TYPES OF MOULD (JENIS ACUAN)

There are two major types of molds:

1.

Two plate mold

2.

Three plate mold

TYPE OF MOULD

TWO PLATE MOULD

THREE PLATE MOULD

HOT RUNNER

HOT RUNNER

COLD RUNNER

COLD RUNNER

CONVENTIONAL SPURE

1. Two Plate Mold

A two plate mold is the simplest type of mold. It is
called a two plate mold because there is one parting
plane, and the mold splits into two halves. The runner
system must be located on this parting plane; thus the
part can only be gated on its perimeter.

1.1 Direct Gate Method:

Figure 1 shows a simplest structure only for a single
impression (parts) mould.

Figure 1: Direct Gate Method

1.2 Side Gate Method

Figure 2 shows the structure of side gate method for a multiimpression mould in general. This method is also used for a
single-impression mould in special shape.

Figure 2: Side Gate Method

2

1.3

Side Gate with stripper plate Method

Figure 3 shows the structure of side gate method with stripper

plate.

Figure 3: Side Gate with stripper plate method

2. Three Plate Mold

A three plate mold differs from a two plate in that it has
two parting planes, and the mold splits into three sections
every time the part is ejected. Since the mold has two
parting planes, the runner system can be located on one,
and the part on the other. Three plate molds are used
because of their flexibility in gating location. A part can be
gated virtually anywhere along its surface.

2.1 Pin Point Gate Method:

Figure 4, illustrates the structure for a single impression mould. In
general, this method is taken for a multi- impression mould and for
a multi-point gate.

Figure 4: Pin Point Gate Method

2.2

L type Runner Method;

STANDRD MOULD BASE (2 PLATE MOULD):

1. TOP CLAMPING PLATE.

2. LOCATING RING.
3. CAVITY PLATE.
4. CORE PLATE.
5. SUPPORT PLATE.
6. BOTTOM CLAMPING PLATE.
7. PARELLELS / SPACER BLOCK
8. EJECTOR RETAINER PLATE.
9. EJECTOR PLATE.
10. STOP BUTTON / STOP PIN.
11. PILLAR.
12. SPRUE BUSHING.
13. SPRUE PULLER PIN.
14. RETURN PIN / EJECTOR RETAINER PIN
15. GUIDE PIN.
16. GUIDE BUSH.

Function of Mold Base Parts ( FUNGSI BAHAGIANBAHAGIAN ACUAN)

I. T0P CLAMPING PLATE:
Memegang bahagian pegun/tetap acuan untuk plat pegun/tetap daripada
mesin suntikan.
(Holds the stationary part of the mold to the stationary platen of the
injection machine).

2. LOCATING RING OR SPRUE RUSHING RETAINER RING:

Di pasang ke dalam counterbore pada plat pengapit atas( top clamping) dan
digunakan untuk menempatkan acuan pada platen fix half, muncung dan sprue
bushing adalah sejajar/selaras.
(Fits into a counterbore in the top clamping plate and is used to locate the mold on the platen of the
press so the nozzle and sprue bushing are aligned).

3. CAVITY PLATE:
Sebahagian daripada bahagian bergerak acuan yang ke dalamnya peneraju atau
pemandu pin dipasang. Juga digunakan untuk memegang teras, blok rongga,
dan spru sesendal.
(Part of the stationary section of the mold into which the leader or guide
pins are mounted. Also used to hold core, cavity blocks, and sprue
bushing.)

4. CORE PLATE:
Plat bahagian atas pada acuan seksyen moveable . Merupakan garis perpisahan
daripada acuan dengan plat rongga penahan. Digunakan untuk memegang
sesendal pin peneraju dan juga teras dan rongga blok.
(Top plate of the movable section of the mold. Forms the parting line of
the mold with cavity retainer plate. Used to hold the leader pin bushings
as well as core and cavity blocks.)

5. SUPPORT PLATE:
Dipasang di belakang plat teras penahan untuk menjaga plat ini dari lenturan
dibawah tekanan yang tinggi digunakan dalam pengacuan suntikan.
(Mounted behind the core retainer plate to keep this plate from bending
under the high pressure used in injection molding).

6. BOTTOM CLAMPING PLATE:

Memegang bahagian bergerak acuan untuk platen boleh alih itu daripada
mesin suntikan.
(Holds the moving portion of the mold to the moveable platen of the
injection machine).

7. PARALLELS/SPACER BLOCK:
Dipasang pada plat pengapitan bahagian bawah di bawah plat sokongan untuk
membentuk ruang yang membolehkan bar lenting untuk bergerak apabila bahagian
produk adalah di tolak keluar.
(Mounted on the bottom clamping plate under the support plate to form a
space which allows the ejector bar to move when the piece parts are
ejected.)

