This trial version can use only a part of item.

Undercut Process

In this chapter you will learn about the process for an undercut part.

Undercut refers to the convex or concave area of part. When removing the part from
the mold, you need some device so that the part of the mold which contacts to the
undercut can be moved to remove the part from the mold since the part will not be
removable directly without the device.
This process is called Undercut process.
Undercut process uses different methods depending upon whether the undercut is
outside or inside the part.

Here are some examples of parts with undercut.

Push-pin Grip of a driver Grip of a cup

Now, let's learn about external slide core method, internal slide method, and hydraulic
cylinder method of undercut process.

External Slide Core Method

The external slide core method is usually used for the process of outer undercut.
Working along with the open / close movement of a mold, this method slides the slide
core to process the undercut.
The hydraulic cylinder method is also available, which will be explained in detail later

Slide Core Body Unit

The portion where the undercut process is performed linked along with the movement of
mold opening. The amount of movement of the slide core and the angle and the length of
the angular pin are key factors to this unit.
The locking block installed to the cavity plate receives the pressure from the injection
when closing the mold. Upon opening of the mold, the slide core moves backward by the
force from the angular pin and the spring, thus releasing the part.
As the hole will be misaligned and the angular pin will not be inserted if the slide core
moves too far backward, a core stop block needs to be installed.
This correlation is illustrated below.

(Click each name in the figure to display the

description.) The relief distance and the tilt
angle of the angular pin are as
follows:
S: Undercut amount
S1: Slide stroke amount
: Tilt angle of slide core
: Tilt angle of angular pin
S1 = S + 5mm up
= +(2 - 5 )
20
In order to prevent the slide
core and the loking block
from intervening with each
other in mold opening and
closing, make the tilt angle of
the angular pin smaller than
that of the locking block.
Also, a gap of 0.5mm is added
to the hole for angular pin for
errors occurring at processing.

Push Back Spring

The mass when the slide core is sliding varies depending on the direction of sliding.
<Example>
Suppose you install a 5kg slide core on the side parallel to the ground. How long should
the spring be? The stroke is 20mm.

D: Spring diameter
L: Spring free length (see a catalog by each manufacturer)
E: Spring close length (see a catalog by each
manufacturer)
F: Stroke
G: Length of shrinkage by slide weight
K: Spring constant (see a catalog by each manufacturer)
W: Slide weight

If using light load [K = 0.6kgf / mm] for spring:

<Example of Catalog>
Spring constant Free length Max. deflection Outer diameter
Usage count
(K) (L) (F + G) (D)
350,000
0.6kg/mm 65mm 32.5mm 16mm
times

To figure out the slide mass, it is 1.5 times the weight of the slide core:
W =5*1.5=7.5kg

As the length of shrinkage due to the weight of the slide mass

is: G = W/K :
G = 7.5/0.6 = 12.5mm
As the free length of the spring is: L = E + F + G :
L = 32.5 + 20 + 12.5 = 65. Referring to the catalog,
Use the spring with L = 65.

Answer D = 16 L = 65mm
Are there any calculations or
recommendations available to assist
me with selecting a Mold Spring?

Some customers call in for assistance

in selecting mold and die springs offered by DME. We present the following method. If you require additional
assistance, please do not hesitate to contact us.

Please note: the terms compression vs. deflection, and force vs. load are used interchangeably in this text.
The general formula for compression springs is

F = L * K where:

F = force or load [lb]

L = deflection or compression [in]
K = spring constant [lb/in]

Our catalog always lists the force at 1/10” compression, and we will call it DC (DME Constant). This force is
actually 10% of standard K spring constant defined in engineering calculations. The Engineering K is the theoretical
load at 1” deflection and the DC is the load at 0.1” deflection, so

K = 10 * DC

The DME catalog also lists the force at maximum allowable compression. The maximum compression is given as
the percentage of the Free Length, although the length and percentage are seemingly inconsistent units.

The force at 0.1” compression is also marked with DC in the attached chart. The 50% Maximum Recommended
Deflection means that the spring can be compressed by maximum 50% of the Free Length (we marked as FL in the
chart), 30% deflection is when the spring is compressed by 30% of its Free Length. Since the force is proportional
to the compression, the Force-Length graph is a straight line.
To better explain the numbers provided in the DME catalog, for example, let’s consider the SMD2030 spring as
shown on page 343 in the DME Mold Components catalog:
Catalog number: SMD2030

From the Catalog:

FL (Free Length) = 7.50 [in]

DC = 1.2 [lb] (load at 0.1” deflection) => K = 10 * DC = 12 [lb/in]
F50 = 45.0 [lb] (load at 50% deflection)

Let’s double-check the F50 force given in the catalog by calculation:

L50 = 0.5 * FL = 0.5 * 7.5 = 3.75 [in] (50% deflection)

This is 3.75 / 0.1 = 37.5 times more than the 0.1 [in] deflection, so the F50 force is 37.5 times larger than the force at
0.1” deflection:
F50 = (0.5 * FL) * K = 3.75 * 12 = 45.0 [lb]

If we want to know the force at a certain (different) deflection, we need to multiply this number with the K spring
constant.

For example: What would the load (force) be at 2.65 [in] deflection?
F = 2.65 * K = 2.65 * 12 = 31.8 [lb]

Usually we need a certain Pre-Load in the fully extended position in order to have a minimum force. The basic force
calculation is the same as above.

If we know the Travel (working compression) plus the Pre-Load, their sum is the Total Compression. The Total
Compression should always be less than or equal to the maximum recommended deflection. The Total Compression
(which is the Travel plus Pre-Load) divided by the percentage in the catalog gives you the minimum necessary Free
Length. If this Free Length is available in the catalog, this is the spring you need to pick. If this calculated minimum
Free Length is not available, you need pick the next longer standard Free Length.

Please note that if the calculated forces are acceptable, always try to use longer Free Length springs, so the Total
Compression is less than the maximum allowable compression. This increases the useful life of the spring.

Another example (the same spring):

Pre load: 0.125”

Travel (working compression): 3.4”

Spring can be compressed to: max 50% (from the catalog) = 0.5

Total Compression = Pre Load + Travel = 0.125 + 3.40 = 3.525 [in]

3.525 / 0.5 = 7.050 [in] required minimum Free Length => this is not listed in the catalog => pick the next longer
standard Free Length spring => 7.5 [in] => Recalculate the actual forces as described above with the K spring
constant given in the catalog for the 7.5 [in] Free Length spring.