INJECTION MOULD PROCESS,

MACHINE &
MOULD CONSTRUCTION

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 INJECTION MOULDING MACHINE

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Injection Moulding Machine

The main functions of an Injection moulding

machine is to take preheated granules from hopper,
heat it in a progressive way in the barrel, mix the
material homogenously by screw rod and then
inject the hot melt under high pressure through a
nozzle into a closed mould.

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 Mechanical Nozzle between
Toggle barrel and mold
(not shown)
Hopper
Heater
bands

Clamping
Unit Hydraulic
Unit

Mold cooling fed Barrel Screw

Hyd. from external unit (Ram)
Cylinder

Working of Injection moulding machine

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Plasticising

There are two types of plasticizing methods in injection

molding machines ,viz. Plunger plasticizing and Screw
plasticizing.
 Most efficient out of the two is the Screw type
which can produce high pressure and homogenous melt by
screw rotation as well as reciprocation.
 Plunger types are used for easy flow materials
and for smaller capacity machine up to 5 Tons.

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Plunger Injection Machine

Nozzle Torpedo Feed Hopper

Piston

Heater
Mould

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Plunger Type injection Moulding Machine

MOVING HOPPER
PLATEN
TIE RODS BAND HEATER
AUTO
FEEDER

TEMP.
CONTROLLERS

NOZZLE
SPREADER

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Reciprocating Screw Injection Machine

NOZZLE

MOLD HEATERS SCREW SCREW DRIVE

MOTOR

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Screw Type Injection Moulding Machine
(INJECTION UNIT)

FIXED
PLATEN

INJECTION BAND
CHAMBER HEATER

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Screw Rod Design
1.General purpose screw rod length is divided into three
sections viz.
a) Feed b) Transition and c) Metering

a). Feed section controls the quantity of granules taken

from Hopper every cycle.

b).Transition section converts efficiently the solid granules

into homogenously melted liquid.

c).Metering section controls the amount of material that

can be injected every shot.

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Injection moulding screw rod with
barrel assembly S Ø Hf
Hm pitch
δ
Ds

METERING
Section MELTING (Transition) FEED Section
(25%L) Section(50%L) (25%L)

L
Hm = 0.22 minimum flight depth
DS = Nominal Screw Dia.
( Metering)
Ø = 17.8 0 Helix angle (one turn L = Overall length
per screw dia.)
δ = 0.005 flight clearance (Radial)
Hf = Flight depth at Feed L / D = 16 : 1 to 24 : 1
Hf / Hm = 2.0 to 2.2 Compression ratio
Typical metering type injection molding screw & barrel
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Standard Nozzle

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Needle Shut Off Nozzle

NEEDLE

PLATE SPRING

USED FOR NYLON MATERIAL TO AVOID DROOLING

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Non return valve (ring type)

BACK PRESSURE

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Non return valve (ball type)
Non return valve
(ball type)

Rotation
stage

STOP PIN BALL

Reciprocation
stage

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Machine clamping systems
Hydraulic clamping system

Shut height
Daylight

TIE BAR
Moving Moving Fixed
plattenplatten Bed

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Machine clamping systems
Hydraulic clamping system

Daylight

TIE BAR
Moving Fixed
platten Bed

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Double toggle clamping

Clamped
position

Opened
position

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Single toggle clamping

Clamped
position

Opened
position

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Double toggle clamping

Clamped
position

Opened
position

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Injection moulding machinespecification

1.Shot capacity : --
Max.volume of plastic, machine can inject in one
shot,

Specified as swept volume vs,in c.c. depends on

density and melt temperature of the plastic.

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Injection moulding machinespecification

2. Plasticising capacity :
Max. amount of plastic (polystyrene), the machine
can bring to moulding condition in a given time.
Expressed as kg. / hour of polystyrene

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Injection moulding machinespecification

3.Clamping tonnage :
Maximum force machine can hydraulically
develop to clamp the two halves of mould against
the internal force due to injection of plastic,
expressed in tonnes.

4. Injection pressure : Max. pressure with which

machine can inject plastic through nozzle,
specified in kg/cm2

DEPENDS ON THE L / D RATIO OF SCREW ROD

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 Types of Molds
&
Details
of Construction
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 Session Objectives:

Types of Mould and Details of Construction

1. Construction
2. Materials for mould
3. Relationship of mould with part

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BASIC MOULDS / STANDARDS
What is Injection moulding ?
Process of Injection moulding is to melt Thermoplastic by
heating & force it into a closed mould.

Hot plastic takes the shape of mould cavity and solidifies inside
the cold mould.

Plastic loses heat and mould gets heated up.

Mould is opened sufficiently to eject the component.

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 Spacer
MOVING Guide FIXED
HALF Bush HALF
Rest
Button
Register
Ring
Ejector Guide
Pin pillar Sprue
Bush

Ejector
Plate
assy.

Core
Return
pin

PARTS OF A MOULD
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 Parting Surface (P.S)

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 Parting Surface (p.s.)

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Parting Surface (p.s.)