8. EJECTOR RETAINER PLATE (Knockout pin plate):

Counterbore untuk kepala pin lenting, pelenting pin balasan, dan
pin alat untuk mengeluarkan spru.
(Counterbore for the heads of ejector pins, ejector return pins, and
sprue puller pin).

9. EJECTOR PLATE (Knockout bar ):

Diperketatkan bersama-sama dengan plat pelenting penahan untuk membentuk
satu unit. Bertindak sebagai plat belakang untuk pin dalam plat pelenting
penahan.
(Bolted together with the ejector retainer plate to form a unit. Acts as a back up plate for the pins in
the ejector retainer plate).

10. STOP BUTTONS/STOP PIN:

Dipasang pada bahagian bawah clamping plate, ia adalahuntuk plat pelenting.
(Pressed into the bottom clamping plate, they are lands for the ejector
plate).

11. PILLARS:
Bar bulat diletakkan di antara plat sokongan dan pengapitan bahagian bawah
plat. Ketinggian sama seperti persamaan. Diperketatkan untuk plat pengapitan
bawah, ia digunakan sebagai sokongan tambahan bagi plat penahan teras.
(Round bars placed between the support plate and the bottom clamping plate. The same height as
the parallels. Bolted to the bottom clamping plate, they are used as additional support for the core
retainer plate.)

12. SPRUE BUSHING:

Mencelah menentang muncung mesin suntikan. Mempunyai kon-lubang
berbentuk melalui mana bahan dipaksa ke pelari acuan.
(Butted up against the nozzle of the injection machine. Has a conical-shaped hole through which the
material is forced into the mold runner).

13. SPRUE PULLER PIN:

Pin terletak secara langsung di bawah pembukaan spru itu. Digunakan untuk
menarik spru dibentuk daripada sesendal selepas tembakan telah dibuat.
(Pin located directly under the opening of the sprue. Used to pull the
molded sprue out of the bushing after a shot has been made).

14. RETURN PINS (Ejector return pins) (Safety pins) (Push backs):
Terletak di plat pelenting penahan. Daya plat lenting dan pelenting
plat penahan, dan oleh itu pin lenting, pada kedudukan bawah seperti
yang ditutup acuan.
(Located in the ejector retainer plate. Force the ejector plate and ejector
retainer plate, and therefore the ejector pins, to the bottom position as
the mold closes)

l5. GUIDE PINS:

Keras dan pin keluli bawah ditekan ke dalam salah satu plat. menyelaraskan
kedua-dua bahagian asas acuan.
(Hardened and ground steel pins pressed into one of the plates. Align

the two halves of the mold base).

16. GUIDE BUSH:

Sesendal keluli keras dan bawah yang ditekan ke dalam salah satu
plat. Bertindak sebagai permukaan yang mengandungi untuk pin pemimpin.
(Hardened and ground steel bushings which are pressed into one of the
plates. Serve as bearing surfaces for the leader pins).

BAHAGIAN CORE DAN CAVITY

Cavity:
It is female part of the mould, which gives the external shape of the Component. Pockets,
Slots, holes are considered as Cavities. These are highly
polished to a mirror finish,
requires better finishing appearance on the outer
surface of the component
Core:
It is male part of the mould, which gives the internal shape of the Component. All
Projections are considered as Cores. These are
not required high polish as the
Component is to be sticks on to core.

Parting Surface:
That part of the mould plate, adjust to the impression, which butt together to form a seal
and prevent loss of plastic material from the impression.

10

EJECTOR SYSTEM

TYPE OF
EJECTION
PIN

STRIPPER

RING/PLATE

AIR

SLEEVE

VALVE

EJECTION SYSTEM
Plastic material shrinks on solidification this property compels plastic components
to sit tightly on the core and makes the removal difficult. The mechanism of
removal of moulded part from the core is called ejection system.
Injection moulding machines are provided with an automatic activation of an
ejector system which is situated behind the moving platen.
Ejector Grid:
Ejector grid is the portion of the ejection system which provides a space into which
the ejector plate assembly is mounted. This grid allows to and fro movement of
the ejector plate assembly within the grid.
The grid normally consists of back plate and spacers
TYPES OF EJECTOR GRID
In line Ejector grid: Inline type of grid consists of two support block and a back plate. Usually on top of
spacers core back plate is mounted.
This type of system is suitable for small mould when the distance between two
riser blocks increase additional block may be incorporated in between in stead of
increasing the thickness of core plate or core back plate. Sometimes additional
local support pillars may be used

11

Frame type ejector grid:

Some times grid is made by enclosing all the four sides which is called frame type
ejector grid.
It prevents foreign particles to enter and there by ensures smooth and accurate
functioning of ejector assembly movement.
It provides better support than inline grid.
Circular support pillar grid:
Ejection grid can be made by mounting circular support pillars on to the back plate
and enclosing these circular pillars by thin metal plates to prevent foreign
particles in ejection system used for large moulds.

