MOULD MAKING & DESIGN

Present Approach Of Mold Design

Minimum of 3 months
Production Trials Corrections Trials Mold Manufacturing Order Material Mold Design Product Design

Activity

Lead Time

 To

reduce

yThe no of trials. yThe time to prove the Molds. yThe launch time of the new product. y Development Time. y Rejection Rate. y Production cost per Piece. To achieve optimum Wall Thickness. To optimise yProduct Design. yCycle time. yShot weight. y Mold Design. y Processing Parameters. To Increase yProfit. y Quality yEnergy saving. The bottom line: Cost savings Time savings reduce time to market! Create more reliable, better-quality designs

CAD/CAM Based Approach

Concept design 3-D modelling CAE analysis

OPTIMISATION

Manufacture

Resin Supplier

Part Designer

Part design & Resin supply & Material Compounding Compounding CAE & Shared Design Information

Process Molder Optimization

Mold Design Mold Designer

Mold Manufacturing

Mold Maker

Processing Time Analysis

Injection Time Holding /Packing Time Cooling Time Mould Open / Close Time 5 to 10 % 10 to 15 % 70 % 10 %

Cooling Time Constitutes 25 % of Total Production cost

Product, Product drawing & Production specification

Production Volume (requirement in time) Estimated Moulding Cycle (Cycle time) Is the Drawing clear ? Projection 1st angle, 3rd angle Tolerances Notes on Drawing Draft angle, etc. End use requirement Moulding Material Shrinkage

Factors to be considered during the Design

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Optimum production requirements/time Number of Cavities and Layout of Cavities Selection of Moulding Machine Layout of Cavities Type of Mould Design of Feed system Temperature control (Cooling system) Design of Ejection Design of Runner and Over flows Shrinkage consider by volume of Component Mould Material

Number of Cavities in a Mould Factors that controls the Number of Cavities in a Mould are:
a. On the Machine Side: Shot capacity Solidifying capacity Clamping force Pressure Size of the Platens b. On the Component Side: Projected area of the Moulding (Clamping force) Configuration of the Moulding (Pressure) Wall thickness of the Moulding (Pressure) Size of the Moulding (Mould size, Platen size & Flow length)

C On the Material Side Pressure Material Temperature Mould Temperature Density of the Material Bulk Factor of the Material

Shot Capacity

(Crystalline and Amorphous Materials) Total thermal heat content of the Material at the Moulding Temperature

Solidifying Capacity

INJECTION PRESSURE
Injection pressure inside the mould will depends on: The flow characteristics of the material Thickness of the moulding Cavity depth Projected area of the moulding Flow length Type, size and finishing of the feed system.

Layout of Cavities:
For efficient and Economical Layout the following points to be considered during Layout of the Cavities. Optimum disposition of Cavities Minimum Runner length Balanced Layout

Optimum disposition of Cavities Reduce the Mould size Reduce the Mould cost. Reduce the pressure drop

Minimum Runner length Fill all the cavities with required pressure and temperature. Balanced Layout Attain uniform clamping Prevent local flashing of the mould.

6. Design of Feed system

Feed system connects The flow of the material from Spreader to the cavity Feed system contains Sprue alone (Direct sprue gate) or Sprue, runner and gate in multi-impression moulds

(a) Runner Design The designer should keep in mind the following points during design of runner. Shape and Cross section of the runner Size of the runner Layout of the runner Shape and Cross section: Various shapes and cross sections are: Circular Semi- circular Trapezoidal Hexagonal Square Rectangular