Parting Surface is the common meeting

surface of the two halves of Mould
 Seals the profile of Cavity and Core.
 Resists the force of Clamping.
 Accommodates FEED and VENT
Systems

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Parting Surface (Profiled)
Parting Surface

Cavity
Core
Cavity opened on one
half only to required
width and depth

Moulded
Component

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Proposal for Parting Surface (Profiled)
Cavity
Core insert

Core 1 Moulded 2 3
Component

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Parting Surface (p.s.)

 Enables easy manufacture, polish of core & cavity

 Allows measuring of core & cavity dimensions
 Helps to remove part from cavity
 Makes ejection of part possible from core
 Accommodates side core assemblies for ‘U’ cut features
on part.

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Types of Parting Surfaces

1. Flat or straight parting surface

2. Stepped parting surface
3. Angled parting surface
4. Complex or Profiled parting surface

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Types of Parting Surfaces
P.S. P.S. P.S.

Cavity Cavity Cavity

Core

Core Core

FLAT P.S. STEPPED P.S. ANGLED P.S.

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Angled Parting Surface

PART CAVITY
FIXED
MOVING OPENED HALF
HALF
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 Angled parting surface

F Clamp Force

Locked
mating face

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 F

Two rows for Equal balance of forces

BEST BALANCED
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 Local Profiled Parting surface

Component

Core

Core Local
Profiled P.S.

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Local Profiled Parting Surface

Gap

Core Cavity

Sectional
View

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Profiled Parting Surface

From the Profiled Parting Surface in each half , the

required cavity width and depth are machined.
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Selection of Parting surface

1. Select on maximum dim. of component

2. Select on Un important surface
3. It should ease manufacture of core & cavity
4. It should allow removal of Part from cavity
5. It should allow safe ejection from core
6. It should not result in any extra mark
7. Accommodate Feed, Vent & Side core

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Select Parting Surface & Show
Core and Cavity arrangement
Component No-1
R
Cavity

Parting
Surface
Core

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Component No -2
R R

Cavity

Parting
Surface
Core

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Alternate arrangement of Core & Cavity
Component No.2

Cavity

Parting
Surface
R R
Core

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 Component No-3
R

Cavity

Parting
Surface

R R Core

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 Alternate arrangement of Core & Cavity
Component No-3
R
R

Cavity

Parting
Surface

R Core

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 Select Parting surface for the
component shown

2D DRAWING OF COMPONENT

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 PARTING SURFACE
OF MOULD

EJECTION

SOLUTION
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 Select Parting surface for the
component shown

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 Feed system

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 Feed system
Feed is the path plastic melt takes from Nozzle of
the moulding machine to the cavities of the mould
through :
1. Sprue
2. Runner
3. Sub runner
4. Gate
without much loss of Pressure and Temperature

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Feed system

Runner Gate

Sprue
Cold slug well

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Sprue Design

Sprue is the divergent tapered portion of Feed system

that receives the hot melt from machine Nozzle.

 Sprue length to be minimum

 Taper of Sprue 3 to 5 degrees max.
 Sprue surface to be polished
 Smallest dia. of sprue taper > Nozzle hole Dia. by 0.5mm.
 Radius of sprue bush > Radius of Nozzle by 5mm.
 Sprue Bush collar min. thickness to be 15 mm.
 Sprue Bush length to suit reach of Nozzle

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Sectional Assembly of Mould

1. Key
1
4 2 2. Cavity
5 R 3. Sprue Bush
Ød 4. Core
3
6
5. Sprue Puller
6. Ejector Pin

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COLD SLUG WELL
FUNCTION:

1. To trap the cold material that the nozzle injects at the

start of every injection cycle.

2. To enable the Sprue to be pulled every cycle.

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Method of sprue pulling :

For pin ejection

a) Negative taper in Sprue Puller Bush

b) Sprue Puller cum Ejector Pin with ‘Z’ cut
c) Small ‘U ’cut grooves in Sprue Puller Bush

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Methods of Sprue Pulling
Ejector Pin __ve Taper Ejector Pin Groove

Cold Slug Cold Slug

Ejector Pin Cold Slug

NOT
RECOMMENDED

Gap
‘Z’ Cut
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Method of sprue pulling :

For stripper ejection

a) Ball nose end Puller pin with ‘U’ cut

b) Conical ended Under cut Puller pin
c) Negative Tapered Undercut pin

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Sprue pulling method in Stripper Ejection mould

Core Stripper Plate

Part

Core Plate
Sprue

Core Back Plate

Sprue puller

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RUNNER

• RUNNER is the portion of Feed system that connects

Sprue to Gate.
• It leads the melt from center of SPRUE up to the Cavity.
• It is an open channel machined in the Parting Surface.

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RUNNER

When the melt flows through the length of Runner, there will
be PRESSURE as well as HEAT losses which will make
the filling of cavity difficult.
Hence the length of runner should be as Short as possible.
Runner should have maximum Area for Efficiency of flow, at
the same time its Perimeter should be minimum.

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RUNNER

Efficiency = Runner cross sectional area

Perimeter
 Most Efficient Runner shape is a FULL
ROUND which is recommended for the difficult to flow
plastics ie. Viscous , such as Poly Vinyl Chloride, Acrylic,
Polycarbonate etc..

