Plastic Mould (Theory)

INDO GERMAN TOOL ROOM
AHMEDABAD
CCTT
Semester - 3
INDO GERMAN TOOL ROOM, AHMEDABAD
COURSE MATERIAL
Subject:
PLASTIC MOULD (THEORY)

AHMEDABAD
VERSION - 0
INDO GERMAN TOOL ROOM, AHMEDABAD
COURSE MATERIAL
Subject:
PLASTIC MOULD (THEORY)

AHMEDABAD
VERSION - 0
INDO – GERMAN TOOL ROOM AHMEDABAD
CHAPTER : A1 INTRODUCTION TG2
Plastic
The plastic is a Synthetic Plainer of high made cular Weight composed

of repeating organic chemical units called monomers. polymer is a
single large molecule formed as a result of the union of two or more
molecules od simple r substances Plastics are classified as mainly two
groups
(i) Thermo plastics
(ii) Thermo sets
Thermoplastics or thermo resin consist of long molecules each of it

may have its Side chain that are not attached to other molecules Thus
they can be repeatedly softened and hardened by heating and cooling
usually these materials are in granular forms and no chemical change
takes place during moulding.
In thermosetting resin the reaction portion of the molecule s forms cross

links during polymerization once cured ( polymerized) the material can not
be softened by heating Normally available in powder from and are
cured in the mould at high pressure and temperature .
With the progress in technolog y the line between these plastic has
become less distinct progress involved which makes use of the most
Economic Processing of thermoplastic then converting it to thermo set
plastics
E x : Extruded polyeth ylene wire Coating machin eries have also been
modified to provide economy of ther moplastic Processing to thermo set
materials.
Ex : Injection moulding of thermo sets some plastics are the members of

both the groups like thermo plastic polyesters and thermo set polyesters
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Thermo plastics
The plastics in general use are polystyrene (P.S). Acrylo nitrite butadiene
Styrene (ABS) , LOW density polyethylene ( LD.P.E) High density
polyethylene [ H.D.P.E) POLY propylene [ P.P] Polymethyl methaerdlate (
PMM) Polyvenyl Chloride (P.V.C) Poly carbonate [P.C]
These plastics are produced commertially in granular from for optimum

processing the most important requirement is a completely cleaned free
running granule The constant bulk density is importa nt requirement is a
completely cleaned free running granule . The constant bulk density is
important requirement is a completely cleaned free running granule The
constant bulk density is important requirement is a completely cleaned free
running granule. The constant bulk density is important on machines where
volume feed is employed The Surface of molecule of the granule should
maintain the absorption of moisture at a tolerable level even during
lengthy period of storage other Wise t his leads to production of Stream
and hence faulty component . The nature of the material must permit the
plasticization at a practical range of temperatures and allows a
homogeneous melt to fill the cavity the material should be stable Under
temperature must permit the plasticization at a practical range of
temperature s, and allows a homogeneous melt to fill the cavity the
material should be stable under temperature changes and should be Stable
Under temperature changes a nd should not decompose chemically Since
the Variation in temperature is possible if the material remains in the
cylinder to long period , due to the stop age in cycle In such cases the
material With low material Stability decomposes T his is known as
“Burning” and its effect is seen more clearly on transparent product where
the degraded materials forms streaks [lines] or discolored in products
Thermal instability may separate out the chemicals in plastics there by
releasing poisonous gases which may corrode the cylinder or harm the
operator .
In addition to bulk materials Ingraoliants are also aded to change its colour
consistency or other properties these includes dyes, fillers plasticizers,
dispersers an d materials to did the free flowing These are termed as
fillers and additives The best materials exchibutes Uniform and small
shrinkage on cooling
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PLASTICISATION
The thermoplastic materials changes from granular from to

homogeneous plastic stage suitable for the injection moulding termed
as plasticization it takes place in machine cylinder as the material passes
through a thermo elastic Stage which is marked by a breakdown in
intermolecular bonding force Due to the loosening of this structure
solidifying decrease As the until the melting point Where the material is
said to be in “thermoplastic” Stage The molecules are completely mobile
in this stage The molecules are completely mobile i n this Stage and we
say that material is plasticized
Melt Flow Index (MFI)
This indicates the flow capacity of different thermoplastics and is

inversely related to the molecular weight of the plastics Higher the
molecular weight of the plas tics Higher the molecular Weight of the
plastics Higher the molecular Weight of the plastics Higher the
molecular Weight lesser the MFI and Vica Versa it is gauged as the
amount of material that is pushed out through a standard orific e at a
particular temperature and pressure Time limit is 10 min in general cases
The MFI polypropylene is measured at 230°C under a pressure of 216N.
Spiral flow index (S.F.I)
It is another way of expressing the flow of a particular way of expressing

the flow of a particular grade of resin in side a mould A mould With a
Spiral With a spiral grove is used for this purpose With the cavity
marked in C.M rated by printing hot foiling pointing etc
Grade SFI at 260° cyl temp 17 MPA injection pre
M 17-30 25
M 30-30 32
M 56-30 36.5
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M 00-30 46.5
Flow length to wall thickness ratio
The L/T ratio expresses the flow behavior of the material inside the
mould it is defined as largest flow path to thick ness of the moulding
under optimum moulding conditions The maximum obtainable ratio With
different grades of plastics also depends upon MFI ratio for moulding ( P
.P) Polypropylene
Grade MFI L /T
M 17.30 1.7 150
M 30.30 3 225
M 56 .30 5.6 275
M 00-30 10 350
Thermo plastics are further classified into two groups They are called as
commodity plastic and Engineering plastics comm odity plastics are PA,
Acrylics and SAM.
Polystyrene ( P S )
Possess: high glass and sparkle and is transparent Low Water absorption
it is hard and rigid It can be easily coloured moulding can be decorated
by printing hot foiling , painting etc.
Application : Thin walled rigid container for packing toys , refrigerator s

and transport pipes for carrying Water , and chemical ropes furniture etc
LOW Density poly Ethyl lene [L DPE]
Trade name Ackathence; Indo thene ; pol ythene it is a crystalline plastic

not usually available in transparent It can be coloured and it flows
easily.
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USES
Shopping baskets, Waste paper basket artificial Flask hair brushes channel
lining etc.
Poly propylene (P P)
Trade name koylene
It is a stiff and Strong material pocess high glass flows very easily it
provides greater production rate uses : This can be employed in any
industry like automobile ( radiator cooling tan ) tail lamp housing
textile industry bobbin Electrical and chemical industry , Electronic
industry regulator covers knobs etc Valves and pipe Eittings consumer
products camera parts vacuum flasks house hold items , mugs jars soap
box etc medical products Syrings, sterili zation containers etc
Acryonitrile Butadyne Styrol ( ABS)
Trade Name: polysac ABS OR ABS Polac.
It is hard and through material with good resistance pre drying is necessary
and is carried out at 80 °c for about uses Automotive parts ; Roads sign s,
Radiator grills , helmates, shoe heels, furniture’s etc Radio, TV cabinets.
Acrylics ( PMMA) Poly methyl methacrylete Trade name pers pecs
properties : “PMMA” is a hard , rigid material With excellent optical

clearity, Good weat her re sistance low -water absorption and good
dimensional Stability un -affected by human tissues stiffer even than
ABS, PS, “PMMA” has to be pre dried up to 70 °c for about 4 hours
components can be buffed and polished , Ultrasonic Weldin g and
chemical Welding are possible , Street light fixtures Sign boards , dials
cabin Windows etc.
Poly Venyl chloride [P.V.C]
Trade Name : Nocil P.V. C; caliplast ; Sri Ram venyles Properties

P.V.C is strong stiff resistant to oils it has low impact Strength and heat
distortion temperature Rigid P.V.C is strong stiff resistant to oil but
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difficult to process on heating - hydro chloric acid is Evolved Which
attacks machine and the operator Stabilizers are added to multiply effect
Plasti Sized P V C:
Plasticizer is added to get soft and flexible product Which is easily

processed Increase in Plasticizer concentration gives more easy flow of
material. Uses It is used When high abrasive resis tance toughness and
resistance to climatic conditions are required Rigid P.V.C is used for
pipes for Water and chemical etc. Plasticise P.V.C is used for Pipes for
Water and chemical etc . Plastic P.V.C is used for foot Wear soles
electrical insulation lining chemical Vessels etc
Poly carbonates [PC]
Trade name
P.c is outstanding in transparency toughness and temperature resistance

and good rigidly up to 140 ° c Good electrical insulator and virtually Self
extinguishing, but cost is high and processing technics are different Good
resistance to Water dilute acids Animal or Vegetable fats oils resistant
to strains by tea coffee, fruit juice etc.
Uses : Largely used in electronics because of fire resistant, good

insulators and durability Terminals Switch plates used in rail and bus
windows Which undergo frequent Scrambling and high breakage rate
used in sport goods With high Strength.
Polyamide [ P A]
Trade name Akulone ; Tufnyl ; Gujlon; Nylon Properties Nylons ( PA)

have different grades They have good abression resistance and tough
ness than other acetals It has low melting point and can be processed at
lowtem perature it has Strong moisture absorption properties Hence it
should be pre dried and used Machine selected for moulding Nylon
Should have nozzle Shut off device because of its low Viscosity.
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Uses Transparent parts for mechanical medical use components with