12

Ejector plate assembly: It consists of retainer plate

which holds ejector element like pins, sleeve etc
and ejector plate, which
supports the ejector pin
etc and helps in actuating
pins.
An ejector rod is screwed
with ejector plate and
other end of ejector rod is
free which is pushed by
the actuating rod of the
injection moulding machine.
This assembly system shall
depend mainly on the size
of the mould. For smaller
mould and ejector rod
bush is fitted into the back
plate in which the ejector
rod slides.
For heavy moulds two or
four bushes are fitted in the ejector plate assembly itself. This assembly with the
help of guide pillars mounted on the back plate is made to slide to eject the
component.
Length of the ejector rod depends on the ejection stroke which is again dependant
on the max depth of hole of the plastic component.
After placing the ejector elements in the retainer plate, ejector plate is placed at the
back of retainer plate and screwed together tightly.
Thickness of retainer plate is governed by the thickness of head of ejector
elements length and breadth depends on the distance between ejector element
placed at max distance in the direction of x and y.
Thickness of ejector plate depends on the ejection force required to eject
component. Length and breadth is same as retainer plate.
Ejector plate assembly return system: In general two systems are used for the purpose of returning of ejector plate assy.
For the next shot.
One is push back system and other spring return system.
In push back pin system four pins called push back pin are fitted at four corners in
the ejector plate assy. Just opposite to these pins four more pins called returning
pins are fitted in the fixed half of the mould. When mould starts closing these
13

returning pins pushes the push back pins there by the ejector plate assy. Returns
to rear most position.
In spring return system the spring is fitted to the ejector rod supported by cap or
washer screwed at rear end of ejector rod so that it is slightly at compression
between ejector back plate and cap or washer. This system is used for smaller
mould. For larger mould more than one spring are used between retainer and
core back plate.
Push Back Return System:
Push back pins (return pins) are basically large diameter ejector pins fitted close to
the four corners of the ejector plate assembly. A cross section through part of a
mould which illustrates a push back pin is shown in Figure 5-13. In the molding
position as shown at (a) the push back pins are flush with the mould plate
surface. In the ejected position the push back pins protrude beyond the mould
plate surface (b). Thus when the mould is in the process of being closed, the
push back pins strike the fixed mould plate and progressively return the ejector
plate assembly to its original position (a).

Push-back return system

in close condition(a)

push-back return system

in open condition(b)

Spring Return System:

14

For small mould, where the

ejector assembly is of light
construction, a spring or stack of
Belleville washers can be used
to return the ejector plate
assembly. A typical arrangement
of the spring actuating method is
shown in Fig. 5-14. In this design
the spring is fitted on the ejector
rod. A cap is attached to the end
of the ejector rod to hold the
spring in position under slight
compression. In operation when
the ejector assembly is actuated,
the spring is compressed further.
Immediately the mould closing
stroke commences, the spring
applies a force to return the
ejector assembly to its rear
position.

The Basic Ejection Techniques: Pin ejection

- Stepped pin ejection
- D shaped ejection
Sleeve ejection
Blade ejection
Stripper plate ejection
DESIGN OF PIN EJECTION SYSTEM:
Cut = Thickness of plastic component
Dep = Diameter of ejector pin
Cd = Depth of hollow portion of plastic component.
Bs = Bearing surface of plastic component for

15

Side wall contact on the core.= Cid Cd (cm2) Thumb rule

Where,
Cid = Inside diameter of component = core dia
For every 100sqcm of bearing surface are 1sqcm of ejector pin is recommended
Total area of ejector pins = Bs
.
100
Max. Diameter of pin = Thickness of plastic component.
Nep = Number of ejector pins required
=

Bs4
100 (Dep)2

Bs
25 (Dep)2

Ejector pin should be placed at thicker portion of the plastic component and
should be placed in such a way that they do not get bend during ejection.
PIN EJECTION:
This is the most common type of ejection as
in

general

it

is

the

most

simplest

incorporated in a mould with this particular

technique the moulding is ejected by the
application of pressure a circular rod called
as ejector pin. The ejector pin headed to its
attachment to ejector plate assembled, the
working diameter of ejector pin is must be
good slide fit. In matching hole in the mould
plate, if it is not the plastic material with
creep through the clearance and the mass
of material will progressive of build of
bending the mould plate. The rare part of
ejector pin is fitted into a suitable hole which
is bored and counter-bored in retainer plate.
The rare case of ejector pin is back up of the
ejector plate. The accommodation provides must allow the ejector pin float way the feature
is necessary. As taken above, the ejector pin must be slide fitted in the hole in the mould
plate. The direction of movement of ejector pin is therefore controlled by this hole should
not be bored absolutely in right angle when the ejector unity assembled.
16