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RUNNER
 Other shapes of Runner used for easy flow
plastics are Semi Circular and Modified Trapezoidal

D
L L

Modified trapezoidal
Semi Circular

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Runner Size Depends on : -

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Runner Size Calculation
4
1. Runner Diameter √W X √ L
d =
3.7
d ---- Diameter of Full Round Runner , mm
W---- Mass of component + Feed system , gms.
L ---- Length of runner , mm
2 . Runner Diameter for Viscous Plastics
Increase by 25 % for Viscous plastics such as
P.V.C,P.M.M.A, P.C.etc.

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Runner Size Calculation
1) The formula gives ‘d’, diameter in mm
for the full round runner d

2) If semicircular runner is required

Use the relation D = √ 2 X d
D-- Semicircular Runner dia, mm D

3) For Modified Trapezoidal 10°

d
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GATES
1. GATE is the smallest cross section in the feed system
which connects runner into the cavity. Hence the
quantity of plastic flow into the impression is controlled
by gate

2. GATE freezes first, preventing plastic from over packing

the cavities thereby avoiding defects. Early freezing of
gate results in under filling of cavities.

3. GATE leaves a witness mark on the component where it

is disconnected and that should be acceptably small.

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Location of Gate Point on Component
1. Unimportant surface of component to be selected
2. Thickest section to be selected
3. Length-wise direction to be selected
4. Avoid gate caused defects, such as:

 Short shot
 Weld line
 Warping and
 Jetting

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1 . Sprue gate
SPRUE
 Suitable for feeding large GATE

size component in single cavity

moulds.

 Secondary operation
required to cut gate.

 Leaves a large witness mark

Eg. Bucket, Container

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2 . Edge gate
L
 Widely used gate.

 Simple rectangular shape of gate

that connects to side of moulding. H

 Easy to break.

 Leaves a small witness mark.

 Suitable for multi-cavity mould.

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3 . Over Lap Gate

 It is same as edge gate

but opened in the opposite side CAVITY

to that of cavity. Core

 Avoids defect ‘JETTING’.

OVERLAP
 Leaves projection above the GATE
component at gate point after de-
gating.

RUNNER

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4. Fan Gate

Runner
 Variation of edge gate.

 Suitable for thin, large sized

moldings that tend to warp or bend.

 Secondary operation to cut

gate required.

Fan Gate

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5. Film Gate

 Variation of fan gate.

 Suitable for filling thin, large area
moulding.
 Prevents warpage .
 Secondary operation needed to
cut gate.
 Leaves longer witness mark than
Fan type gate.
Film Gate
Main
Branch Runner
Runner

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6. Diaphragm Gate
 Suitable for moulding Tubular Spru
e
type components in a single cavity Gate
mould.

 Avoids weld mark and short fill.

 Secondary operation is a must

to cut the gate around I.D.

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7. Ring Gate
 Alternate gate design for
Tubular mouldings in a multi-
ANNUALA
cavity mould. RRUNNER
 Gate feeds plastic externally all-
around O.D.
 Avoids defect weld mark and
short fill.
 Secondary operation to cut gate
from O.D., a must.
 Wastage of plastic in annular
runner and gate is more than
others.
MAIN
RUNNER
ANNUALAR
RING GATE
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8. Tab Gate

Moulded
 Tab is an intentional projection Mould
provided on moulding into Cavity Tab Part

which plastic is injected at right

angle .
 Avoids the defect ‘Jetting’
caused by Edge gate on thick
moulded parts
 Secondary gate cutting
needed. Witness mark seen.
 Material wastage is more.
X = 0.9 t
Y=D
Z = 1.5D
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9. Tunnel Gate
 Gate specially devised to
get cut automatically in mould.

 Suitable even for tough plastics.

 Small witness mark and no

projection or pip at gate. cavity

 Gate opening is little complex. Core

 Also known as Submarine gate. Gate ,

sharp edge
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10.Submarine Gate
Electrode
Submarine
Gate opened Cavity
Runner opened
opened

Cavity Block

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Submarine gate through Ejector pin

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10. Winkle gate

 Suitable for Feeding plastic from Insert

inside of the moulding.
 The conical tunnel gate is
redesigned with a curved progressively
reducing cross sectional hole.
 Manufacturing of this complicated
gate profile is made between two inserts.
 Auto-degating of feed is achieved
By long ejection at sprue center.

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 Ejection

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EJECTION
Ejection function of a mould is delicate since the part while
solidifying shrinks to grip over the core tightly which makes
smooth release without distortion, strain mark, break or
damage of component very difficult.
Some design aspects that cause ejection difficulty are:-

 Parting surface selected in mould

 Straight surfaces of mould cavity & core
 Vacuum created by part sliding on core
 Undercut in part design
 Design of ribs, boss and surface texture
 Thin walled parts moulding

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 Types Of Ejectors

 Straight Pin Ejector

 Stepped Pin Ejector
 Sleeve Ejector
 Blade Ejector
 Stripper Plate Ejector
 Stripper Ring Ejector
 Stripper Bar Ejector
 Valve Ejector
 Air Ejection

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 Ejection type 1. Pin Ejector
Pin ejectors are the simplest and most widely used ejection
types to remove the moulding from core of the mould.
Pin ejectors are hardened cylindrical Steel pins held in
ejector plate and made to slide through the hole in core
insert.
Number of such ejector pins positioned on the core make
smooth ejection of moulding during the forward ejection
stroke, but mark of ejection will be visible.