good mechanical Strength high rigidity and impact strength dimensional
stability can be produced.
Thermo plastics polyesters :
Melt at 225 ° hard strong extremely though can be extruded and blow
moulded Uses Switch parts, gears, bearings blow molded bottles etc .
Poly Urethane (PUR)
Trade name: Foom
Properties:
It is highly abrasive and impact resistant material it posesses good

electrical properties It can be made in Solid moulding or flexible foams.
It is mainly used in manufacturing of Pure -Springs foam materials packing
cases etc.
Thermo setting Materials.
Among plastic Materials -thermo – setting materials generally provide –one

or more of the following Advantages provide – One or more of the following
Advantages
(i) High thermal stability
(ii) Resistance to deformation under load and high dimensional stability.
(iii) High rigidity and hardness.
These advantages are coupled with light and excellent electrical resistance
properties. The compression and transfer moulding together Wit h recent
evolution of thermo set injection moulding technics after low processing
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Cost Thermo Setting moulding compounds consists of two major
ingradiants.
( i) A resin System Which generally contain such components such as

curling agents hardeners and plasticizers
( ii) Fillor and or roiin forcements Which may consist of mineral or

inorganic or organic chopped cloth paper.
The resin System Usually exerts the dominant effect deter mining to great
extent cost dimensional stability electrical qualities heat resistance Chemical
resistance decorative possibilities and Elammability Fillers and rein force
ment effect all these properties to Varying degrees but their most
dramatic effects in strength toughness and some times in electrical
qualities The characteristics and properties of eight genetic families of
thermo set moulding components are given below.
( 1) Alkydes : Alkydes are primely electrical materials There mould ability

is excellent cure tim e is short and pressures are low , they are Stable
upto a temperature of 120 ° to 150° General purpose grades are normally
mineral filled compounds filled with glass or fibers and mineral fillers
give lower Cost anol good mould ability Longer fibers give optimum
strength
Typical uses of alkydes includes circuit breaker , insulation capacitor and

resistor capsulation, cases housings and Switch gear Components
(ii) Allylics:
Diallyl phthalate [DAP] is most commonly used m oulding material in allylic

family They are relatively costly They pocess excellent dimensional
Stability and high insulation resistance They can With stand temperature
of 150° to 175°c They are normally reinforced With glass as betos acrylic
and polyester fibers
(ii) Epoxies:
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These materials offer excellent electrical properties and Stability Coupled
With high Strength and moisture adsorption it is used in combination
With glass, fibers [ Epoxy glass reintorced plastics ] in aircr aft
components reinforced plastics] in aircraft components filaments of
wound rocket motors, casing for missiles , Pipes, tanks, pressure vessels
and jigs and fixtures They are also used in Encapsulation or casting of
various electrical and electronic components.
( iv) Ureas : [ Urea -for malde hyde ] Excellent colourability moderately

good Strength and low cost arethe primary attributes of these materials
Dimensional Stability and impact Strength are poor
Uses: for producing lighting fixtures, wiring device etc
(v) Phenolics: [ Phenol Formalde hyde]
They are lower in cost posess good heat resistant properties coupled
With good mechanical Properties and excellent moulding They are
generally limited in colour [ usually black and dark brown] and colour
Stability.
They are generally filled With saw dust. They are suitable for use at
temperature about 150° Heat resistant grades are usually mineral or glass
filled –can With Stand temperature up to 200° to 260°C.
They are used for moulding Wiring devices Switch gear relay System
connectors etc.
(VI) Melamine’s
They posess extreem hardness, excellent and permanent Colourability, arc

resistant and not cracking Ch aracteristics . They are self extinguishing
Dishes and other house ware articles and some other electrical items
are produced from this.
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(VII) Polyesters:
Polyesters resin may be formulated as brittle and hard tough and

resistant or soft and flexible When rein forced With glass fibers they
exhibute excellent mechanical properties, high Strength to weight ratio
and chemical resistance . They are used as liquid resins for Costing of
furniture parts, polyester glass i s used for parts Such as auto mobile body ,
building pannels, furniture part’s
Fillers and Additives
Plastic are material that are comprising not only of large polymeric
molecules but also include small additional molecules material that have
been added to give plastic Some particular Characteristic The
characteristic The characteristic of colour Flexibility ,rigidity, flame
resistance Weathering behavior ,rigidity flame resistance Weathering
behavior and possibility can s ignificantly altered by the use of additives
and fillers Plastic additives may be grouped into two groups.
The First group comprises of those additives Which modify the base
polymers characteristic by physical means Additives of this type perform
as plasticizing lubricants, impact modifiers fillers and Pigments.
The Second group of additives active their effect by chemical relations

This type include flame retrades, Stabilizers ultra Violet absorvers and
anti oxidants.
Fillers:
Fillers are classified as inorganic organic , mineral natural and synthetic

They are more commonly used with thermosetting materials Such as
Phenolic urea’s and melamine The Elim of thermo plastic as well large
amount of fillers are refered as extenders because they increase balkiness
and decrease the cost of costing Since the properties of an extend
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casting often suffer the use of fillers is often limited to less critical
applicant ions
Fillers normally endow the plastic With Specific mechanical , Physical

and electrical properties Fillers is usually Comparies between 10 -15% of
the mass of the mix.
One of the most Widely used filler for thermosetting Plastic is Wood flour.
It consist of finally ground powder of hard Wood or nut Shells . They
are low thermal Stable and low dimentional Stabler, and poor electrical
properties .
Mineral fillers used are the pure form of Silica quartz , inorganic
pigments refined metal oxides, Sulphate etc.
The Process by which polymers are formed into long chain formation in a
chemical reaction known as Polymerization
1 Addition
2 Condensations
Large amount of inorganic and mineral fillers increase brittle ness (

mineral fibre ) Combines of fibers Recently asbesstoss have come
Under Stringed Safety regulations The factors for choosing the fillers are
( i) Cost, availability and Uniformly
(ii) Competability or melt ability With the resin
(iii) moisture absorption
(iv) Physical absorption
(v) Thermal Stability and mould temperature
(vi) Resistance to Chemical
(viii) Effect of plastic flow characteristics
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Purpose Filler
Bulk Wood flour

Saw dust
Wood pulp
Sisal jute
Purified cellulose
Mica rock
Rain forcement Glass Fibres and Spheres

Asbestos fibers
Cellulose fibres
Cotton fabric
Paper
Synthetic Fibers
Hardness Inorganic Digments

Mineral powders
Metallic oxides
Powdered metals
Graphite
Silica
Thermal insulation Asbestos

Diatomaceous earths
Ceramic oxide
Silica
Chemical resistance Glass fibre and fabrics Synthetic Fibres and

fabrics Synthetic fibres and fabrics
Graphite
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Metallic oxide
Appearance Dyestuffs
Carbon blocks
Powdered metals
Phosphorescent minerals woven fabrics
Plasticizers:
Plastic may need t o be plasticised to enhance flexibility resiliency and melt

flow with out the addition of a plasticiser it would not be possible to make
plastics sheeting tubing film and other flexible forms of plastics The
Plasticisers enable the molecular chains of polymers to move freely
With respect to one another, with minimum entanglement or internal
friction A Plasticiser thus acts as an internal lubricant It is not
chemically linked to the plastic .
Nearly 80% of all Plasticisers are liquid are used in PVC, but they are used
in celluloic nylon, ABS, Polystyrene etc.
Most Plasticisers are liquids a few are Solids that melt at compounding
temperature. All must exhibit good compatibility with the resin they
modify They are usually colourl ess odorless and posses good thermal
stability But they decrease the Strength characteristic heat resistance
dimensional stability and Solvent resistance of resins
The popular general purpose plasticise are the phthalates, eporcies,

phosphate adipad diesters, sebacates etc Plasticisers Compose up to 50 to
60% of a final PVC product
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COLOURANTS.
The use of colorants makes it possible to produce a variety of materials

in colour varying from pastals of deep hues . These types of colorants are
used dyes pigments of organic and inorganic nature. Dyes are fairly
Soluble in plastics While the pigments are not The choise depends on
resin compatibility or the need for suitability. The colorants should be
Stable Dyes ha ve lower thermal stability and will be discolored on
overheating colour concentrates are also supplied with the plastics by the
manufacturer.
Heat Stabilisers
Stabilisers are used to prevent the degradation of resin during proces sing
When melts are Subjected to high temperatures. They are also used to
extend the life of the end parts PVC is vulnerable to degradation during
processing and is the prime consumer of heat Stabilisers The commercial
Stabilisers are based on Solid barium , cadmium, lead etc
ANTI OXIDANTS
Antioxidants are used to protect materials from deterioration through