STEPPED EJECTOR PIN

Consider the case of where the small

diameter (3mm) ejector pin are required the
stepped ejector pins, now slender long
length diameter ratio in ejector pin have the
tendency to construct in use. It is desirable
to keep the working length to such as
ejector pin to minimum this is achieved by
designing ejector pins. A stepped ejector
pin manufactured from a solid rod,
alternating. It could have to be steel. The
small diameter portion being fitted as
suitable hole matching in large diameter
portion. The two parts will brazed together
.this later method has advantages that
should the ejector pin break only the
smaller diameter portion be remade. The stepped ejector pin is normally used face
pin for ejection of moulded bushes and ribs, note that the main ejection is provided
the standard plain type ejector pin. The length should be kept as short as possible.
This length is need only equal length in contact with the mould plate is kept into
minimum by in corpora ting a clearance diameter hole in the mould plate .A
suitable length the small diameter ejector pin is 5 to 6 times the diameter.

D- SHAPED EJECTOR PIN

This is the name given to a flat sided

ejector pin. It is the made quite simply
by machining. A flat on to a standard
ejector pin. It is used primarily for the
ejection for the thin walled box type the
procedure adapted for producing D
shaped hole as shown in figure.

Mark required position of ejector

pin.
Bore the required diameter hole
in the bolster.
Machining out the recess to
accommodate the insert.
Fit the inserts and hold back
with screws.

BLADE EJECTION
The main purpose of blade
ejector is for the ejection of
vary slender such as ribs and
other projection. Which can
not satisfactorily be ejected by
17

the standard type of ejector? The blade is basically a rectangular ejector pin,
while the blade ejector is machined solid rods
It is more usually fabricated the element in which case a blade of steel is inserted
into a slot machine into a standard type of ejector pin.
The blade may be pinned or alternated it may be brazed .the advantage of two
part construction is that the blade can easily replaced should become damaged.
The blade ejector element is fitted to the ejector assembled in a manner to that
described for the standard ejector pin. The rectangular plate ejector
accommodated in a completely shaped hole in the mould part.

THE SLEEVE EJECTION

The sleeve ejector is mounted into the ejectors pin plate like a conventional
ejector pin. The core pin which fits into the sleeve is mounted into the clamping
plate. As the ejector unit is activated, the sleeve pushes the piece part off the
core pin. Sleeve ejectors are used to push bosses and knob-like piece parts off
core pins. It is undesirable to allow the sleeve to be in contact with the core pin
over its entire length. To reduce frictional wear, to facilitate fitting and to lesson
the possibility of scoring, the surface contact between the two parts is kept to a
minimum.

18

Stripper Plate Ejection:

Stripper plate ejection is generally used
where ejector pin marks would be
objectionable on the piece parts and
where maximum ejection surface is
required. Stripper plates are used on
single and multiple cavity moulds. An
angle of approximately 5 is machined in
the stripper plate and on the plunger, as
shown in fig. 5-18. This prevents scoring

of the plunger as the stripper plate

moves in and out over the plunger.
The illustration shows two methods
of keeping the stripper plate from
coming completely off the plungers
and out of the mould. View at
shows the use of a stripper bolt to
limit the travel of the stripper plate.
View at B shows the return pin held to the stripper plate by a screw. This allows the
stripper plate and ejector plate to operate as a unit. In more complicated designs,
pull rods mounted in the stationary portion of the mould are used to activate the
stripper plate.

19

DESIGN OF KNOCK-OUT ROD

L = Length of the ejector rod.
= Height of ejector rod bush + Ejector stroke length +10mm
Ejection stroke length = Max. Depth of component +8mm
H = Thread diameter length
= Ejector plate thickness 3mm
= 15 to 20mm in general
D = Ejector rod diameter (Table-1)
d = Threaded diameter (Table-1)

Design of Knock-Out Rod & Bush

Table
L in mm
D in mm
d in mm
Up to 150

15

M10

150-200

20

M12

250-300

25

M16

DESIGN OF KNOCK-OUT BUSH:

H = Height of the ejector rod bush = Thickness of back plate
H = Thickness of collar = 4to 5mm
D1 = Internal diameter of bush= Outside diameter of ejector rod.
D2 = outside diameter of bush

= D1 + 8 to 10mm

D3 = Diameter of collar of bush =D2 + 6 to 8mm

20

TYPES OF LAYOUT OF CAVITIES

Cavities should be placed in such a way that when they are connected with sprue
through runner and gate will ensure the uniform filling of impressions.
In general multi-cavity mould having same shape and size of impressions are
connected through runners and gates of similar cross sectional area and length
and cavity should be placed at equidistance from the centre of the sprue.
For multi cavity mould having differently shaped impressions should be
connected through following system:

21

SYMMETRICALLLY AT SAME PCD LAYT-OUT OF A FOUR IMPRESSIONS MOULD.