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2. Sleeve Ejector
Sleeve ejector is a hollow cylindrical pin similar to pin
ejector. It is also held in ejector plate and guided over core
pin. During forward ejection stroke the sleeve pushes the
moulding out of the core pin which holds it. Best suited for
ejecting bosses on a component.

core pin
Sleeve ejector moulding

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Sleeve Ejector Assembly
Sleeve ejector

Moulding -ejected

Core pin

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Sleeve Ejector Assembly
Sleeve ejector
Moulding - ejected

Core pin

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3. Blade Ejector

For ejection of thin walled mouldings, instead of pin

ejector rectangular blades of thickness equal to part
and suitable width are used so as to increase the
ejection area.

LOCK PIN

BLADE
EJECTOR
HOLDER PIN

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4.Stripper Plate Ejection
 Best ejection arrangement for thin walled moldings.

 Increased area of ejection because of all- round

nature of ejection.

 Suitable for multi-cavity moulds of cylindrical parts.

 No witness mark seen on part at ejection portion.

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 STRIPPER BOLT
STRIPPER PLATE

COMPONENT

CORE

STRIPPER PLATE EJECTION

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 STRIPPER BOLT
STRIPPER PLATE

COMPONENT

CORE

STRIPPER PLATE EJECTION

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 Core Plate Stripper Ring

Stripper Bolt

Ejector
Plate

CORE INSERT
Stripper Ring Ejection
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 Core Plate
Stripper
Bolt
Stripper Ring
Ejector
Plate

CORE INSERT

Stripper Ring Ejection

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5.Valve Ejector

CORE INSERT

MOULDING
VALVE
EJECTOR

EJECTOR
PLATE

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6. Air Ejector
Core Insert

Pneumatic Actuator
Valve Ejector

Ram

MOULDING

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7.Air Valve Ejector
AIR VALVE 3 SLOTS
SEAL NUT SPRING

SEC-XX

AIR

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 VACUUMN
PART SLIGHTLY
EJECTED
AIR
POPPET
VALVE

STRIPPER

COMPRESSED
AIR SUPPLY

CORE

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Ejection Requirements Of a Mould
 The minimum Ejection required for a mould is
arrived at by the following thumb rule : -

 Minimum Area of Ejection = 1 % of total lateral

surface area of component in contact with Core.
ie. No. of ejector pins x Area of each ejector pin =
sum of lateral surface area of component in contact
with Core / 100

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Selection Of Ejectors
 Pin Ejectors are easy to manufacture to high accuracy and
its corresponding hole in Core to slide also economically
produceable.
 Provide more ejector pins than the calculated minimum
 Distribute the total no. of pins equally for uniform release.
 Parting surface ejector pins are more effective than face
ejectors.
 Position no. of ejection pins near Bosses, Ribs and other
obstructions.
 Thin walled components are better ejected by stripper or
sleeve
 Transparent components are suitable for Blade or Stripper
Ejection

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Ejection
Various ways of minimizing ejection difficulties
1. Apply releasing agent
2. Polish core in the direction of ejection
3. Provide suitable draft
4. Decrease cooling time of moulding
5. Decrease injection rate
6. Decrease holding pressure
7. Decrease holding time
8. Slowdown ejection speed
9. Increase mould temperature
10. Plating with low friction surface
11. Provide air poppets to release vacuum

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 Mould Cooling

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Mould Cooling
Moulds need cooling for :-

1. Constant Mould Temperature for uniform Quality

2. Reduced Cycle time for Productivity

3. Improved Surface Finish without Defects

4. Avoiding Warpage by uniform mould surface temperature

5. Long mold Life

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Mould Cooling

Cooling depends on :-

1) Cooling Medium used

2) Conductivity of mould steel
3) Room temperature of moulding shop
4) Diameter of cooling circuit hole
5) Length of cooling circuit
6) Position of cooling hole from mould surface
7) Flow rate of cooling medium

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Mould Cooling

1. Cooling Medium :-- Generally Water is used for cooling

Moulds as it is available plenty. It can be cooled or chilled
and recirculated conveniently under pressure.

2. Conductivity of Steel used for Mould :-- Efficiency of a

mould to cool the surfaces of Cavity and Core depends on
the Steel’s Thermal Conductivity i.e. the rate at which heat
is removed from Hot plastic and conducted to cooling
medium, water.

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Mould Cooling

Material Conductivity
( cal / cm.sec. 0C)
Tool steel ----------------- 0. 115
Copper ----------------- 1. 043
Beryllium copper ----------------- 0. 24
Aluminum ----------------- 0. 502

Hence mould with Cores and Cavities made out of

Berilium Copper can be run at a faster automatic
cycle.

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Mould Cooling

3. Room Temperature affects the cooling rate of moulds.

Heat transfer by conduction ,Convection and Radiation
take place from the Hot Mould to the atmosphere whose
temperature varies according to weather conditions.

4. Diameter of Cooling Hole : ----

The bigger the dia. of cooling hole, it allows more
quantity of water to flow through in a given time. For
efficient conduction of heat TURBULENT FLOW
( Rynold’s No. above 3000) of water is recommended.
Minimum hole size used in moulds : 6 mm Dia.
Maximum hole size used in moulds : 12 mm Dia.