oxidation brought from deterioration through oxidation brought on by
heat, light or chemically induced nectanism oxidation couses, brittleness,
melt flow instability, loss of tensile properties and discoloration.
ULTRA VIOLET LIGHT ABSORBERS.
Virtually every plastic degrades in sunlight. They lose their colour and
physical properties. PS, PVC, ABS, polyest ers are affected much The
choice of ultra Violet absorber depends on the application, the basic
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resin , the ultimate effect and the required durability of the end product
( ultra violet absorbers are used up in time)
FLAME RETARDANTS
Flame retardants are used to affect combustion in plastics.
Combustion in plastics.
Flame retardants Work on four basic principles When
(1) They insulate or
(2) Create an endothermic cooling reaction or
(3) Coat the product and exclude oxygen or
(4) actually influence combustion through reaction
The most common flame retardants are antimony , boron, halogens,

nitrogen and phosphorous The most common in PVC are phosphate enters
ANTISTATICS AGENTS
Antistatic agents also called destatis isers are used to reduce the build up of
electrostatics charges on the surface of plastic materials by increasing
surface conductivity. Plastics Susceptible to electroStatics Charges are PE ,
PP, PS, PA, Polyesters, urethanes cellulosises crylics and acrylo nitriles.The
most common antistatic for plastics are amines ammoniam compounds,
phosphate esters, and polyethylene glycol esters. Antistatic agents are
selected on the basis of application, durability necessary concentration, and
effectiveness at low humidity
REINFORCED PLASTICS
Rain forced plastics are composite material consisting of a thermo plastics or

thermoset matrix Combined With another Stronger and Stiffer material
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usually in fibre form Which acts as the rain forcemeat of the load
applied to the composite as possible The plastic matrix exists primarily
to transfer the load applied to the composite as possible. The plastic
matrix exists primarily to transfer the load from point of application into
the load from point of application into the load bearing fibres.
The effective ness of such fibres rein forcemeat is dependent on a number of

factors. The degree of adhesive between plastic and fibres is fundamental.
other factors of importance are the relative volumes of reinforcement and
plastic matrix , the length of fibre used and the physical chemical and
temperature properties of fibre and plastic
REINFORCEMENTS
Glass filaments are a low cost readily available reinforcement Gl ass

Fibers With perfect surface have very high ultimate tensile Strength.
Glass fibers are manufactured by extruding molten glass through a die
and then drawing the glass down to a fine diameter strand ( 0.01)
CERAMIC FIBERS
TO active the highest possible Strength Stiffness and temperature

capabilities of reinforced plastic , ceramic fibre reinforcements may be
used. Carbon and boran fibres are presently used.
FIBRE TO PLASTIC BONDING
The effectiveness of fibre reinforc e ment depends on the bond between

plastic matrix and fibre glass are generally coated With Substances
Which act as coupling agents to encourage good bonding .
MOULD RELEASE AGENTS:
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In moulding any the reinforced materials, regardless o f the type of

reinforcement or the resin used , the tendency of part to Stick to the
mould Surface is a common characteristics To facilitate the removal of
such parts from the mould a release agent ( also called parting agent or
mould release ) is use d. The release agent forms a barrier film between
the mould surface and the part There are two types or release agent
commonly used.
( 1) External release agent which are applied to the mould Surface.
e.g.: Regenera ted cellulose, polyvinyl alcobol ( PVA), PVA and nylon
Solutions pure carnauba wax etc.
( 2) Internal release agent Which are combined With the resin.
e.g Zinc and calcium stearates , Silicone oils High melting point waxes
etc
2 Injection Moulding Machines
An injection moulding machines performs the job of plasticising and

injection the thermo plastic material in to a mould held between two
clamping platterns Mould clamping in most of the machines is of two types
Viz Mechanical and Hydraulic
Injection moulding machines plasticising capacities range from 10 kg/h

to 370 kg/h An injection machine may be horizontal or vertical Means
used for plasticising are plunger pre plasticizer two Stage Screw and the
reciprocating screw Reciprocating Screw machines are widely used.
Plunger Injection Cylinders:
This consists of a barrel heated with electrical resistance heater bands

in which is a fixed Spreader called tarpedo the interior of barrel and
surface of the Spreader is also heated electrically in some of the
machine designs The barrel heater bands are generally arranged in
Zones to achieved required temperature across the cylinder The plunger
forces the Plastic granules fed f rom the hopper through the narrow
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passage way between the barrel and tarpado As the granules move
forward to-wards nozzle , They are melted by the heat obtained from the
barrel and tarpado The granules are fed to the cylinder eit her
Volumetrically or by a weight fceder Which deposits a precisely
weighted charge into the cylinder The weighed mass equals the weight
of the Shot Which consists of the combined Weight of the shot Which
consists of the combined Weight of products plus the Spure and runner
System Packing or Under fill of the mould must be avoided to ensure
best dimensional control of the part best Physical properties lowest stress
levels in the product and consistent product Weight
Pre - Plasticizer Two Stage plunger Injection cylinder
The pre- plasticising Cylinder mounted at an angle to shooting Cylinder

is identical With plunger injection cylinder The purpose of pre -
plasticiser cylinder is to feed the matted plastic in to Shooting Cylinder is
too feed the metted plastic in to Shooting Cylinder The Shooting
Cylinder is fitted With a nozzle and plunger The plunger is provided With
a stroke control Which may be mechanical or el ectrical Such as a limit
Switch Which closes the hydraulic valve – controlling Shooting plunger
piston in this way precise shots Weight can be obtained Which may be
mechanical or electrical Such as a limit Switch Which closes the
hydraulic valve –controlling shooting Plunger piston In this way precize
Shot Weight can be obtained Which is the prime advantage of this way
precize shot Weight can be obtained Which is the prime advantage of
this system other advantage are low injection pressure that can be used
greater shot Weight and low cylinder temperatures In operation the
plasticising Cylinder forwards the material through open valve between
the shooting cylinder The Shooting cylinder which is forwa rd at this
position is forced backward as the position is forced back ward at this
cylinder is filled It moves back until it hits the stop and valve close
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when the shooting cylinder plunger is made to go forward by hydraulic
pressure on the piston the plastic mass Flows through the nozzle into
the mould
pre – Plasticise two Stage Screw Injection Cylinder
This System is identical to two stage plunger type pre plasticiser except
that the screw extruder is S ubstituted for plunger type injection cylinder
Improved homogeneity of plastic mass delivered by screw to Shooting
cylinder is the prime advantage of this System other advantages are
same as plunger type The main dis -advantage of b oth System is
degradation of heat sensitive materials which is the result of multiple
flow paths and possible hang up areas.
Reciprocating screw Injection Cylinder
Almost all the injection moulding machines used today are of this type .
The thermoplastic resin flows from the hopper in to the cylinder as the
screw rotates the granules are conveyed forward and melted The melt
flow from last flight of Screw through the non –return Value As the
mass collects a head of the screw it exerts a pressure on the end of the
Screw and forces it backwards Back pressure on the material can be
regulated by adjustment of relief valve in hydraulic injection cylinder
Suitable back pressure adjustment fo r the material being moulded is
very important to obtain ultimate originality of plastics being moulded
special shut off Nozzles are required When high back pressure is
generated The Screw is fitted with a stroke limiting divice [ limit
Switch] Which Stops the Screw rotations and Feed from the screw When
required plasticised Shot volume is created ahead of the screw During
injection the hydraulic ram moves the Screw forward The non return
valve closes as the mo vement Starts preventing back flow into the
screw The screw The screw thus acquires the characteristic of a plunger
and forces the plastic mass through the nozzle into the mould.
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The reciprocating Screw machine has many advantages over o ther

plasticising methods The primary advantage is the uniformity or
plasticity obtained from the screw which produces higher quality
mouldings at lower temperatures and apparent pressures The broader
range of materials can be moulded including the heat sensitive materials
Such as rigid P V C. colour changes and material changes can be
accomplished rapidly With small materials loss While puring.
Purging: Purging is the process of cleaning one colour or type of

materials from cylinder of machine by forcing it out with new colour or
material purging materials are also available.
Injection moulding machine basic Arrangements
The modern injection moulding machine consists of the following basic

parts.
(i) The feed hopper for holding and feeding the material
(2) Reciprocating Spure and barrel – Where the material will be heated
and is brought to the injection stage.
(3) An arrangement for applying pressure to the spure to force the plastic
materials into mould
(4) A fixed and moving plattern on which the mould is loaded The
moving plattern will have injection arrangements.
(5) Mould clamping arrangement either by toggle or by direct hydraulic

lock which holds the mould halves together during injection.
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(6) A System of controls for operating plastisicclug , injection and the

mould closing mechanisms In correct sequences and with variable
arrangement , for regulating driving the process cycl e.
The screw
The Screw of an injection moulding machines is commonly divided

into three Sections or Zones.
(i) The feed Section

(ii) The Compression Section
(iii) Melting zone.
The feed Section transports plastic material from th e hopper to the

heated is in powder or gromular form is Compressed to a homogeneous
melt in the compression Section The final mixing and heating of the
material into a homogenous melt is carried out in the metering Zone .
The d rive for the rotation of the Screw during the feed cycle is obtained
from a hydraulic motar or a variable Speed electric motar Check Values
are used on screw to avoid the material from coming back along the
Screw during injection stroke .
The Nozzle:
The nozzle is connected to the end of the barrel , through Which the
Softened material passes into the mould.
For general purpose Standard nozzles are made in varying diameters to

