DESIGN OF PLASTIC MOULD

PRESENTED BY AMIT S. GOSAVI

A) COMPONENT DRAWING

2D DRAWING OF COMPONENT

3D DRAWING OF COMPONENT

COMPONENT DETAILS 
     

MATERIAL - POLY PROPYLENE DENSITY - 0.96 gm/cm3 SHRINKAGE - 1% QUANTITY - X SURFACE AREA - 1000mm2 VOLUME - 2069.82 mm3 MASS - 1.98 gm

NOTE THAT DESIGNER SHOULD GET IT CLEARE FROM CUSTOMER THAT ON WHICH FACES PARTING LINE & GATE MARK ARE ALLOWED.

B) INJECTION MOULDING M/C

MACHINE DETAILS .SP30  SHOT CAPACITY 44gm  STOKE VOLUME -49gm  MACHINE .

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CORE CAVITY & SHRINKAGE ALLOWANCE .

CORE & CAVITY CORE: CORE:IT IS A PORTION OF THE MOULD PROJECTING OUTSIDE. AND MOLTEN PLASTIC IS INJECTED IN THE IMPRESSION. WHICH FORMS INTERNAL SHAPES OF THE MOULDING. CAVITY: CAVITY:- IT IS A PORTION OF THE MOULD PROJICTING INSIDE. AFTER INJECTION THE CORE & CAVITY INSERTS ARE EXPOSED TO COOLING MEDIA TO SOLIDIFY IT. THE SPACE FORMED IN BETWEEN CORE & CAVITY IS KNOWN AS IMPRESSION. WHICH WHICH FORMS EXTERNAL SHAPES OF THE MOULDING. EJECTION SYSTEM TO SEPARATE IT FROM CORE & GET EJECTED OUT OF THE TOOL. PLASTIC GETS SHRINK OVER THE CORE & THEREFORE IT NEED DRAFT ANGLE ON EXPOSED FACES. .

SHRINKAGE ALLOWANCE DECREASE WITH  Presence of filler . Cavity pressure (injection press. Component section thickness. Mould temperature. SHRINKAGESHRINKAGE-: volumetric change of molten plastic at the time of mould cooling.) Injection cycle time.. SHRINKAGE ALLOWANCE IS PROPORTIONAL TO .      Plasticizing temperature.

) d = Component dimension (mm. Per mm.The actual dimension of impression will be based on the original dimension plus the shrinkage allowance  D = [ d*(1+S) ] S = Shrinkage allowance (mm.) .) D = Final tool dimension (mm.

9998 = 2gm 2.98*1.96 = 1. . QUANTITY OF PRODUCTION DETERMINATION OF MOULDING WEIGHT MOULDING WEIGHT = VOLUME *DENSITY =(2069.82/1000)*0.STAGES INVOLVED IN INJECTION MOULD DESIGN 1.01 = 1. SHAPE & SIZE 2.98gm MOULDING WEIGHT PER CAVITY WITH LOSSES(W) = 1. STUDY THE COMPONENT DRAWING 1. TYPE OF MATERIAL 3. RATE OF PRODUCTION 4.

WE ARE GOING TO USE SP 30 MACHINE FOR 4.3. SHOT CAPACITY = SWEPT VOL.067 =7 .35 = 49 x 0.85 * W/M = 0.464/1.35 = 16.85*16. DETRMINITION OF NO. SELECTION OF INJECTION MOULDING MACHINE THE CURRENT COMPONENT.96 x 0. SELECTION OF TYPE OF MOULD FOR THE CURRENT COMPONENT WE ARE GOING TO DESIGN SPLIT CAVITY MOULD 5.98 = 7. x DENSITY x 0. CAVITY 1) DETERMINED BY SHOT CAPACITY SHOT CAPACITY IS THE WEIGHT OF PLASTIC INJECTED IN ONE STROKE OF PLUNGER.464 gm NS = 0.

06*(1000/3600)*15]/1.68 3 6.98 3.85*2. HEAT OF PLASTIC x MOLDING TEMP OF PLASTIC NP = = = = (0. PLACEMENT OF CAVITY .C. HEAT OF PP x MOLDING TEMP OF PP Sp.DETERMINED BY PLASTICISING CAPACITY PLASTICISING CAPACITY OF A MACHINE IS THE WEIGHT OF PLASTIC PROCESSED PER HOUR P. FOR PP x Sp.C. SELECTION OF PARTING SURFACE (S) FOR THE CURRENT COMPONENT IT IS FOUND FLATE PARTING IS BEST 7.= P.85*PC*TC) /3600*M [0.

) E= MODULUSE OF ELASTICITY FOR STEEL (2.003]1/3 =1.578cm =16mm Y= MAXIMUM DEFLECTION OF SIDE WALL (cm) C= CONSTANT P= MAX INJECTION PRESSURE (Kg/cm2.084*720*(4.1*106 *0.5)4/2. DESIGN OF CAVITY & CORE PLATE MINIMUM CAVITY WALL THICKNESS (t) =[ C *P * D4 / (E*Y) ] 1/3 =[0.8.1*106 Kg/cm2) D = THICKNESS OF IMPRESSION (cm) .

