STEPS INVOLVED IN DESIGN

Step-1

 Study the component drawing, features, dimensions with tolerances and

material
 Give the shrinkage and draft allowances depends on material and angle
respectively
Step-2

 Decide the parting surface

Step-3

 Types of ejection and stroke length

 Stroke length = Component height + 10 mm
Step-4

 Mechanical construction (core and cavity) – MANUFACTURING PRIME FACTOR

 Decision on Integral type or Split type

Step-5
Calculation:

 Weight of the component

 Runner Length (depends on length, thickness, viscous or not, (Diameter))
 Runner always round or modified trapezoidal
 Gate Calculation – Pye (Gate land- 1mm)
 Gate type – (Submarine gate = Frustum of the cone)

Step-6

 Sprue Bush always 6-60

Step-7

 Ejectors always prefer bigger diameters

 Waterline
 Screws
 Decision on the above to obtain efficient cooling ( 5 mm gap should be
maintained)
  Collar for inserts should be thick, sidewise maximum 3 mm

Step-8

 Sprue bush, sprue puller type (type of ejection)

Step-9

 Blade ejectors- polishing, manufacturing aspect splits or integral type

Step-10
For bosses

 Core pin – Modified standard ejector pins

 Core pin should be 0.1 or 0.2 mm inside to avoid flash
Step-11

 Core and cavity holder decision

 Thickness of the back plates (below the holders), take directly from DME catalogue,
also misomi, etc
 If more holes in the holder, make it thick

 Minimum thickness of the holder should be 26 mm

Step-12

 Unsupported span between the spacers should be minimum

 Always give return pins (two or four return pins based on span)
 Ejector guide pillar (EGP) should be given, when the diameter of the ejector pin less
than 6 mm
 Ejector plate upto 300 x 300 mm - 2 EGP (diameter 16mm)
 More than that – 4 EGP
Ejector adaptor sketch

Sprue puller pin

D- Shaped
Step-13
Clamping

 1st preference-direct clamping (Refer Machine platen diagram)

Step-14
Machine selection : (Capacity should be more in the machine)

 Shot weight
 Plasticizing capacity
 Mould base size
 Clamping force

Step-15

 Decide on mould top / mould feet

 Water line – bottom or opposite to the operator

 CORE AND CAVITY MACHINING IS THE PRIME FACTOR

 REST LOOK FOR THE READYMADE SUPPLIER