4.

0 Number of cavities calculation

Shot weight calculation - Plasticizing capacity
calculation -Cycle time calculation - Clamping
force calculation - Determination of number of
cavities - Determination by shot capacity - by
plasticizing capacity- by clamping capacity
 NUMBER OF CAVITIES IN MOULD
DEPEND ON :---

1. PRODUCTION REQUIREMENT TO MEET TARGET.

2. MACHINE’S CAPACITY a) shot

b) plasticizing
c) clamping

3. MAX. SIZE OF COMPONENT AND THE MOULD THAT CAN FIT

INTO THE MOULDING MACHINE BETWEEN TIE RODS.

4. MAX. INJECTION PRESSURE REQUIRED TO FLOW AND FILL

THE PARTICULAR PLASTIC INTO MOULD
CALCULATION OF NUMBER OF CAVITIES IN MOULD
EXAMPLE : -- Following are data available
Components to be produced per day = 5000
Effective production time per shift = 7 Hours
Total no. of shifts per day = 2

Component Data : -- Material = Poly propylene

Density = 0. 9 gm. / cc. ; wall thickness = 2. 0 mm.
Weight of one component = 3. 6 gm.
Weight of feed system = 0. 9 gm.
Max. projected area of component = 12. 5 cm2
Projected feed system area = 2. 5 cm2
Machine Data :--- SP 30 Windsor machine
Injection pressure ( Max. ) = 1950 Kg. / cm 2
Shot capacity , Swept volume = 44 cm3
Plasticising capacity = 15 Kg / Hour
Safe no. of cavities in mould to utilize optimum capacities of machine
And also meet the daily Production is calculated as shown below : --

Machine’s safe Shot capacity = Vs X ρ X C X ή

Vs – Swept volume cm 3; ρ --Density of plastic gm./ cm 3
C -- Material constant ( 0.85 for crystalline & 0.93 for Amorphous)
ή – Efficiency of machine = 85 %
Hence safe shot capacity of m/c = 44 x 0.9 x 0.85 x 0.85
=28. 6 gm / shot
One component wt. + feed system wt. = 3.6 + 0.9 = 4.5 gm.
Hence no. of cavities as per shot capacity, =28.6 / 4.5 = 6

m/c’s safe Plasticising capacity (PP.) = Pl. capacity P.S.X QPS / QPP X ή
= 15Kg./hr.X 57/ 130 X 0.85
= 5. 6 Kg./ hr.
Assuming cycle time of 30 sec., no. of shots/ hr = 3600 /30 =120
Hence no. of cavities as per plast. capacity, = 5. 6 X1000 / (120x4.5)
= say 10 cavities
Contd.
CALCULATION OF NUMBER OF CAVITIES IN MOULD (contd.)

Clamping tonnage = no.of cavity x proj. area x cavity press.

For P.P. ,Inj. press. recommended is 700 to 1400 Kg./ cm2
Wall thk. being 2mm, pi .can be taken as 800Kg / cm2
Cavity press. = 1/ 2 or 1/ 3 of Inj.press.
Since PP. is easy flow material ,cavity press. = 1/2X 800kg/ cm2
Therefore Clamping tonnage = N x 15 x 400 /1000 tons.
Equating to machine’s safe clamp tons. of 30 x 0.85
No of cavities as per clamp. N = 30 x 0.85 x1000 / 15x400
say N = 4 cavities
The least no. of cavities 4, out of the three capacities is selected.
Check for production rate per day :--
Total productive time / day = 2x7 hours
Cycle time being 30 sec, no. of shots/ hour = 120
Therefore production /day = 14 x 120 x 4 = 6720 components
 SHRINKAGE AND ITS APPLICATION
SHRINKAGE :-- All materials when heated expand and on cooling
contract. The method of injection moulding also is subjected to expansion
of plastic during injection phase and its contraction during cooling for
solidification, Hence the volume change from mould dimension to the
part dimension causing SHRINKAGE of plastic.

SHRINKAGE of plastic depends on material and its processing.

Various factors that affect shrinkage are :---
1. Basic plastic material
2. Filler used and percentage
3. Part wall thickness
4. Melt temperature
5. Mould temperature
6. Injection pressure
7. Injection time
8. Hold on pressure
9. Hold on time
10. Gate area
 SHRINKAGE

MOULDING SHRINKAGE IS AFFECTED BY THE FOLLOWING : --

• Shrinkage increases with ----

• Increase in melt temperature
• Increase in mould temperature
• Increase in wall thickness
• Low injection pressure
• Shrinkage decreases with ----
• Low melt and mould temperature
• High injection pressure
• Long injection time
• Filler material and its content
 SHRINKAGE OF COMMON PLASTICS

PLASTIC MATERIAL SHRINKAGE

percent mm / mm
( A. B. S, ) 0.4 to 0.6 0.004 to 0.006
Polystyrene ( P.S.) 0.5 to 0.6 0.005 to 0.006
Nylon ( P.A.) 1.0 to 2.5 0.01 to 0.025
Acrylic ( PMMA ) 0.4 to 0.8 0.004 to 0.008
Polycarbonate ( P,C.) 0.6 to 0.8 0.006 to 0.008
Polyacetal ( P.O.M.) 1.5 to 2.5 0.015 to 0.025
Polypropylene (P.P.) 1.0 to 2.0 0.010 to 0.020
Polyethylene (L.D.P.E) 1.5 to 3.0 0.015 to 0.030
Polyethylene(H.D.P.E) 1.5 to 3.0 0.015 to.0.030
Poly vinyl chloride (PVC) 0.1 to 0.2 0.001 to 0.002
Application of Shrinkage-- Example

CUP
R3

Material : ABS
Shrinkage: 0.005 mm/mm
Component Drawing with shrinkage added
R3.02

EXAMPLE DIA. 50 ON COMP.

BECOME (50+50X0.005)=50.25
CORE INSERT
MATERIAL : MOLD STEEL
45 – 50 HRc

*
*
DIM WITH INDICATE
SHRINKAGE ADDED

*
CAVITY INSERT
MATERIAL : MOLD STEEL
45 – 50 HRc

*INDICATES DIM. WITH

SHRINKAGE ADDED
 Assy.
of
core &
cavity

Cavity Insert
Core Insert