R= Distance between sprue centre and cavity insert or distance at which cavity insert
to be placed from the centre of cavity holding plate
R = (CLd+5)/ (2Sinx/2)
CLd = Collar dia. of cavity insert.
C I = I.D. of cavity insert.
GL = Gate length (0.5 1mm)
CE = External dia of cavity insert.
X = 360/Number of cavities.
L = Runner length = R-(CI/2+GL)

Runner of different cross-sectional area but same length.

Gate should have similar cross-sectional area.
It is required when dissimilar cavities are placed at equidistance
of the sprue.
It is called runner balancing.

from the centre

Runners of same cross sectional area and length.

Gate should have different cross sectional area
This is done when dissimilar cavities are placed at equidistance from the centre
of the sprue.
This is called gate balancing.
Runners of different cross sectional area and length.
Gate should have same cross sectional area.
When cavities not placed at equidistance from sprue centre.

22

SELECTION OF RUNNER
Runner is a channel in the mould which connects the spur with gate
For a single day-light mould runner is made on the parting surface.
Runner may also be placed below the parting surface for complex mould.
Runner cross sectional shapes should be so design that it provide maximum
cross sectional area from the pressure transfer point of view and at the same
time it should have minimum contact on the periphery from maximum heat
transfer point of view.
Keeping the above in view the following cross
section of runner
are usually used:
- Round
- Trapezoidal
- Modified Trapezoidal.

Out of this round runner is most efficient from heat transfer point of view, but
cutting half of the runner in fixed half and other half in movable half matching of
two halves to get full round runner is difficult.
Instead of round runner if half-round runner is used it leads to problem of ejection
of component and feed system.
Round and Modified Trapezoidal runners are mostly used.
Runner length is kept as short as possible for rapid filling of cavity & to reduce
pressure loss. Corners formed at the junction of main & secondary runner should
be rounded off to reduce flow resistance.
23

CALCULATION OF RUNNER DIAMETER =

W X 4L
3.7

Where, w = wt. of comp. in gm, (volume X density)

L = runner length in mm
Runner efficiency =Area / Perimeter
Area is important to ensure the delivery of particular volume molten plastic material
into the cavity in specific time duration i.e. within injection time.
Perimeter of the runner profile is important as less perimeter is preferred for less
heat loss from the molten plastic material . There by maintaining proper melt
condition for smooth flow of the molten plastic through spure, runner , gate and
finally into the impression
Size of runner depend on flowing factors
Runner length
Wt. of moulding
MFI of the moulding
For high viscose material the runner size will be higher than the calculated value.
As the behavior of the plastic material has the restriction for easy flow .in addition
to the this care May taken in the flow path to maintain high surface finish there by
reducing the frictional flow restriction during the filling of the cavity

RECOMMENDED MAIN AND SECONDARY RUNNER DIAMETER

Weight of component
in gm
Up to 15

Runner length
in mm
Under 50

Runner Dia
in mm
2.5
24

Up to 15

Over 50

15-50

Under 50

15-50

Over 50

50-200

Under 80

50-200

Over 80

Over 200

Under 100

Over 200

Over 100

10

SELECTION OF GATES
Direct Sprue Gate
Application: for temperature-sensitive &
high viscose materials, high-quality parts
and those with heavy section.
Advantage : results in high quality & exact
dimensions.
Disadvantage: post-operation for sprue
removal, visible gate mark

Rectangular edge gate

The cross section being simple cheap to machine.

Gate dimensions can easily be modified.
All common moulding materials can be moulded by this.
Witness mark is left on the visible surface of component. For polystyrene,
acetal; it is more clear.
Use of soap case, Instrument box etc.
Normal size is (3 X1) mm Approx. for components up to 30gm wt.
Large components with hard flow material size may (10 X 8) mm.
Components can be de gated at machine by operator.

