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Understanding Injection Mold Design

Understanding Injection Mold Design

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Published by Ywaicheng
Author Herbert Rees has more than 50 years experience working with molders, mold makers, product designers, and mold designers in the injection molding field. Rees' intention is to explain what is truly important in a good mold design and to avoid overwhelming the reader with too many specialized details. This purpose is achieved nicely in a compact, well-written, and easy-to-read tutorial.
In his introductory chapter, the author gives a concise history of injection molding, mold making, and mold design. The topic of mold design economics is also discussed. The designer is asked to consider production requirements, product life, and part tolerance when designing the most cost-effective mold. Often an inexpensive mold will meet the needs of the customer, says Rees.
Author Herbert Rees has more than 50 years experience working with molders, mold makers, product designers, and mold designers in the injection molding field. Rees' intention is to explain what is truly important in a good mold design and to avoid overwhelming the reader with too many specialized details. This purpose is achieved nicely in a compact, well-written, and easy-to-read tutorial.
In his introductory chapter, the author gives a concise history of injection molding, mold making, and mold design. The topic of mold design economics is also discussed. The designer is asked to consider production requirements, product life, and part tolerance when designing the most cost-effective mold. Often an inexpensive mold will meet the needs of the customer, says Rees.

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Published by: Ywaicheng on Jun 15, 2013
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02/10/2014

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By: Herbert Rees
 
U
nderstanding Injection Mold Design
 
is the latest inthe excellent Hanser "Understanding" series of minitutorial books. This 115-page, fully indexed bookcontains one appendix, two tables, and 36 technicalillustrations that are almost completely free of errors.Author Herbert Rees has more than 50 years experienceworking with molders, mold makers, product designers,and mold designers in the injection molding field. Rees'intention is to explain what is truly important in a goodmold design and to avoid overwhelming the reader withtoo many specialized details. This purpose is achievednicely in a compact, well-written, and easy-to-readtutorial.In his introductory chapter, the author gives a concisehistory of injection molding, mold making, and molddesign. The topic of mold design economics is alsodiscussed. The designer is asked to consider productionrequirements, product life, and part tolerance whendesigning the most cost-effective mold. Often aninexpensive mold will meet the needs of the customer, says Rees.
Click here to order this excellent book... 
In the second chapter, Rees writes about starting new in the mold design field. Here the authorrecounts the obvious advantages of designing molds with the aid of a computer. He also stressesthat a good designer must have more than proficiency with a computer; a good designer must keepan open mind, understand what is required of the mold, and seek input from people with moldmaking and molding experience.Chapter 3 is a short chapter dealing with the basic aspects of an injectionmolding machine. Chapter 4 is devoted to the fundamentals of the injectionmold. It begins with sections on the mold cavity and core, parting lines,runners, and gates, along with simple but adequate diagrams. Clamping force,projected area, injection pressure, and their relationship to mold strength areexplained next. The need for and actions of mold venting are also discussed.Mold cooling is covered extensively, and eight rules of mold and plate coolingare detailed.Chapter 4 concludes with coverage of ejection (including nice illustrations of each ejection system),shrinkage, and mold alignment. The entire gamut of alignment devices—from nothing at all to leaderpins and bushings, taper locks, wedge locks, taper pins, and combinations of these devices—isreviewed. The strength of each device is covered, along with preferred applications. Whencombinations are used, the device that should do most of the alignment work is highlighted.Chapter 5 describes the steps that need to be taken before starting to design a mold, such asgathering information and preparing documentation. Questions to be considered include whethertolerances are shown on the product drawing, if they agree with the mold quotation, and whetherthey are reasonable and suited to the function of the part. Rees then recommends considering thecycle time, expected annual production requirements, and machine specifications. Of course themold must fit in the press, and there must be adequate clamping force and good shot andDesigners mustconsider productionrequirements,product life, and parttolerance for themost cost-effectivemold.
 
plasticating capacity. Core pulls, air ejects, valve gates, and other options may be present as thedesign dictates.Once these preliminaries are attended to, Rees details the mold design process, beginning withchoosing the mold base, which he calls a shoe. He discusses mold base steels, comparing theadvantages of standard prebuilt mold bases against mold bases built in-house. He then describesmold hardware, such as pins, bushings, ejector pins, and sleeves. Mold drawings, the stack layout,and product cross sections are touched upon next. Here undercuts, internal threads, unscrewingcomponents, and other features are illustrated.Hot runner, cold runner, and three-plate runner systems are presented with the help of illustrationson runner balancing, sizing, and layout. Other topics include venting, ejection, cooling, and moldalignment.Chapter 5 concludes with a discussion of mold layout and assembly drawings, bill of materials, andfinishing touches. In a very short Chapter 6, Rees recommends another design review with themolder after the initial sampling. Chapter 7 identifies typical designs, such as molds for containersand cup-shaped products, along with technical products.Chapter 8 is a short but important chapter on estimating mold cost, where nothing can take the placeof experience, according to Rees. Two widely used methods for cost estimating are explained.Chapter 9 describes machining operations. After a brief history of the mold making trade, Reesreviews such operations as EDM, jig grinding, CNC machining, and gun drilling. Materials selectionis also covered in this chapter, including two excellent tables on mold steels and properties of moldmaterials. The chapter ends with an explanation of the heat treatment process.An appendix lists sources for CAD/CAM programs, fluid flow programs, and stress analysis.
Understanding Injection Mold Design
packs a lot of information into a small volume. I recommendthis book for students as well as seasoned professionals, be they designers, mold makers, ormolders.
—Reviewer: Brent Borgerson, process engineering manager, Matrix Tooling/Matrix PlasticProducts, Wood Dale, IL,brentb@matrixtooling.com
.
 
Edition: FirstPublished: 2001Softbound 115 pagesAuthor: Herbert Rees
Description
  Today, most molders, including many mold makers, specialize in certain areas. There are specialistsfor thin wall molding, screw caps, large beverage container crates, pre-forms for PET bottles, smallgears, and many others. But, regardless of the size and type of the product to be injection molded,whether small or large, with single or multiple cavities, or who designs or builds the mold, the basicmold design principles are always the same. These basic design principles for good mold design are the focus of Understanding Injection MoldDesign. The designer will not find elaborate drawings of existing molds, but instead he or she willlearn about the many factors that must be considered when successfully designing a mold."I undertook to write this book essentially to explain what is really important in the design of aninjection mold, so that a good mold, best suitable for the application, can be created even if there isno precedent. It is meant to be used to guide the designer to think, and to frequently ask, why,where, when, how, etc., when considering the many possible choices before settling on a finalconcept." -from author Herbert Rees

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