Professional Documents
Culture Documents
Page No
Cylinder
d0 - diameter
l0 -
Cylinder
d0 - diameter
l0 - length
d02
.ln 1.599 (TM - Tc)
aeff. 23.132
(TD - Tc)
d02
.ln 0.975 (TM - Tc)
aeff. 23.132
(TD - Tc)
1
.ln
23.14 + 2 aeff
d02
l02
1
.ln
23.14 + 2 aeff
d02
l02
Sphere
d0 - diameter
d02
.ln
4.aeff. 2
Parallelepiped
b0 - width
h0 - height
l0 - length
1
1 2+ 1 2+ 12
b0
h0 l0
Parallelepiped
b0 - width
h0 - height
l0 -
1
1 2+ 1 2
b0
h0
Cube
b0 - width
b02
.ln
3.aeff. 2
(TD - Tc)
.ln
.aeff
.ln
d02
.ln
4.aeff. 2
2 (TM - Tc)
(TD - Tc)
.aeff
64 (TM - Tc)
3
(TD - Tc)
1
1 2+ 1 2+ 12
b0 h0 l0
16 (TM - Tc)
2
(TD - Tc)
1
1 2+ 1 2
b0 h0
1.178(TM - Tc)
(TD - Tc)
.ln
.aeff
.ln
.aeff
b02
.ln
3.aeff. 2
64 (TM - Tc)
3
(TD - Tc)
7.802(TM - Tc)
2
(TD - Tc)
64 (TM - Tc)
4
(TD - Tc)
512(TM - Tc)
6
(TD - Tc)
Wall Thickness
This calculation uses the narrowest wall as the one from which the "narrow beam" is created. A
vertical beam is treated as a beam fixed at one end & supported at the other. A "horizontal
beam" is treated as fixed at both ends.
For h1:
To calculate the wall thickness, imagine a strip 1cm wide cut out of the open end of the cavity.
If Y < Z, assume fixed ends, along a length of Ycm, and assuming a cavity pressure of 4000N,
A force of P = Y . 1cm . 4000 N then acts on the 1cm wide strip.
The wall is subject to a bending load. For the load calculation. The following calculations then
apply:
W = P .Y
12b
If Y > Z, assume fixed one end, along a length of Z cm, and assuming a cavity pressure of
4000N,
A force of P = Z . 1cm . 4000 N then acts on the 1cm wide strip.
The wall is subject to a bending load. For the load calculation. The following calculations then
apply:
W = P .Z
8b
If X > Z, assume fixed one end, along a length of Zcm, and assuming a cavity pressure of
4000N,
A force of P = Z . 1cm x 4000 N ( = 200,000 N) then acts on the 1cm wide strip.
The wall is subject to a bending load. For the load calculation. The following calculations then
apply:
W = P .Z
8b
Cooling Channel
For the calculation of Cooling Channel dimensions, the following calculations are used:
The heat content of the material being molded is:
q = A . th . dens . sph . (Tc - Tm)
where q is the heat content of the material being molded (J)
A is the mold part area
th is the part thickness
dens is the density of the material molded
sp is the specific heat of the material molded
Tc is the melt temperature
Tm is the mold temperature
The power of removing the heat in the cycle time is given by:
P = q/t
where P = power (W)
q is the heat content of the material being molded
t is the cycle time
The water flow rate required to remove this heat within the cycle time while only increasing the
water temperature a specific amount:
Flow =
P
litres/min
densw . spw . (Twout - Twin)
(=1000kg/m3)
where densw is the density of water
spw is the specific heat of water (=4183J/kgK)
Twout is the water temperature out
Twin is the water temperature in
The diameter to achieve the minimum Reynolds number for full turbulance is:
Re =
Flow . densw .4
Viscw . .d
The total length of cooling channel within the mold, required to extract the heat, given the
temperature rise within the cooling channel:
l=
Gate Size
For a circular die, the Newtonian shear rate is given by:
= 4Q
r3
where
Injection Time
The filling time of the mold is determined by the following calculations:
(dwpf/pfr)3
8. [(Tx-Tc)/(Tm-Tc)]3
where t is the filling time (secs)
dw is the material thickness (mm)
pf is the material flow length (mm)
pfr is the material flow path ratio
t=
Pillar Spacing
The following calculations are used as part of determining pillar spacing:
First load case-
dmax = w.L4
384EI
L
E = Modulus of Elasticity, I = Moment of Inertia, w = Pressue N/mm
If the deflection is excessive, place a support midspan:
w
dmax = w.(L/2)4
384EI
L/2
L/2
If this deflection is excessive, continue placing supports mid way until acceptable deflection is
achieved.
Runner Size
Consider the following runner design Tertiary runner
Secondary runner
Primary runner
To calculate pressure drop from across a runner layout, an assumption is made that all runners
are full-round type.
For each runner, the volume is given by:
V = r2 L
where r is the runner radius
L is the runner length
The total shot volume = (the sum of all runner volumes + part volumes)
The shear rate is:
Sr = 4Q
3
r
10
For the tertiary runner segment the total volumetric flow rate through each tertiary runner:
Q= (total shot volume - volume in the primary runner - the volume in the secondary runner)/[2.(injection time)]
The shear rate, shear stress and hence pressure drop through the Tertiary runner are then
calculated.
The total pressure loss from the sprue to each gate is then the sum of the pressure losses through
each runner segment.
11
Core Design
32. P. D . L
15 E. D4
4.62 x P. D . L2
3 E. D2
12
the point xs where the resulting force over the core acts is:
xs = L (D - L.tan a) / (3.D - 2.L.tan a)
where a is the taper of the core
L is the core length
D is the core diameter
The maximum contact pressure from shear is:
ps =
P. L (3.D - 2.L.tan a)
6.D.W
13