accommodate the cylinder bores . and Spure diamet ers and in varying
lengths depending on heating requirements Standard nozzles are made
with Straight bore restricted at outlet end tapered as required to match
the cylinder bore at inlet end Depending upon the type of resin the othe r
configurations are also used . This facilitates The melt to be injected at
optimum temperatures. Band heaters or internal cartrigdges or heating coils
are installed in the nozzle. The material Such as nylon which Show low
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melt viscosity can b e moulded With a nozzle In this case the reverse
taper is used to free off the melt or prevent the drooling between the
shots These types nozzles can also used for Cellulosics and cleaning and
improved Spure breaks with out long St rings For Corrosive pdymers
like pvc the nozzles made of Stainless Steel are used Chrom plated
nozzle are not proved to be Satisfactory because of the tendency of
plating peeling off from corners
Machine Specifications:
Injection moulding machines are commonly classified -according to the

clamping force that they can generate and the amount of material they
can inject.
Injection Capacity or Shot Capacity
It is the maximum volume of material t hat can be injected by the screw

during one cycle of operation
Plasticising capacity
It is the amount of the material that can be processed by the machine

per hour. It is expressed in kg/hr
Injection pressure:
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It is a pressure by which a material is injected through the nozzle it is
given in kg/cm2
Clamping Force
It is the maximum force that the clamping System can exert on the
mould or it is the maximum force by which the mould halves can be
closed together it is given in tonnes or kg New tone
Maximum Daylight:
It is the furthers distance that the machine platen can be Separated from
each other it can be obtained by adding the maximum mould thickness
to maximum opening stroke.
Different materials require different injection pressures The following

classification is given for general guidance.
High Pressure (H P)
Nylon ; Rigid pvc; SAN ; A BS ; A cyclic ; Pc
Medium pressure (MP)
HDPE PP, PS
Low pressure: -
Soft pvc, LDPE
Most Window Sp - Series machines have a unique feature of different

type of pressure heads capable of being fitted on the same barrel and
screw It is advisable to have two types of head for processing different
materials
23
Press capacity: -
Essential considerations are
(i) Shot capacity
(2) Plasticising capacity
(3) Clamping force
(4) Injection pressure
Shot capacity
The plunger machine is often rated in terms of maximum Shot Weight

With Polystyrene the rating in ter ms of another material can be
determined from following relation
Shot capacity} = Shot capacity x Density of B x Bulk factor of A

With mal B with a Density of A x Bulk factor of Bulk factor of B
A = Plastic material used for Specif ying the rating of injection moulding
machine [poly – Styrene]
B = Plastic material actually to be used
The Screw type machine is normally rated in terms of Swept volume x S x C
S = Density of Plastic at normal temperature and pressure = g /cm 3
C = 0.85 for crystalline materials
C = 0.93 for amorphous materials
Plasticizing capacity
This is expressed as kg/hr of plastic ciser polysterene
24
Plasticizing rate } = [ plasticizing rate] x Specific heat of A x mould temp
of ‘A’ of mat B kg/h of m aterial A Specific heat of B Mould temp
of B
OR
Plasticizing rate = Plasticizing rate of material A x QA of mat B

QB
Q = total heat content of the plastics (Joules /kg)
A = Polystyrene
B = Material actually to be used.
The machine Selection Should be capable of plasticising Rate : Mass of

moulding ( Kg) x No of mouldings /hour for maximum efficiency the
machine Should not operate abo ve the 80 to 85% of the rated Shot
weight or plasticising capacity
Cycle time:
tC = maximum Cycle time ( Seconds)

m = mass of the shot (kg)
P = Plasticising capacity of the machine With the particular polymer being
molded {kg /h}
Clamping force:
Clamping force required to keep must mould closed during the

injection must exceed the force given by the product of the opening
pressure. In the cavity and total projected area of all the impressions total
projected area of all the impressions runners and gates Lower Clamping
25
valves can be used With screw presses owing to the lower injection
pressure possible With these machines Thin sections need a high
injection pressure to fill and there fore require more c lamping force.
Easy flowing materials like polyethylene, Polysterene - fill more rapidly
and hence they require lower clamping force
In case of S pure injection 33 to 50% of injection pressure Should be

taken for Clamping purposes T he maximum injection pressure can be
obtained from machine manufacturers data.
Clamping force = [projected Area of moulding] x 33 to 50 % Injection

including runners cm 2 pressure Tonnes/cm 2
Determination of number of cavities
The number of cavities in injection moulds is determined in most of the

cases by the machine performance but some times it is determined by –
moulding shape or mould locking pressure .
Determination by shot capacity
[based on 85% of rated shot capacity]
NS = 0.85 X W
m
Determination by plasticising capacity:
[based on 85% of rated plasticising –capacity]
No = 0.85 P X TC
3600 x m
Determining by clamping capacity
Nc = ___C____
Pc x Am
26
N S No of cavities depending on shot capacity W = Rated Shot

Capacity for particular polymer m = Mass of moulding Weight /cavity
kg/or g
N p = No of cavities based on plasticising capacity for particular polymer
kg/h
TC = Over all Cycle time [Seconds]
Nc = No of cavities based on clamping capacity
Pc = cavity pressure [M. Pa]
{approximately tely 63 MPa Considering 33 to 50% of injection pressure }
Am = projected area in moulding including the runner [ m2],
The mass of spure and Runners related to the moulding must not be
neglected this must not be neglected this must be considered in the
formula while determining the moulding mass The moulding mass/cavity
must be Satisfied by following factors
Moulding mass Factor
0.3 to 0.5 1.5

0.5 to 1 1.4
1 to 3 1.3
3 to 5 1.25
5 to 10 1.15
10 to20 1.10
Above 20 1.05
27
Multification factors of small mouldings – processed in multiimpression
moulds are even higher than these quoted above
Example
Determine the number of cavities for a mould available data
mass of component = 309
Projected area of component
(including Sprue, runner and gate = 2800 mm2
Material = Acrylic
Cycle time = 17S
machine available = Sp 80
( i) Determination by Shot capacity Shot capacity of machine = 98 9

CP.C. require H P head)
Shot capacity of the machine With ac rylic Shot capacity of the machine with
acrylic
= Swept volume (cm3) x S x C

= 100 x 1.2 x 0.93
= 111.6 9
NS = 0.85 W
M
= 0.85 x 111.6 3.16
30
3 cavities
( 2) Determination by plasticising capacity plasticising capacity of

machine = 40 kg/ ( screw diameter 42 mm) Plasticising capacity With
acrylic
28
= plasticising rate of x QA
poly Sterene ( kg /h) QB
= 40 x 239.4
302.4
= 31 .66 kg/h
Minimum Cycle time tc = M x 3600

P x K = 10 3
= 30 x 3600
31.66 x 103
= 3.4 S.
Cycle time 17S (more than minimum Cycle time)
NP = 0.85 x P. Tc
3600 x m
= o.85 x 31.66 x 10 3 x 17
3600 x 30
= 4.23
= 4 Cavities
( 3) Determination by Clamping capacity
Rated clamping capacity 800KN.
N c = ___C____
Pc x Am
29
Nc = 800
63 x 10.3 x 2800 x 10-6
= 4.5
= 4 cavities
Select the minimum number of cavities Possible
= 3 cavities
(Determination on Shot capacity)
Injection Moulding Quality Control Defects in injection moulding
The most common defects which occur in case of injection moulded

components are listed below
(1) Short Shot
30
(2) Flash
(3) Warp
(4) Flow mark
(5) Silver streak
(6) Dull Surface
(7) Weld mark
(8) Air bubble
(9) Burn
(10) Bend
(11) Cracks
(12) No product drop
In majority of the cases the source for the each of the above defect s could be
the followings
( A) Machine : Injection moulding conditions and the functioning of

various System in the machine can influence the quality of product
( B) Mould : Design manufacture assembly maintenance Setting on the

machine and operating condition of the mould will greatly affect the
quality of the product.
(c) Resin: Resin preparation heating conditions and specific

characteristics of resin under use also influence product quality.
The probable cause s under each of above three sources which lead to
defects machined earlier are as follows
( i) Short shot
31
(a) machine
(1) Injection capacity of machine not Sufficient
(2) Metering two low
(3) Injection pressure not sufficient
(4) Melt resin temperature low
(5) Injection Speed low
(6) Nozzle orifice too small
(7) Material flow from happer to nozzle is not free
(B) Mould
(a) Gate balancing is not good

(b) Gas/Air pulls out from cavity not good
(c) Size /shape of gate runner and spure are small
(d) Mould temperature low
(e) Cold Slug too Small
(f) Thickness of cavity is not sufficient
(g) Mould closing not good
(c) Resin (a) Material flow not good

(b) Lubrication not good
(2) Flash
(A) machine
32
(a) High Injection pressure
(b) Mould closing pressure low
(c) metering too high
(d) Resin temperature high
(e) Injection pressure time toolong
(B) (a) mould centre alignment not good

(b) Mould touching Surface clearance too high
(c) Mould Surface dirty and resulting in gap
(e) Projected area of the article too large
(C) Resin (a) Low viscosity
(3) Warp
(A) Machine
(a) Low injection pressure