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Mould Cooling

5. Length of Water Circuit : ---- More length of water

circuit if provided cooling effect will be more but size of
mould plates selected restrict the length. Parallel circuits
are more uniform in cooling than Series. General practice
is to design with maximum length possible and while try
out eliminate those which are ineffective.

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Mould Cooling
6. Position of Water Hole :--- If the hole is very close to
Mould surface, ‘OVER COOLING’ or sudden chilling will
take place. If placed far away ,cooling effect will be nil
and component distortion can occur. A safe distance of
about 8mm to 10 mm is recommended between mould
surface and Hole edge.

7. Flow Rate : --- The rate of water flow through the

mould depends on Hole diameter and Pressure. If it is
possible to circulate more water, cooling experienced will be
effective.
A normal flow rate of 80 to100 litres/min.is recommended.

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CAVITY PLATE COOLING

x
WATERHOLE
DIA.
CAVITY CAVITY x
PLATE x
x

PLUG

OUTLET WATER
INLET
CONNECTOR

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 DIRECT COOLING OF
CORE INSERT
Core insert is provided with a WATER
central hole which is plugged OUTLET
tightly and fitted with a Baffle to CORE PLATE
divide hole into two equal sections.
BAFFLE
Water enters inlet hole in
core plate, enters central
PLUG
hole in the core insert, gets
deflected by Baffle towards HOLE AT
the face of core, cooling all CENTER OF
CORE CORE INSERT
internal surfaces and then
INSERT
passes through outlet hole.
‘O’ Rings seal the leakage ‘O’ SEAL
of water through press LOCK
fitted face of Core insert PIN
and Core plate. WATER INLET

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 CORE
INSER
WATER
T
OUTLET

BAFFLE

HOLE IN CENTER OF
CORE INSERT
WATER
INLET

BAFFLE COOLING ARRANGEMENT – DIRECT

COOLING OF CORE INSERT

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 PROJECTION

assembly before press fitting

O’ SEAL
core insert to core plate

CORE
INSERT CORE PLATE
Slot for ‘O’ Seal placement
‘O’ SEAL
assembly after press fitting COMPRESSE
core insert to core plate D

CORE INSERT

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 WATER OUTLET

WATER
GROOVE

CAVITY
CAVITY
INSERT

‘O’
SEAL CAVITY
WATER INLET
PLATE

115
ANNULAR COOLING OF CAVITY INSERT
 WATER
CORE OUTLET
BACK CORE INSERT COOLING
PLAT ( BUBBLER SYSTEM )
E CORE
INSERT

BUBBLER PIPE

CORE ‘O’ SEAL

PLATE

WATER INLET
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 DIRECT COOLING OF CAVITY INSERT

CAVITY PLATE

PLUG

WATER NOZZLES
SCREWED
CAVITY
OUTLET

CAVITY INLET
INSERT

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 Standard
Mold Base

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 BP SB CB CR CV TP

EPL

MOULD
Sectional View
4 EP ER

SMB SMB

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 L
X
R BP SB CB CR CV TP

d1
P

EPL
W
M T

W1 = W+50
Y
4 EB ER

V
L1 = L +50

SMB

SMB
Standard mould Set
(Assembly)
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 P
M
MOULD SET

Plan View

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 Guide Pillar

S.No d1 d2 d3 A B
1 11 or 12 18 22
To Specify write 06-03-01/Ød1/A/B
2 15 or 16 24 28 Material : E230
3 19 or 20 28 32 Case Hardened to 0.8 depth
4 23 or 24 32 36

5 33 or 34 42 46

6 41 or 42 50 54

7 49 or 50 60 64

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 Advantages of Case Hardening Steel

 Tough Core and Hard outer surface

 Higher Hardness ( up to 64 HRc ) than through

hardening steel, for longer life

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 Guide Bush

S.No Ød1 Ød2 Ød3 B

1 11 or 12 18 22
2 15 – 16 24 28
3 19 – 20 28 32
4 23 – 24 32 36
5 33 – 34 42 46
6 41 – 42 50 54
7 49 - 50 60 64

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 Ejector Return & Guide

Mould Base Return Pin Dia

Series
Up to 2020 12.5
2525 to 3545 16
4050 Onwards 20
Mould Base Ejector Guide
Series Pin Dia
Up to 2525 16
2530 to 3535 20
3540 Onwards 26

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 Sprue Puller Bush

To specify write 06-

03-11/D/L
Material : K 605 or EN
30B or EN 24

ød4
øDH7 d1j6 ød2 ød3 l1 l2 L

2.5 12.0 3.5 16.0 3.0 3.0 10.0

4 13.0 5.0 17.0 4.5 4.0 13.0
5 14.0 6.0 18.0 5.5 4.5 15.0
6 16.0 7.0 20.0 6.5 5.0 18.0
8 18.0 9.0 22.0 8.5 6.0 20.0
10 20.0 11.0 24.0 10.5 7.0 22.0
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 Sprue Bush

To specify write 06-03-22/No/L

Material : EN 30 B or K605

No D K d1 d2 L R t Remarks
1 16 SP 30
3.5 SP 80
2 22 To suit
Cavity SP 130
3 38 22 5.5 18 18 8.0
Plate FR 40
4 32 5.5 SP 180
Thickness
FR 85
FR 110

