitymolds.Typically,multiplecavitiesare
orientedonasinglepartinglineandtherequiredclampforceisthesumoftheclampneededbyeachcavity
plustherunnersystem.Instackmolds,cavitieslieontwoormorestackedpartinglines.Theinjectionforcesexertedonthe
plateseparatingpartinglinescancel,sotheresultingclampforceisthesameasforjustonepartingline.Stackmoldsproduce
morepartspercyclethanwouldotherwisebepossibleinagivensizemoldingpress.
Author:ZHILIANMOULD
PageLink:http://www.zhilianmould.com/blog/molddesign/
CopyrightPleasemarktheoriginalinformationwhenreserved!
MFAandMFV
Materialpropertiesforpartdesign

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