(b) Low injection speed
(c) metering not enough
(d) Resin temperature very high
(e) Nozzle orifice Small
(f) Mould opening speed high
(B) Mould
(a) Mould temperature high

(b) Mould temperature of upper and lower sides not Uniform
33
(c) Gate diameter small
(d) Runner sprue distance long
(C) Resin
(a) Resin Shrink rate high

(b) Flow of resin high
(4) Flow mark
(A) Machine
(a) Injection Speed low

(b) Nozzle diameter Small
(c) Injection pressure low
(d) Metering not enough
(B) Mould
(a) Mould temperature low

(b) Mould cooling not proper
(c) Cold Slug Shape small
(C) Resin
(a) Resin flow not good
(5) Silver Streak
34
(A) Machine
(a) Machine capacity not Sufficient

(b) Resin decomposition in heating cylinder
(c) Injection Speed high
(d) Air entrapped in heating cylinder
(B) Mould
(a) Mould temperature low

(b) Ventilation for gass not proper
(c) Cavity design not good
(d) Size of gate, runner, Spure Small
(e) Cold Slug Size Small
(f) Mould Surface dirty
(C) Resin:
(a) Pressure of moisture in the resin
(6) Dull Surface
(A) Machine:
(a) Over heating of material in cylinder

(b) Nozzle temperature low
(c) Nozzle diameter Small
(d) Injection Speed too slow/high
(e) Cusion volume tool low
(B) Mould
35
(a) Mould temperature too high/low
(b) Size of gate - runner - Spure Small
(c) Cold Slug Size – small
(d) Cavity Surface not clean
(e) Gas vent not good
(C) Resin
(a) Oil and Water blent present in resin
(7) Weld Mark
(A) Machine
(a) Resin temperature too low.

(b) Injection pressure low
(c) Injection speed low
(d) Nozzle temperature low
(B) Mould
(a) Gas vent not good

(b) Cavity design not good
(c) Gate, runner, Sprue Size small
(d) Mould cooling time long
(e) Mould temperature low
(C) Resin
(a) Shrink rate large

(b) Water and oil – present in resin
(g) Burn: -
(A) Machine
36
(a) Material over heating in cylinder
(b) Air entrapment in heating cylinder
(c) No cooling of cylinder at upper Setting Point
(d) Cylinder temperature high
(e) Injection pressure high
(f) Injection Speed high
(B) Mould:
(a) Grease or oil presence inside mould cavity
(b) Gate diameter too small
(c) Gas vent not good
(C) Resin
(a) Lubricating used with resin is too much

(b) Volatile material got mixed with theresin
(10) Bend:
(A) Machine:
(a) Injection pressure high
(b) Injection pressure keeping time long
(c) Material melting not proper
(d) Resin temperature low
(e) Injection Speed low
(B) Mould:
37
(a) Ejection not good

(b) Ejector Balance not good.
(c) Cooling time Short
(d) Mould temperature high
(C) Resin
(a) Annealing not good
(11) Cracks
(A) Machine

(b) Temperature of resin low
(c) Injection pressure Keeping time long
(B) Mould
(a) Gate Size big

(b) Mould temperature low
(c) Ejection not good
(d) Cavity design is not good
(C) Resin
(a) Annealing not good
(12) No product drop
(A) Machine

(b) Resin temperature high
(c) Injection pressure Keeping time long
(d) Metering tool long.
38
(B) Mould
(a) Cooling not Sufficient.

(b) Mould temperature is very high
(c) Gate diameter big
(d) Gas vent not good
(e) Gate balance not good
(f) Small Sprue hole, and Surface finish is not good
(g) Nozzle touch not good
(h) Radius of Nozzle tip is greater than that Spure bush.
(i) Lower cavity temperature high
(j) Cavity inside milling corner radius too small
(k) Cavity inside milling Surface not good
(L) Ejector balance not good
(C) Resin
(a) Lubricating not good
39
4 Plastic Injection Moulds
Basic terminology
The mould is generally divided into two parts
(i) Fixed half

(2) Moving half
The half that is attached to the Stationary Platten of the machine is

termed as fixed half The other half of the mo uld is know as the moving
half The other half of the mould attached to the moving platten of the
machine is known as moving half Generally the core is situated in
moving half Generally the core is situated in moving half for easi ness
of providing an ejection System..
Impression:
The injection mould contains With in it an impression into Which the

plastic material is injected and cooled the impression gives the
moulding its form There fore the impression is d efined as that part of
the mould Which imparts Shape to the moulding The impression is
formed by two mould members.
( i ) cavity it is the female portion of mould and it gives external form

to the moulding Gi) Core it is the mal e portion of mould and forms the
internal shape of the moulding .
Cavity and Core Plates
The basic mould consists of two plates The plate in Which the cavity
is formed is known as cavity plate Similarly the plate from Which a
core projects is a core plate When the mould is closed these two plates
come together forming the space between core and cavity which is the
impression.
40
Sprue Bush
During injection moulding process the plastic material is delivere d to the

machine nozzle as a melt it is then trans ferred to the impression through
a passage This passage is a tapered hole With in a bush and bush is
called a sprue bush Thus the Spure bush can be defined as that part of
mould in which the spure is formed spure bush is connecting member
between machine nozzle and mould face Spure bush Should be made
from 1.5 % Nickel chrom Steel and it Should be hardened to withstand
stresses The backward movement of the bush is prevented by fitting a
register ring which Serves a dual purpose of securing the spure bush and
fast mould location The internal aperture of spure bush has an induced
taper of 3 ° to 5 ° Which facilitates the removal of the spure from the
mould The taper should be highly polished There two basic types of
spure bush with Spherical resis Which is used in conjunction with
Spherical resis Which is used in conjunction with spherical front ended
nozzle.
( 2) Spure bush with perfectly flat rear face and corresponding nozzle is
used if the allignment between the nozzle and bush apertures is perfect a
leak free joint is achieved With Spherical seating However a miss
alignment result in gap and leakage occurs But in case of a flat faced
nozel no leakage can occur if two opertures are Slightly out of line .
Register Ring
The nozzle and the Spure must be correctly alline if the material has to
pass without hindrance into the m ould by including a register ring a
mould can be alline to the machine The register ring is the flat circular
member fitted on to the front face of the mould its purpose is to locate
the mould in its correct position on the injection machine platen When
the mould is mounted an the machine the register ring fits into a circular
hole Which is accurately machined in the injection platen on the
Cylindrical nozzle axis This ensures that the small aparture in the no zzle
is in direct allinement with the Spure bush hole The register rings form
the direction conection between spure bush and the hole in the
injection platen of the machine
41
Register ring is located on the out side diameter of th e spure bush

resister ring can also be located in the stepped end sprue bush where the
resister ring secured the spure bush is in location
In case of a mould which necessitates the long reach nozzle the resister
ring can not be lo cated on the spure bush The resister ring is located on
the Spure bush The resister ring is located a recess in the rare of the
injection bolster
Runner and gate System
The material can be directly injected n to the impression throu gh the

sprue bush or for multi impression moulds it can pass through a runner
and gate system before entering the impression .
The runner is a Channel machined in to the mould plate to connect the sprue
bush or for multi impression moulds it can pass through a runner and gate
system before entering the impression.
The runner is a channel machined into the mould plate to connect the
spure With the entrance to the impression The gate is a channel
connecting the runner With th e impression it has small cross Sectional
area When comp aired With rest of feed System.
Guide pillars and Bushes
To mould an even walled moulding it is necessary to Ensure that the cavity

and Core are kept in allinement this is achieved by providing guide pillars
and Guide bushes on the mould plates the Guide pillar has its Working
f is bend it can be easily removed Without damaging the fitting hole.
but the attempts to remove a bend constant f pillar will damage t he
fitting hole.
42
A Guide bush is incorporated in the mould to provide a Suitable wear
resisting Working Surface for the guide pillar and to permit replacement
in the event of wear or damaged
Heel Blocks or parallel Blocks
Heel blocks are Support Stocks, mounted on to the back plate to support the
mould plates. Heel blocks are Support Stocks , mounted on to the back
plate to support the mould plates. Heel blocks provide a Space into which
the ejector plate assembly can be fitted and operated
Ejector plate
Ejector plate is used for serving the purpose of transmitting the ejector
force from the actuating System of the injection machine to the ejector
element
Rest buttons: -
With a large ejector plate System it is preparaable to provide Rest