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 Register Ring

S.No ØDf7 Remarks

1
110 For SP 30

For SP 80 II &
2 120
SP 130 II
For SP 80 I &
3 175
SP 130 I
4

To Specify Write : 06-03-16/ØD

Material : MS

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 Ejector Pin

To specify write 06-03-27/ød X L

Material : Hot die steel
Hardened tempered & ground
Harden 66-68 HRc(in case nitriding

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 Ejector Guide Pillar
d l1 L
12 20
20
16
30
20
20 30
40
20
26 30
To Specify write 06-03-41/Ød X L 40
Material : E230
Case Hardened to 0.8mm Case Depth

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 Ejector Guide Bush

To Specify
write 06-03-42/Ød1

d1 d2 d3 L1 L2
12 20 24 27 15.5
16 24 28 27 15.5
20 28 32 29 17.5
26 34 38 40 25

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 Factors influencing selection of
Materials for Moulds
1. Quality of mould- (dim, appearance of part)
2. Repeatability ( long life)
3. Uniform structure (Fine grain)
4. Free from internal defects
5. Machinability
6. Polishability
7. Weldability
8. Wear Resistant (Hard)
9. Tough (Impact Strength)
10. Thermal conductivity & Strength
11. Corrosion Resistant
12. Cost & Availability

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 Steels for Moulds

1. Structural --- Mould Base & Plates(MS, C45, St.42 En8)

(Medium Carbon Steel, Annealed and Stress Relieved)
2. Material for Core and Cavity Inserts --
P20,En 30B, S7, H13 & 420SS
( Ni Cr Mo Steels)

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  Alloyed Tool steels are selected to meet specific
performance requirements such as:
 High Hardness & Wear Resistance for Parting line
durability
 High Toughness to resist Mechanical Fatigue (HRc
55 to 58 preferred )
 Corrosion Resistance to protect die surface from
plastics like PVC,POM
 Abrasion Resistant against surface wear by Glass
or Mineral filled plastic

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 Commonly used Mould Steels for Cavity & Core
P20 --- Prehardened (HRc 30-32), very Tough
Fairly easy for machining, used for Small Cavity & Core inserts
as well as Large dies exceeding 300x 300 mm sizes (without
HT).
Life up to 5,00,000 Shots economical
H13 --- ORVAR Supreme ( ESR)
Toughness & Ductility -Excellent,
Thermal Shock & mech. Fatigue resistance - High
Large Cavities above 200 x200 mm sizes made by Oil
quenching.
Can be Nitrided to max.66-68 HRc
Dimensional Stability – Good , Gloss – High
Applications :Cavity inserts, Ejector pins, Core pins and Sprue
puller pins
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 Commonly used mould steels
420 SS or Stavax Supreme (ESR)
Corrosion Resistance -- Good
Through Hardening -- Excellent
Toughness & Ductility – Good
Wear Resistance -- Good
Polish ability -- Excellent
Photo Etching & Texturing – Excellent
Applications :--- Corrosive Plastics ( PVC, POM) Optical
Parts (Camera, Lens, Syringes)
Glass Filled Plastics : Large Optical Parts
High Glossy Surfaced Parts

* Supplied in Fully annealed state; Hardened at 980°C to

1050°C, Air Quenched (HRc 58 – 66)
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 Commonly used mould steels
S7 ( Cr, Mo, V alloy with 0.5 % C)
Hardness achievable -- 55-57 HRc (Max)
Thermal Shock Resistance -- High
Toughness --- High
Machining -- Easy
Small cavities -- Air Quenched
Large Cavities – Oil Quenched
MS – Mild Steel
C45 ---- Carbon Steel with average carbon 0.45%
St. 42 - Steel having minimum Tensile Strength of 42 Kgf / mm 2
En 8 - Free Cutting Steel commonly used for Holder, Clamp or
Retainer plates of mould
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 Types
of
Molds
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 Parts of two plate mould

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 Three plate Mold – Closed condition

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 Three plate Mold – Open condition

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 Three Plate Mould – Closed Assembly
X

Stopper Runner
plate

Core insert

Core Plate Cavity

plate
Swing
Hook Lock Stripper
Assy. Plate
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 Mould Opens ‘X’ at First Parting Surface

Feed System Pulled to

moving cavity plate
back side and the Pin
point Gate is cut

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 Second Parting Surface Opens

Spring hook
Lock released

Feed Ejected
in First P.S.

Component
carried by
moving half

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 Stripper Ejection

COMPONENTS EJECTED
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 Split cavity moulds

Parts with under-cuts, holes, projections, Threads

etc., are normally moulded using split cavities
and actuated to open them to facilitate ejection

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 3. Split cavity mould
Suitable for moulding components with all round external
undercut
Types of split moulds
 Sliding Split Type Moulds
 Angular Lift Pin Type Moulds
Methods of split actuations
 Finger Cam Actuation
 Dog leg Cam Actuation
 Cam Track Actuation
 Spring Actuation
 Hydraulic Actuation

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 Finger Cam Actuated Sliding Splits -
Closed mould

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 Finger Cam Actuated Sliding Splits –
Partially Opened Mould

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 Finger Cam Actuated Sliding Splits –
Splits Fully Opened
Heel Block