7 = 1.043mm GATE DEPTH = n*T = 0.7 = 0.981/2*27.51/4/3.7*2.75mm LENGTH OF GATE = 1.75 RUNNER DIA.87mm = 1mm D = DIA OF RUNNER (mm) W = WEIGHT OF MOULDING (gm) L = LENGTH OF RUNNER (mm) 10.=0.5 = 1.(D) n=MATERIAL CONST.7 A=SURFACE AREA .DESIGN OF FEED SYSTEM = W1/2*L1/4/3.9.7*20001/2/30 = 1.DESIGN OF GATEGATEGATE WIDTH = n*A1/2/30 = 0.

2*2.112/4*3. DRG & CAVITY LAYOUT) . SELECTION OF EJECTOR SYSTEM AS THE MOULDING IS CIRCULAR & FLATE SURFACE SLEEVE EJECTION IS SELECTED 13.4*1800 =1411.2kgf DC = MAX.11.DIA.45*0.14*N*FS)1/2 =(4 *14. Q=2/3*DC*H*PF D=(4Q/3. OF CORE (cm) H = HEIGHT OF CORE (cm) PF = CAVITY PRESSURE (Kg/cm 2) Q = SIDE THRUST (Kg) N = NO OF PILLAR FS = PILLAR MATERIAL 12. SIDE ACTUAITNG CAVITY IS REQUIRED (AS PER COMPO.14*16) =5mm Q=2/3*1.GUIDE PILLAR DIA.

METHODS OF ACTUATION SPLIT  SLIDING SPLITS CAM 1-:FINGER CAM 12-: DOG LEG CAM 3-:CAM TRACK SPRING HYDRAULIC  ANGLE LIFT SPLIT ANGLED GUIDED DOWEL CAM TRACK SPRING .

FINGER CAM ACTUATION SPLIT MOVEMENT CALCULATION ‡The distance traversed by each split across the face of the mould plate is determine by the length and angle of the finger cam  L=(M /sin ) + (2c /sin 2 ) L=splits movement. . The operating angle varies from 100 to 250. c=clearance. =angle of finger cam .

SPLIT LOCKING ARRANGEMENT ASSEMBLY) (go to 2D ASSEMBLY) .

vibration. gravity Spring detent method M=distance between the plunger and the depression is equal To split movement    .SPLIT SAFETY ARRANGEMENTS  Safety feature are necessary in moulds with can actuation Split may move out of alignment by shock.

.DESIGNS OF SLIDING SPLITS ‡NECCESARY ARRANGMENT WHILE SPLIT DESIGN 1-:Guiding split in desired direction. 3-: Locking the split in position. 2-:Actuating splits.

PART LIST             TOP PLATE BOTTOM PLATE BOTTOM BACK PLATE EJECTOR PLATE EJECTOR BACK PLATE EJECTION SLEEVE PUSH BACK PIN CORE PLATE CORE BACK PLATE SPLITS GUIDE BLOCK HEEL BLOCK .

           WEARE PLATE FINGER CAM CORE INSERT REST PAD GUIDE PILLAR GUIDE BUSH SACER BLOCK HOLLOW DOWEL SPRUE BUSH LOCATING RING ALLEN BOLT .

2D SPLITS .

3D SPLITS go to 2D ASSEMBLY go to 3D ASSEMBLY go to LINKS .

2D HEEL BLOCK .

3D HEEL BLOCK go to 2D ASSEMBLY go to 3D ASSEMBLY go to LINKS .

2D OF FINGER CAM .

3D OF FINGER CAM go to 2D ASSEMBLY go to 3D ASSEMBLY go to LINKS .

2D OF CORE INSERT .

3D OF CORE INSERT go to 2D ASSEMBLY go to 3D ASSEMBLY go to LINKS .

2D OF BOTTOM PLATE .

3D OF BOTTOM PLATE go to 2D ASSEMBLY go to 3D ASSEMBLY go to LINKS .

2D OF GUIDE PILLLAR .

3D OF GUIDE PILLLAR go to 2D ASSEMBLY go to 3D ASSEMBLY go to LINKS .

2D OF BOTTOM BACK PLATE .

3D OF BOTTOM BACK PLATE go to 2D ASSEMBLY go to 3D ASSEMBLY go to LINKS .

3D OF TOP PLATE go to 2D ASSEMBLY go to 3D ASSEMBLY go to LINKS .

3D ASSEMBLY .

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3D SPLITS 3D HEEL BLOCK 3D OF FINGER CAM 3D OF CORE INSERT 3D OF BOTTOM PLATE 3D OF GUIDE PILLLAR 3D OF BOTTOM BACK PLATE 3D OF TOP PLATE SPLIT LOCK .

 finger cam  finger cam with sensor  split core  assembly sequencing  2D assembly .

.THANK YOU«. .

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