buttons or Stop pins on the undeside of the ejector plate this reduces the
effective Seating area The possibility slightly above due to foreign matter
being tapped behind the ejector plate is avoided by using rest buttons
Spure Breaker
It is necessary to remove the spure from the Spure bush after each
injection for further injection of material into the mould Spure Breaker
or Sprue hooker are used to pull the spure out of Spure bush When the
moulds opens there are different type of Sprue hookers, Generally used.
Ejector: Ejector is the part of the ejector System Which applies to the
ejection force to the moulding There are different types of ejector like
ejector pins, ejector plate and shleeve ejector The types of ejector is
Selected depending on the moulding.
43
Ejector Retainer
Ejector Retainer is a plate Securely attached to the ejector plate for the
purpose of retaining the ejector plate for the purpose of retaining the ejector
Push back pins or return pins
The push back pins are incorporated in a mould to push the ejector
assembly to its rear position as the mould is closed
Attachment of mould to platern
There are two method attach injection moulding m/c and these are
either directly by means of bolts or indirectly by means of bolt and
clamps for direct bolting clearance holes or slots are provided in each
mould half to correspond W ith the hole tapped in the machine platern
Indirect clamping mould is clamped in the platern by means of flat
clamps and bolts
Ejection: 5 Ejection System.
All thermoplastic mat contract as the Solidified Which means that the
moulding will Srink on to the core Which forms it this Shrinkage makes
the moulding difficult to remove the amount of Srinkage depends on the
nat. used it is normal practice there fore to provide some means by
which the moulded part can be positively ejected from the core facilities
are provided on the injection machine for automatic actuation of ejector
system When this is Situactuation of ejecter System When this is
situated behind the moving platten because of this the moulds ejector
System will be most effectively operated it placed in the moving half of
the mould, that is the half attached to the moving plattern there by the
core also must satis factively be located in the moving half the ejec tion
System consist of
44
(1) The ejector grid
(2) The ejector plate assembly
(3) The ejector
(1) Ejector grid
The Ejector grid is that part of the mould which Supports the mould
plate and provides the Space in to Which the ejector plate assembly can
be fitted and operated The grid normally consist the back plate on to
Which is mounted a number of conveniently Shaped Support blocks
there are 3 alternative designs
(1) Inline ejector grid
This consists of 2 rectangular support blocks mounted on a back plate. the

ejector plate assembly is accommodated in the parallel Space between the
2 Support blocks the design is quit Suitable for small types of moulds
where the over all Size of the eject or plate assembly does not necessitate
the Support block being fitted a great distance apart in this design to
avoid the possibility of the mould plate being to avoid the possibility of
the mould plate being destroted by the injection force , A thick mould
plate , or extra Support blocks are often used
(2) Frame type ejector grid
The most common type is the rectangular frame type ejector grid it is
constructed of 4 support blocks mounted on a back plate this t ype is
commonly used for the following reasons
45
(i) It is simply and Cheap to manufacture
(ii) It provides good support to the mould plate on a small mould.
(iii) A rectangular Shape ejector plate can be used
( iv) A ejector plate assembly is completely enclose there by preventing

forming bodies entering the System.
When the out side Shape of the mould plate is circular it is often
convinie to design correspondingly Shaped ejector grid The circular
Support frame is sligh tly more expensive to produced than the
rectangular type as the Size of the mould plate increases the effective
Support provided by the above types of the ejector grid decreases this
Situation can be improved by providing additional local Support block
(iii) Circular Support block grid
In this design circular support blocks are used to support the mould
plate only this System is used for large moulds When no extra Support
would be gained by including rectang ular blocks as well
Ejector plate assembly
The ejector plate assembly is the that part of the mould to which the
ejector element is attached the assembly is contained in a pocket formed
by the ejector grid directly behind the mould plate the assembly consists
of an ejector plate A retaining plate and an ejector rod one end of the
ejector rod is threaded and it is Screwed into the ejector plate the ejector
rod is guided in an ejector rod functions not only a s an actuating
member but also as method of guiding the assembly.
Functioning
The moving half or ejection half of the mould is mounted on the moving
plattern of the Injection moulding machine The actuating rod can be
adjusted for various alternative ejector Strokes When the mould opens
46
the moulds ejector rod at some point of the stroke strike the actuating
rod arresting the entire ejection assembly the mould plate and ejector (
grid ) continue to open u ntil the opening stroke is complete this relative
movement between the ejector plate assembly and mould plate is
necessary to operate the ejector elemenent in normal arrangement for the
smaller types of injection System the m/c actu ator rod passes through
the centre of the moving plattern. on larger m/cs several actuator rods are
used so that the balanced force can be applied to the ejector plate in this
case the actuator rods push directly on to the ejector plate a Separate
method of guiding and supporting the ejector plate assembly is necessary
When ejector rod bush are not incorporated
Ejector plate
The purpose is to transmit the ejector force from the actuating System
of the injection machine to the moulding through an ejector elements the
force required to eject the moulding is appreciable , particularly when
the moulding is appreciable particularly When the moulding is
appreciable particular When the moulding are deep and have little drop
the ejector plate must be Sufficiently thick not to difflect side forces are
applied to the ejector elements Which result in crease wear in the
mould plate holes bend ejection pin and in extreem case s in the
complete Seize ore of the System
Retaining Plate
its purpose is to retain the ejector elements it depth of the head of the
ejector element it retains retaining plates are normally made of mild
steel
Guiding and Supporting Ejector plate assembly
The type of guide system used it is depend largly upon the size of the
mould for smaller moulds the ejector rod is guided in a ejector rod bush
secuirly fitted into the b ack plate which maintains alinement and prov ides
support for the ejector plate assembly an alternative method for allining
47
and Supporting the ejector assembly is by providing guide bushes
incorporated with in the assembly and guide pillars attached to the Back
plate these guide pillars can be used as local support plate also.
Ejector rod and Ejector rod bush
The ejector rod is attached to the ejector plate by means of thread the
ejector od bush is press –fitted in to the back plate both ejector rod and
ejector rod bush are case hardened to resist wear
Ejector plate assembly returns System
In astripper plate mould the stripper plate is directly connected to the

ejector plate by tie rods When the mould closes the Stripper plate Strike
the fixed mould plate there by causing the Stripper plate and the ejector
plate to be returned to their rear positions.
Push back pin return System
push back pins are large f ejector pins Which are fitted to the ejector
plate assembly In the moulding position the push back pins are plush
With the mould plate Surface In the ejected position the bush back pins
project beyond the mould plate surface Thus When the mould being
closed the push back pins Strike the fix mould plate and progressively
return the ejector plate assembly to the rear position
Spring Return System
For Small moulds where the ejector assembly is of light construction A

spring can be used to return the eject or plate assembly the spring is
Fitted on the ejector rod with the cap to keep in position.
48
Stop pins
With the a large ejector place or large ejector bas system it is preferable
form System stop pins on the underside of the ej ector plate the heads
of the stock pins should the relatively larger to prevent the possibility of
their head being hoped into the back plate. Stop pins reducing the
effectives seating area thus preventing the possibility of ejector elem ents
remaining Slightly above due to the forign matter being trapped behind
the ejector plate assembly the ejector plate
6 chapter Ejection Techniques
When a moulding cools it contracts by an amount depending upon the

material being process When the moulding has no internal form, Ex A
Solid rectangular block The moulding will Srink away from the cavity
Walls there by preventing a Simple ejection ( techique ) there by
preventing a Simple ejection System can be adopted Ex z Jet of air
When the moulding as it cools will Srink on to the core and Some
positive type of Ejection is necessary the basic ejection Systems are as
follows
(1) Pin ejection

(2) Steeve ejection
(3) Bar ejection
(4) Blade ejection
(5) Air ejection
(6) Stripper plate ejection
(1) Pin ejection
This is the most common and Simplest type ejection the moulding is
ejected by the application of the force by the ejector pins In operation the
ejector plat e assembly to which the ejector pin is attached is moved
forward relative to the mould plate thus the ejector pin pushes the
moulding from the cavity the working f of the ejector pin in the mould
plate in order to avoid the plastic ma terial creeping through the clearance
the ejector pin is soldered and proper Seating is provided in the retaining
49
plate the accommodation So provided must allow the ejector pin to float
The reason for this arrangement is as follows
The direction of movement of the ejector pin is controlled by the hole in

the mould plate if this hole is not at right angle to the mould plate face
then this arrangement allows pin and the retaining plate thus avoiding
chances of dending or breakage . In its rear position the top Surface of the
moulding face pin should be flush with the top of the core If the pin is
projecting above and indentation will be formed on the moulding If it is
sunk below the core the boss on the moulding is formed The top Surface
of the pin must have the same high finish as the rest of the impression
The location of ejector pins and number used depends on the component
shape and Size Aim is to ejecting the moulding With as littl e destrotion as
possible the ejector pins Should be located such that the moulding is
pushed off evenly from the core Ab rubd changes in shape ( corners )
tend to impede ejection there fore the ejectior pin Should be located
adjustant to t hese sides this is better to use max No of ejector pins in
order to avoid destrotion When able to keep the Working length to a
minimum this is know as the Stepped type ejector pin pin ejector is a
cheapest of the mechanical eject ion method ejector pins are hardened
to obtain a wear resisting Surface.
D Shaped ejector pins
This is flat Sided ejector pin this is made by machining a flat on a standard
ejector pin. It is used for ejecting thin Walled wax type mouldings
Sleeve Ejection
In this method the moulding is ejected by means of a hollow type of

ejector pin or sleeve it is used in the following circum stances
(1) For the ejection of certain types of circular mouldings
(2) For the ejection of circular bosses on a moulding of any Shape
( 3) To provide positive ejection around a local core pin forming the