25

If,

h = Depth of gate in mm
Then,
A = Surface area of cavity (mm)
t = Thickness of component.
Lg = Land length in mm. (1mm to 1.5mm).
n = Material constant

Material

h = nt
W = nA
30

Value of n
26

Polyethylene, Polystyrene

0.6

Poly acetal, Polycarbonate,

Polypropylene

0.7

Cellulose acetate,Acrylic Nylon

0.8

Pvc

0.9

Overlap gate
In this type of gate the material coming from the gate is forced to impinge on an
opposing face of the impression and then the material progressively fills the
impression displacing the air.
If a gate is provided at the centre of on end of a solid rectangular block then the
material will enter the cavity with a jet form and will be solidified when comes in
contact of cool mould walls. After this the material required for filling the4 cavity
will flow around the original jetted material giving rise to a flow line.
It is used for block type component, radio knob etc.
Land length
Gate width
Gatelength
Gate Height

L1 = 0.5 - 0.75mm
W = nA/30 (n = Material constant)
L2 = n+W/2
h = nt (t = component thickness)

Fan gate
This is a modified rectangular edge gate.
The width of the gate increases with the decrease of depth towards impression to
get a constant cross sectional area through out the gate length.
Land length is little more than rectangular gate.
27

Used for the component having large volume and thin wall thickness like scale,
jeweler box etc.
Width of gate at bigger end, W = nA
30
Minimum depth of gate, h1 = nt
Maximum depth of gate, h2 = Wh1
D
Land length, L = 1.3 mm
Where,
N = Material constant
A = Area of cavity surface (mm)
t = Thickness of component (mm)

Diaphragm gate

It has a circular runner which is connected with the sprue centrally.

A gate is cut to connect the impression with runner.
If bore is not important gate is cut in the core which is easy to cut.
This is used for tubular shaped moulding in a single cavity mould (baby cycle
wheel, lamp shade).

28

Ring gate
In this case as usual runner is used with a gate all round the external periphery
of the component.
It ensures uniform feeding around the core pin.
Ring gated components are normally provided with stripper plate ejection.
The gate is in the form of a concentric film between the runner and impression.
Used in producing tubular mouldings like body of a float valve, water gun, plastic
bangles with multi impression two-plate mould.
L= Length of gate
h= Depth of gate
n= Material constant
t= Thickness molding

Film gate
Long rectangular type edge gate is called film gate.
Due to longer length wrap age of the component reduced.
29

Depth of gate is kept lesser than rectangular edge gate.

Runner is extended beyond the end of component.
It is used for thin walled large components like compact disc
cover, motor Cycle wind screen etc
Where,
h=Depth of gate, L= Land length of gate, n= Material constant
t= Thickness of component

Subsurface/Tunnel/submerged gate
When a gate is provided below the parting line is called a subsurface gate
It is a circular or oval gate
The runner is terminated at distance X from impression.
A secondary runner usually of conical form is machined at an angle to the
impression wall and is stopped short of the impression wall by a distance L.
It is used for moldings of injection syringe
L(Land length) = 1.9mm (minimum)
= 30 - 45

Angle subtended by centre line of

Secondary runner and impression wall

30

Application: primarily for smaller parts in

multy-cavity molds and for elastic materials.
Advantages: automatic gate removal.
Disadvantage: for simple parts only
because of high pressure loss.

31

Pin-point gate
Application: for multi-cavity moulds &
center gating.
Advantage: automatic gate removal.
Disadvantage: large volume of scrap &
higher mould cost.

TAB GATE
32

A projection or tab is moulded on the side of the component.

At right angle a rectangular gate is provided to join the tab and runner.
This is an alternative to overlap gate.
This was designed specifically for use with acrylic material to obtain stress free
high optical clarity.
This is used for solid block or thick type job where mark is allowed on side of the
component only, like clock glass, lens etc.
Tab width: Y= D
Tab depth: X = 0.9t
Tab length: Z = 1.5D
Where,
D = Runner diameter,
t = Wall thickness of plastic component

33

Application: for high-quality

technical parts, independent of
cycle time, also suitable for material
difficult to process
Advantage: no material loss from
runner system & automatic gate
separation.
Disadvantage: expensive moulds
especially due to control equipment.

Application: for materials with large

softening & melt temperature range&
rapid sequence cycles
Advantage: automatic separation
material loss from only after shut down
Disadvantage: danger of cold material
gating into cavity after interruption

34

COOLING SYSTEM

One of the most important acceptation of mould design is the provision of suitable
and adequate cooling arrangement in all injection moulding. Even though it
involves having a heated mould, the purpose of mould is to cool the molten plastic.
The means of cooling and insulated to prevent any escape of heat by conduction
or radiation. It would quickly cool the material will be mould and would no longer
fulfill its function. The cooling system is an essential mould feature, requiring
special attention in mould design. It should ensure rapid and uniform cooling of the
moulding. In design of mould component and layout of the guides and ejectors.
The allowance should be proper size and position of the cooling system. Rapid
cooling improves process economy, while uniform cooling product by different
shrinkage, internal stresses and mould will relies problem. In addition uniform
cooling ensure a shorter moulding cycle. A rapid and uniform cooling is achieved
by a sufficient number of properly located channels. The location of this channel
should be consist with shape of moulding and should be as close as cavity will
allowed by strength and rigidity of the mould.