Sleeve
Ejector

Core
Pin
Component
Ejected

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 External undercut components
suitable for split molds

Joint Line

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 External undercut components
suitable for split molds

Joint Line

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 External undercut components
suitable for split molds

ADAPTOR

NOTE : Arrows indicate the direction of undercut

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 External undercut components
suitable for split molds

Pulley

NOTE : Arrows indicate the direction of undercut

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 External undercut components
suitable for split molds

FERRULE
NOTE : Arrows indicate the direction of undercut

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 External undercut components
suitable for split molds

Clip PEN CAP

NOTE : Arrows indicate the direction of undercut

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PGS - NTTF
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 Inclined Hole to clear
Split cavity details finger cam
Main Parting
Surface Tapered surface to
match the wedge

Split Parting
Surface

Split Cavity
Collar for Guiding

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 SPLIT CAVITY DETAILS

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 Angular Hole
Main Parting for Cam Pillar
Taper Surface
Surface`
for Wedge

Cavity
opened

Split Parting Collar for

Surface Guidance

Water hole
Design of Split Die Cavities
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 SPOOL

Material Nylon
Density 1.15gm/cc
Shrinkage 1.5 %

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 Split Mold for Spool

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 Split Die – Plan View

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 Sliding split die -- detail drawing
200

150
g6

g6
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 Angular lift pin type split mould

CLOSED POSITION
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 Angular lift pin type split mould
OPENED POSITION
Ø M

Spring

Component

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 SIDE CORE
FOR COMPONENTS
WITH
LOCAL EXTERNAL UNDERCUTS

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 Local external undercut components
suitable for side core

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 Local external undercut components
suitable for side core

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 Local external undercut components
suitable for side core

Side Hole

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 Local external undercut components
suitable for side core

Note :-- Arrow indicates direction of Side core action

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 Local external undercut components
suitable for side core

Note :-- Arrow indicates direction of Side core action

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 Local external undercut components
suitable for side core

Note :-- Arrow indicates direction of Side core action

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 Local external undercut components
suitable for side core

Note :-- Arrow indicates direction of Side core action

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 INTERNAL SIDE CORE
ASSEMBLY LOCK HEEL
CARRIAGE WEAR PLATE

FINGER WEAR
CAM PLATE

Z Z

MOULDING

GUIDE RAIL
PARTING SURFACE
SECTION ZZ Sectional View ZZ

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 Side core carriage fitting details

SIDE
CORE
PIN

WEAR
PLATE

CARRIAGE

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 Internally mounted side core

WEAR
PLATE

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 Sketch of important details

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 Side cavity mounted on core side
Wedge Block

Wear Plate
Wear Plate

Finger Cam

Carriage Side Cavity

Ejector

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 Hydraulic Curved Side Core
Actuation

Bolster

Carriage
Curved Part

Curved Guide
Rack Strips

Actuating
Arm Pinion
Curved core
pulling
arrangement

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 Injection compression moulding

Injection Moulding Compression Moulding

Injection Compression Moulding

In the Injection phase melt is

injected into a movable mould to
complete the filling during the
compression phase resulting in
uniform packing.

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 Injection compression moulding
The injection moulding process is performed in 2 steps:
- Injection &
- Compression

During injection, the high pressure of molten plastic forces

the mould to open on account of lower locking tonnage.

On completion of injection, the pressure is released to

allow the moving half of the mould to lock thus allowing the
melt to fill the entire cavity with desired packing.

Mould is designed with horizontal parting to facilitate

Injection - Compression process on hydraulic machines.
.
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 Injection compression moulding

Injection
pressure

Injection phase

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 Injection compression moulding

Compression phase

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 Hot runner
It is the technology to bring the molten plastic from the
machine barrel to the cavity through one or more gates
without loss of temperature. This system does not create
cold runners or sprues.

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 Why Hot Runner ?

 Minimum or no runner.
 Minimum or no pressure drop.
 Faster cooling.
 Shorter cycle time.
 Optimum gate location.
 Decreased shot volume.
 Allows auto cycle.
 Higher production.
 Unbalanced temperature control.
 Elimination / reduction in weld Lines.

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 Standard parts of Hot Runner
System

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 Hot Runner System Manifold Plate

Backing Plate
Manifold Manifold Heater
Thermocouple
Manifold Alignment
Sprue Heater
Dowel
Sprue Bushing
Manifold Hold
Down Screw

Center Locating
Insulator Locating Ring

Guide Pin Drop Bolt

Manifold Plate Plate Alignment Dowel

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189 189
 Hot Runner System
Manifold
Nozzle
Hot runner

Hot sprue

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 Hot Runner System

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 Hot Runner System

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 Maximum flow path for different materials
Thermo plastic Material Maximum. flow path for
1mm thickness
Cellulose Acetate 100mm
NYLON / PA 150mm
PVC---rigid/flexible 100mm
PMMA/ Acrylic 130-150mm
Polystyrene PS 200-250mm
ABS 175mm
HDPE----LDPE 225-250mm
Polypropylene PP 250-270mm
Poly Carbonate-PC 100mm
Poly Acetal-- POM 140mm
SAN 140mm

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 Hot Sprue

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 Hot Sprue

Torpedo tip
Torpedo
Part
Melt

Inner body

Outer Register ring

body

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 Gas Assisted Injection Molding

 Variation of Conventional Injection Molding.