round hole in the moulding
50
The Sleeve is a Sliding fit in the cavity insert and on the core pin and its
wear end is fitted to the ejector assembly large core pins can be fitted
directly on the back plate. the sleeve and the core pin must be allowed to
float because the outside of the sleeve is a Slide fit in the cavity insert .
When the ejector assembly is ac tuated the sleeve is moved relatively to
the core ( and to the cavity ) and the moulding is ejected this is an
effective method because a ejection force is applied to a relatively large
Surface area This design is restricted to Circular types
Blade Ejection:
The main purpose of the blade ejector is for the ejection of very Slender
parts Such as ribs and other projections Which can not be Satisfactly
ejected by the Standard type of ejector pin the blade is basically a
rectangular ejector pin.
Value ejection
The valve ejector is basically a large ejector pin it is used for ejection
of large components this ejector applies the ejector force in the inside
Surface of the moulding
Air ejection
In this method the ejector force is provided by the compressed air
Stripper Bar Ejection
This method is an extensive of butting face ejector pin principle The

ejector element is cause to push against the bottom edge of the moulding
this method of ejection area obtained is greater A single bar is used
along each Wall of moulding This reduces mark left on the surface of
moulding The Stripper bar is coupled to the ejector plate by a tie rod
51
Stripper plate Ejection
This type ejection is commonly used mainly for the ejection of circular
box type mouldings and for mouldings With thin Wall Sections the core
is Sliding o fit in the cavity of Stripper plate When the mould Starts to
open the Stripper plate moves back with core plate once the moulding is
the clear of the cavity the movement of the stripper plate is arrested
while the mould plate continuous the rearward movement the core is
there by Withdrawn through the Stripper pl ate and the moulding through
The Stripper plate mould consist of 3 parts core Plate , S tripper plate
and cavity plate When the mould is open there are 2 Spaces and these
are termed as day light The Stripper plate must be Sufficientl y thick to
resists the bending forces applied to the plate as the moulding is ejected
the length of the Working f of the guide pillar is longer the reason is
that the guide pillar must Support the Stripper plate over the complete
ejection stroke and in addition it must till project enough to enter the
fixed half guide bushes when the mould closes. Method commonly used
for actuating stripper plate
(1) Tie bar actuation
The conventional ejector plate & ejector gr id system are adopted in this
System the Stipper plate is coupled to the ejector plate by the rods as the
moving half moves back wards the ejector rod strikes the actuating rod
of the machine the movement of the Ejector plate and the Str ipper plate is
arrested in and moulding the Stripped from the core In this design the
ejector Plate does not Seat on the back plate on the mould a Separate
ejector rod bush is not included as the stripper plate is guided on the
main Guide pillars.
(2) Length bolt actuation
In this design the ejector plate is arrested by length bolts Suitably Situated
With in the mould the fixed mould plate is recessed to accommodate
52
the head of the length bolt and clearance h ole is provided in the
moving mould plate to accommodate nut and lock not this design is
cheaper to produce and the mould is lighter to handle.
(3) Chain actuation:

In this case chains are used to arrest the motion of the stripper plate
instead of length bolts on end of the chain is connected to the stripper
plate and the other end to the fixed mould plate When the mould is in
closed position the chains hang down in a loop As the mould is open the
chains are progressively straightened until the arrest the motion of the
stripper plate no of Chains per side depends upon the Sizes types of the
moulds this design has certain Dis Advantages
(1) If the chain Swings in beth the mould f aces While it is being
closed Serve damage will occurs
(2) If one of the chains break While the mould is opening and opsent
load is applied to the Stripper plate which tend to destrot this member
(4) Direct actuation
This m ethod is possible on medium and large size injection moulding

m/c where Several actuator rods are used when they are positioned
Symmetrically about the Centerline of moving platten they are used to
actuate the Stripper plate directl y
Stripper ring ejection
The Stripper ring is a local Stripper plate and is used on the moulds
With one or two impressions only the Stripper ring is made to Seat in
the mould plate this is actuated by the rods .
Ejection From Fixed Half
In some cases it becomes necessary to mount the core and the ejector
System on the fixed mould half This mould half must be sufficiently
53
thick to incorporate and ejector grid and ejector assembly behind the
fixed mould hal f the distance the melt has to travel can be minimised by
Sinking the Sprue bush deep into the mould plate assembly The
actuating mechanism must be incorporated in the mould Since the
facilities are not provided on the m/c for actuatin g from the fixed mould
half the distance the melt has to travel can be minimized by Sinking the
Spure bush deep into the mould Since the facilities are not provided on
the m/c for actuating from the fixed mould half side
The following ejection technics are more easily incorporated than others.
Air ejection:
This is the Simplest to install this is just as easily connected to the fixed
half as to the moving half medium of actuation is compressed air
Stripper plate ejection
Stripper plate is mounted between the cavity and core plate it is coupled
to the moving mould by either length bolts or chains when the mould is
opened the Stripper Plate is retained on the fixed half Side until the free
movement allowed by the length has been taken up further movement
actuates the stripper plate and the moulding is ejected pin , sleeve, bar
ejection etc.
Certain types of components necessitate the use, of pin sleeve or bar

ejection in which case a con vent ional ejector plate assembly must be
incorporated
Actuation
Normal practice is to coupled the ejector plate assembly to the moving

half by either plate ass embly to the moving half by either length bolts
54
or chains where the over all dept of the mould is sufficient to
accommodate hydraulic actuators these can be fitted to operate the
ejector plate assembly directly
Spure pullers
When the mould opens it is essential that th e spure is pulled positively

from the Spure bush In the case of Single impression moulds the sprue
pulling methods utilise an undercut pin or an under cut recess Situated
directly opposite the spure entery the plastics materials whi ch flows into
the undercut upon Solidifying provides sufficient adhesion to pull the
spure as the mould is opened the undercut form the part of the cold slug
well design the undercut may be of the reverse taper type or the cold
Slug well can have straight Sides and grooves cut into it A spure pin is
positioned behind the cold slug well so that when ejection occurs the
slug is ejected
A Spure pin is termed as a Spure puller When an undercut is provided on

it another design utilises mushoorn headed Spure puller Which is
commonly associated with the stripper plate design and the under feed
design the mushroom head projects into the runner recess in both the
designs and is not contained with in cold slug well
Ejection force calculation
Force required to strip a moulding off a male core can be calculated

approximately from the following formula
P = S.t. E A CF
d ( d - d m)
2t 4t
Where P = ejection force required
E = modulus of elasticity (gN/m 2)

A = total area of Contact between moulding and mould faces in time of
drawn (m2)
55
Cf = Coificient of friction between plastic and steel
d = f of Circle of Circumference equal to length of perimeter of mould
Surrounding male core ( m)
t = thickness of mould part (m)
m = poision ratio of plastic (0.4 to 0.5)
S = thermal contraction of plastic across diameter d = coificient of thermal

expansion
x temperature between softening point and ejecti on temperature x d ( m)
A rough method to determine the no of ejection pins is by providing

4
100mm2 ejector pin Surface for every 100 x 10 mm2 of side wall
contact ( not projected area
7 Shrinkage:
When a moulding cools it co ntracts by an amount depending on the

material being processed each material has its own Characteristic
Shrinkage the chart gives the percentage of Shrinkage for some of the
commonly used materials.
Material Percentage of Shrinkage
A. B. S. 0.4 to 0.6
Polystyrene (ps) 0.5 to 0.6
Acrylic 0.4 to 0.8
Poly carbonates 0.6 to 0.8
Delrin (Poly acetal) 1.5 to 2.5
Nylon 0.4 to 1.0
Poly propylene (PP) 1.0 to 2.0
56
Poly ethylene (HDPE) 1.5 to 2.5
(LDPE) 1.5 to 2.5
Moulding Shrinkage is effected by various conditions the main once being
Shrinkage increases with
(1) Increase of mat. temperature
(2) Increase of mould temperature
(3) Increase in section thickness
Shrinkage decreases with
(1) Higher cavity pressure (injection pressure)
(2) Increase of mould temperature
(3) Increase in Section thickness
Shrinkage decreases with
(1) Higher cavity pressure (injection pressure)
(2) Longer injection time
(3) Presence of fillers
To assess the exact amount of Shrinkage it is very imp that the

production is near to the optimum and that the cycle has Settle down to
study Conditions. the moulding Should be checked only When in all
reactions because Shrinkage varies with direction of flow differential
Shrinkage rates in the longitudinal and transverse plains may give rise
57
to distortion of flat moulding because of all these factors it is difficult to
give exact amount of Shrinkage for moulding generally the grand of
moulding are IT 11
Values of Shrinkage
Material Moulding Shrinkage mm/mm

ABS
High impact 0.005 to 0.007
Heat impact 0.004 to 0.005
Medium impact 0.005
Acetal 0.002 to 0.035
Acrylic
Easy flow 0.002 to 0.007
General purpose 0.002 to 0.009
Heat resistant 0.003 to 0.01
High impact 0.004 to 0.008
Cellulose acetate
Hard 0.002 to 0.004

Medium 0.002 to 0.005
Soft 0.002 to 0.005
High acetate butyrate 0.002 to 0.005
Nylon 6.6 0.012 to 0.025

Nylon 6 0.007 to 0.015
58
Nylon 6.10 0.010 to 0.025
Nylon 6.11 0.010 to 0.025
Nylon 6.12 0.008 to 0.020
transparent 0.004 to 0.006
Glass filled 0.005 to 0.010
Polyethylene
Low density 0.015 to 0.035