Increasing the depth of cooling line from the moulding surface reduces the heat
transfer efficiency and to wide a pitch gives a non-uniform surface. A straight drill
line are preferred to bubblers they should be designed so that cross-sectional area
remains constant for entire circuit for tube bubblers area in the both side of the
tube should be equal material with higher thermal conductivity should be used. If
all the heat cannot be removed with a steel mould.

The described location of this heating-cooling phase is the mould close to where
most of the heat decapitated that is where the most of the material is located.

DESIGN OF COOLING HOLE:

dT= Diameter of cooling
hole
C = Distance between
centre of the cooling
hole and the surface
of the plastic component. = 2 to 3 dt
t = Thickness of the
plastic component
b = Centre distance
between two adjacent holes = max. 3dt
t in mm

dT in mm

Up to 2
2-4

8-10
10-12
35

4-6

12-15

STRAIGHT SECTION STROKE ROUND FLOW

These are the most common cooling channels found in the mould.
They are normally in series of drilling package of series and that are round in
diameter.

STROKE STRAIGHT SECTION RECTANGULAR FLOW

This type of cooling is used commonly found in backup plate rushed in mould
cooling.

These are the usually series of package but a rectangular shape that compromises
the cross-sectional area.

36

CIRCULAR SECTION ROUND FLOW

Circular sections are used to cool round plate, cylindrical stroke, cone shape cores
and cavity, etc. this arrangement, when properly interfered makes it possible to
follow close radius of the round core or cavity so that the distance of channel is
kept as a uniform depth.

37

CIRCULAR SECTION RECTANGULAR FLOW

These have the rectangular cross-section area for easy of machining.
BUBBLERS
This channel component are normally connected with straight section round flow.
They are used in cooling of pins, cores and deep draw area. Epical two channels
are parallel the surface of the back plate of the different depth. In bottom channel
tubes are screwed go to that top area to be cooled (pin and core) the inlet water
groove & lower channel fills the tube, and then overflow of the outlet each core
tube receives same cooling with maximum velocity.

BAFFLES

These constitute an alternating method for cooling pins, cores, and deep draw
areas, unlikely baffles they are tied together in series triple straight section stroke
the coolant extruded section that intersect with all of the baffles of the channels,
each baffle is a round drill section, with blade to divided in cross-section area in
half. The coolant flowing in straight section runs baffles blades, and makes it
bends to the baffles. In as much as the blade does not extend all the way of the
end of the baffle. If they run blow the back side of the plate, make another so turn
38

back into straight into as goes next baffle. This is an expectable method for smaller
number of cavity from side to side or very large diameter channels and baffles.

METHOD OF CONSTRUCTION OF MOULD

Integer Method
When core and cavity is made in a single block of steel without any bolstering is
called integer method. In these method two halves contains two solid blocks only.
USE

Single impression mould.

For more strength.

39

Big component.

Disadvantages:

Difficult to make multi-cavity mould because even if one part of cavity and core
becomes misaligned then the total block is rejected.

Higher machining cost because big machine with high accuracy is required.

High material cost.

INSERTED METHOD
In this method core and cavity is made from a small block of steel Known as core
insert and cavity insert respectively and fitted in core holding cavity holding plate.
USE

Multi impression mould.

Small components.
Replacement of insert easy.
40

DISADVANTAGES;
To machine recess for collar of insert machining cost increases and mould become
little weak.

DETERMINATION OF NUMBER OF CAVITIES

By Shot capacity
Ns = 0.85 W
m

Based on 85%of rated shot capacity

By Plasticizing capacity
Np = 0.85 X P X Tc
3600m

Based on 85%of rated plasticizing capacity

By clamping capacity
Nc =

C
Pc X Am

Where,
Ns, Np & Nc = Number of cavities based on shot, plasticizing and
capacity respectively.

clamping

41

W = Rated shot capacity for polymer in gm

m = Moulding wt per cavity in gm. (Volume* Density)
P = Rated plasticizing capacity for polymer (gm/hr)
Tc = Over all cycle time (sec)
C = Rated clamping capacity in tons
Pc = Clamping pressure in Tons/cmof projected area (0.630T/cm)
Am = Projected area of moulding including runner (cm)
*Moulding weight m is to be multiplied with a factor to add up
spur and runner weight