 Can be retrofitted to existing injection moulding m/c.
 Injection of molten plastic is
assisted by introduction of
pressurized gas.
 Gas(Ammonia) produces bubble, pushing
the plastic into the extremities
of the mold cavities creating
hollow sections.
 Offers a variety of process and design features.

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 Stages of Gas Assist Molding
Stage 1 : Resin Injection
The polymer is injected into the mold as a short shot.
Stage 2 : Primary Gas Penetration
 Gas introduced into the molten core forming a bubble.
 The gas bubble displaces some of the molten core, pushing
it to the unfilled cavity and completing the mold filling.
Stage 3 : Secondary Gas Penetration
 Begins at the end of the filling stage when the polymer
reaches the end of the mold. Bubble extends as the part
cools and the material shrinks. The extra cavity volume
created is taken up by the gas bubble.
 The pressure provides packing of the part.
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 Stages of Gas Assist Molding

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198 198
 Gas Assited Injection Mould

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 Gas Assisted Injection Molding

Fixed half

Molten Plastic

Moving half
Pressurized gas

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 Vacuum forming

 Vacuum draws the part against the mold “cavity”

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 Pressure forming
 Air pressure presses the sheet against the
mold “cavity”, highly defined details obtained.

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 Stack Moulding

2-Level stack mold

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 Stack Moulding
3-Level stack mold

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 Stack Moulding

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 Stack Moulding

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 Stack Moulding

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 Stack Moulding

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 Stack Moulding
Arrangement

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209
 Metal Injection Moulding
Parts produced by metal injection moulding.

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 Metal Injection Moulding

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 Metal injection Moulding Process
 Metal Injection Molding, or MIM, is the process in which
a fine metal powder, typically in the sub 20µm range, is
mixed with a proprietary binder system to create a
feedstock.

Common Binders used :-

 A combination of waxes and organics, which may
include thermoplastic and other additives.

 The feedstock is then injected into a mold cavity using

molding machines very similar to plastic injection
molding machines.

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 Process….

 The majority of the binder system is then removed using

a thermo/chemical operation.
 The parts are then placed in a sintering furnace where
any remaining binder is removed and the parts are
sintered to their final dimensions.
 The end result is a near net shape part with a typical
density of 98% of theoretical value.
 Depending on the part, this can be the final step, unless
there are any secondary operations to be performed.

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 Process….
 Mix feedstock from metal
powder and binder.
 Inject feedstock in mold.
Metal Powder Binder  Debind part to remove
major portion of binder.
 Sinter in vacuum or
Mixing controlled atmosphere
furnace.
 Finishing operations as
needed.

Sintering Debinding Moulding Machine

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 Metal Injection Moulding Materials
Common materials used:
 Stainless Steel
 Nickel alloys
 Copper alloys
 Titanium and tungsten alloys
 Cemented carbides
 Ceramics.

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PGS - NTTF
216
 Sandwich Moulding

Components of two different materials can be molded

with a special system called coaxial valve gate

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 Coaxial valve gate system
TYPES

Core Back Method Sandwich Method

218
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 Working principle of core-back method

Step 1 Step 2 Step 3

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 Working principle of sandwich method

Step 1 Step 2 Step 3 Step 4

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 Thank You
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221
 Specifications – Fixed Platen

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 Specifications – Moving Platen

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223
 Specifications – Fixed Platen

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224
 Thank You
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225
 Types of Screw Rods

General purpose screw

OVERALL LENGTH

METERING TRANSITION FEED

SECTION SECTION SECTION
KEY

METERING DIA.
DEPTH FLIGHT WIDTH Feed
PITCH Depth BEARING

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 Specifications of SP80 windsor machine
INJECTION UNIT
Plasticizing Capacity * 20 Kg/ Hr.
Maximum Shot Capacity
With Injection chamber Ф34 @ 1800 rpm 75 Cm3
With Injection chamber Ф42 @ 1200 rpm 110 Cm3
Screw Diameter 34 mm
Screw L/ d ratio 18 : 1

Injection stroke 80 mm
Hopper capacity 30 Kg.
* Depends on material
+ Shot weight Based on Polystyrene

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Specifications of SP80 windsor machine
LOCKING UNIT
Mould Clamping force 80 Tonnes
Size of Mould Plates ( h x v ) 500 x 500 mm
Distance between Tie bars 330 x 330 mm
(hxv)
Diameter of Tie bars 65 mm
Max. Mould opening 450 mm
Min. Mould Height 150 mm
Max. Daylight 600 mm

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 Windsor machine Specifications
MODEL PLASTI MAX MAX. MAX. DIST. MIN. MAX.
CISING . CLAM. INJ. BETWEEN SHUT DAY
CAPACITY SHO FORCE PRESS. TIE BARS HT. LIGHT
Kg/ hr T Tonnes Kg./cm2 mm. mm.
(H X V) mm
CAP
Acm
3

SP 30 15 44 30 1950 280X280 100 470

SP 20 75 80 1800 330X330 150 600

80
SP 130 50 130 1800 380X380 200 750
190
SP 180 90 180 1800 430X430 350 900
320

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