Molding Wt (g)
0.3-0.5

Factor
1.5

Molding Wt(g) Factor

5-10
1.15

0.5-1.0

1.4

10-20

1.10

1.0-3.0

1.3

Above 20

1.05

3.0-5.0

1.25

DESIGN OF GUIDE PILLAR

Diameter of guide pillar to be used depends on the size of the mould and side
thrust. Mould having deep and heavy cross sectional cores exerts more side
thrust.
Ps = Stem. dia of pillar ( P0 + 7 to 8mm)
Pc = Collar dia of pillar (Ps +2 tcp)
Tcp = Width/thickness of collar of pillar (from table)

Pillar stem. Dia .(mm) Ps

Up to 20

Collar thickness/Width(mm)

tcp / Wcp

42

20-40

40-60

60-100

100-200

Pl= Length of pillar (can be found out from assembly drawing i.e.
Perpendicular distance from guide pillar holding plate to guide bush
holding plate)
SIZE OF MOLD
(Length x Width)
100x100
100x150
150x200
200x250
250x300
300x400
400x600
600x700

WORKING DIA. OF PILLAR

(In mm)
10
13
16
19
22
25
32
38

DESIGN OF GUIDE BUSH

Bi = Guiding dia of bush = Guiding dia of pillar Po
Bo = Outside dia of bush = stem dia of pillar Ps.
BC = Collar dia of bush = collar dia of pillar Pc
Bl = Length of bush
= Thickness of mounting plate.

43

DESIGN OF LOCATING RING

D1d8 = Fixed platen hole dia 0.1mm (say 125)
d1

= Dsp = Collar dia of sprue bush +0.1mm

D2

= 7mm (for M6 screw)

D3

= Dia of screw head (10mm)

= 20, = 45

H1

= 10mm for small and 12mm for big mould

PCD = 70 90mm
44

= 6 8mm

= 4mm

= 6mm

TYPES OF LOCATING RINGS AND ITS USES

Reduced diameter type

Constant diameter type

Increased diameter type

Increased depth type

45

DESIGN OF SPRUE BUSH

The pact of mould having the tapered channel, connecting the cavity and machine
nozzle is known as sprue bush.
The taper channel is called as sprue.

46

Where,
Dsp= Collar dia. of spur bush (From table 1)
dsp= Outside dia. of spur bush based on spur dia (From table1)
tsp =Collar thickness of spur bush based on spur Dsp (From table 1)
Lsp= Length of sprue bush

As minimum as possible.
Normally 45 to 100mm
Equal to height from top surface of cavity plate to the top surface of top plate.

d = Depth of radius (1.5 - 4mm) Approx

R = Nozzle sitting radius (From table II)
= Nose radius of machine nozzle + 2mm
Dy = Smaller dia. of sprue (Nozzle orifice dia + 0.5-1mm)
di = Bigger dia. f sprue (calculate) (table II)
Di = 2 LSP tan/2+dy
Where,

Lsp= 60mm usually

= 2 to 5
Normally di is kept equal to dia of runner.
TABLE 1
d i (mm)
2.5 - 3.5
3.5 - 5.5
5.5 - 7.5

d sp (mm)
12
16
20

Dsp (mm)
24
32
40

t sp (mm)
16
18
22

d i (mm)
2.5 - 3.5
3.5 - 5.5
5.5 - 7.5

TABLE 2
47

Machine capacity Nozzle orifice Dia

In tons.
In mm.
30
3
80
3
130
5
180
5
300
5

Nozzle Radius
In mm.
10
10
10
10
10

TYPES OF LAYOUT OF CAVITIES

Cavities should be placed in such a way that when they are connected with sprue
through runner and gate will ensure the uniform filling of impressions.
In general multi-cavity mould having same shape and size of impressions are
connected through runners and gates of similar cross sectional area and length
and cavity should be placed at equidistance from the centre of the sprue.
For multi cavity mould having differently shaped impressions should be
connected through following system:
SYMMETRICALLLY AT SAME PCD LAYT-OUT OF A FOUR IMPRESSIONS MOULD.
R= Distance between sprue centre and cavity insert or distance at which cavity insert
to be placed from the centre of cavity holding plate
R = (CLd+5)/ (2Sinx/2)
CLd = Collar dia. of cavity insert.
C I = I.D. of cavity insert.
GL = Gate length (0.5 1mm)
CE = External dia of cavity insert.
X = 360/Number of cavities.
L = Runner length = R-(CI/2+GL)

Runner of different cross-sectional

area but same length.
Gate should have similar crosssectional area.
It is required when dissimilar
cavities are placed at
equidistance from the centre of
the sprue.
It is called runner balancing.
48

Runners of same cross sectional area and length.

Gate should have different cross sectional area
This is done when dissimilar cavities are placed at equidistance from the centre
of the sprue.
This is called gate balancing.
Runners of different cross sectional area and length.
Gate should have same cross sectional area.
When cavities not placed at equidistance from sprue centre.

49