High density 0.015 to 0.030
Poly propelene 0.010 to 0.030
Poly Styrene
General purpose 0.002 to 0.008
Heat resistant 0.002 to 0.008
Tough ened 0.003 to 0.006
Poly tetra flour ethylene 0.050 to 0.100
Poly Venyl Cloride (P.V.C)
Un plasticised 0.002 to 0.004

Rigid 0.002 to 0.004
Semi Rigid 0.005 to 0.025

Flexible 0.015 to 0.035
Syrene acryonitrile 0 .002 to 0.006
Poly Carbonate 0. 006 to 0.007
Shrinkage is 0.5 %
There fore the cavity and core dimensions will be as follows cavity
59
Component Shrinkage The dimensions to be
dimension allowance maintained
f 42 42 x 0.5 = 0.21 42 + 0.21 = 42.21
f 30 30 x 0.5 = 0.15 30 + 0.15 = 30.15
f 20 20 x 0.5 = 0.10 20 + 0.10 = 20.10
16 16 x 0.5 = 0 .08 16 + 0.08 = 16.08
6 6 x 0.5 = 0.03 6 + 0.03 = 6. 03
2 2 x 0.5 = 0.01 2 + 0.01 = 2. 01
Component Shrinkage The dimensions to be

dimension allowance maintained
26 26 X 0.5 = 0.13 f26 + 0.13 =f26.13
16 16 X 0.5 = 0.08 f16 + 0.08 = 16.08
12 12 X 0.5 = 0.06 12 + 0.06 = Sq12.06
16 16 X 0.5 = 0.08 16 + 0.08 = 16.08
8 8 X 0.5 = 0.04 8 + 0.04 = 8. 04
2 2 X 0.5 = 0.01 2 + 0.01 = 2.01
8 Feed Systems:
Before entring the impression the plasticised material passes through the
Spure main runner branch runners and gate this is called the feed
system
Runner
The runner is a channel machined in to the mould plate to connect the

Spure With the Enterance ( gate ) to the impression In the basic 2 plate
mould the runner is positioned on the part ing surface .
The Wall of the runner Chanel must be smooth to prevent any ristriction
flow as the runner has to be removed With the moulding there must be
no machine mark left Which would tends to retain the runner in the
60
mould plate the runner chanel must be polished in line of draw other
factors that are to be considered are
(1) The shape of the cross Section of the runner
(2) The size of the runner and
(3) The Runner layout.
Runner Cross Section Shape
The following cross section Shapes are usually used
(1) Fully round

(2) Trape zoidal
(3) Modified trape zoidal
The reasons why these Shapes are prepered are as follows
The runner should provide a max cross Sectional area from the stand
point of p ressure transfer and a minimum contact area from the stand
point of heat transfer the ratio of cross Sectional area the pberferi Will
give a direct indication of the efficiency of the runner design the higher
the value the greater the efficiency .
A Square Section is modified to a trapezoidal Sectional by providing a
10° angle on the runner wall as the plastic melt progress through the
runner Wall as the plastic melt progress through the runner and mould
System the melt adjestant to the cold mould surface will rapidly decrease
in temp and solidify the material Which flows will pass through the centre
of this Solidified material and the Solidified x as an insulation and
maintains the temp of the ce ntre reason there fore the gate should be
positioned in line With the position ( centre ) of the runner to receive the
material from flow steam this Condition is achieved with the fully
round runner the trapezoidal design is not as Satisfactory Since the gate
can not be positioned in line With the Central flow Stream
Mould cost for a mould containing round runner is higher because a

chanels in two mould plates are to be accurately machined and matched
to h ave an efficient runner System the choise of runner System the
choise of runner section also depends on the positive ejection of the
runner System the increased mould cast being relatively Small a fully
61
round runner is preferred for si mple 2 plate mould with flat parting
Surface for mould with Complex parting surfaces the semi circular
chanels of the round runner should be used for multi plate moulds the
trape zoidal or modified trapezoidal Section should be us ed.
Runner Size:
The following factors are to be considered When deciding on the runner

size .
( 1 ) The wall section and volume of the moulding The cross Sectional
area of the runner must be sufficient to permit the melt to pass through
and fill the impression before the runner freezes
(2) The distance of the impression from the main runner or Spure
Large the cross sectional area of the runner the longer the period the
material takes to cool Sufficiently to be ejected so it is un desirable to
make the runner f more than 10 mm However the mat With the higher
Viscosity the runner size can be up to 12.5 f
Ex : - Rigid PVC and Acrylics
Gates:
The Gate is a channel or orifice connecting a runner With the

impression It has a small cross Sectional area when compared with rest
of the feed system this small cross Sectional area is necessary So that
( 1) A Gate fuses soon after the impression filled So that the injecti on
plunger can be With drawn without the likely hood of void being
Created in the moulding by Suck back
(2) It allows for Simple degating and in some moulds this degating can be
automatic
(3) After degating on by a small degating mark remains
(4) Better control of the fitting of multi impression can be achieved
62
(5) Develops head because of the reduce cross Sectional area velocity
increases and so the friction
Positioning of gate
The position of the gate should be Such that there is an even flow of
melt in the impression So that it fills uniformly and reaches the
impression extreemities at the same time in this way two or more
advancing fronts can meet to form a weld line with in equal mechanic al
weakness and Surface blamish in the moulding A central gating had been
afex has done for Slunder core leg components Such as pen cap the side
gating in this case can cause deflection of the core this is because side
gating in this case can cause deflection of the core this is because Side
gating gives rise to a more rapid flow of material down one side of a
impression resulting in a different pressure Which can move the core
out of position this also result in a thicker wall Section at one side thus
adding another weakness to that of weld line
Balanced gating
It is often necessury to balance the gates of a multi impression moulds

to ensure that the impression will Simultaneously this method is adopted
when a balanced runner System can not be used by atopting the method
of balanced method there are 2 ways of varing the restriction .
(1) By varing the land length

(2) By varying the cross Sectional area of the gate.
Types of gate
The type of gate must be carefully chosen to obtain the obtimum filling
conditions the types of gate commonly used are sprue gate, Edge gate,
63
over lap are Spure gate, Edge gate over lap gate, pin gate, and Sub
surface gate
Spure gate
When the moulding is directly fed from a sprue or Secondary sprue the
feed Section is termed as Sprue gate the dis -adv of this type of this
type of gate mark on the moulding
Rectangular Edge gate
This is a g eneral purpose gate and it is a rectangular chanel m/c in one

mould plate to connect the runner to the impression its Advantage are
(1) The cross Sectional form a Simple and it is Cheap to machine
(2) Close accuracy in the gate dimensions can be achieved
(3) The gate dimensions can be easily and quickly modified
(4) All common moulding mati can be moulded through this type of gate
The dis advantage of this gate is that after gate removal a witness mark
is left on a visible Surface of the moulding
OVER LAP GATE
This is the variton on the basic rectangular type gate the possible Jetting
by using a rectangular gate is avoided by this gate for box type
moulding this type of gate can be used
Fan Gate
This is another type of Edge gate but does not have a constant dept and
width the fan Shape spreads the flow of melt as it enters the impression
and more uniform filling is obtained with less flow mark and surface
blemishes this typ e of gate can be used with all conventional moulding
materials a part from Certain grade of Rigid PVC
64
Tab gate
This is a particular gating technique for feeding solid black type

moulding A projection or tab is moulded on the slid e of the component
Diaphragm gate
This gate is used for Single impression, tubler Shape moulding on two plate
moulds
Ring gate
The function of this gate is identical to that of a Diaphragm gate this type of
gate is used for tubler type mouldi ng when more than one impression is
required in a simple two plate mould The gate provides for the feed all
around the external Pferifer of the moulding and permits the use of the
conventional runner System
Film gate
This is a long rectangular type edge gate and it is used for large thin
Walled component to assist in the production of wargpeg free products
Pin gate
This is the circular gate used for feeding into the base of the
component and it is refered to Spure gate because it is Small in diameter
Round edge gate
This gate is formed by machining a matching Semi Circle Chanel in

both mould plates between the runner and impression
65
Sub Surface Gate
The sub Surface gate is a circular or ovexl gate Which Submerges and
feeds into the impression below the parting Surface of the mould this
gate is even called a Submerged gate or Submarine gate its adv are
( 1) To form being on one mould plate has n o matching problems and

precise dimensions can be achieved
( 2) If the more ovexl form is used the filling rate of the impression
can be controlled independently of the gate Seal time
(3) The gate is sheared from the moulding during its ejection
(Degating is automatic)
(4) Leaves very Small degating mark
Sprue Size
Sprue Size for polystyrene
Mass of moulded part (9) min Sprue f ( mm )
10 3.5
10-20 4.5
20-40 5.5
66
40-150 6.5
150 -300 7.5
for other materials the Sprue diameter Should be multiply by the

following factors
(1) Acrylic - 2.0

(2) Softened PVC – 0.8
(3) Nylon - 0.8
(4) Cellulose acetate - 1.0
(5) Polyethylene – 0.5
Runner diameter calculation:
To calculate the runner f
D = Öm 4 L
3.7
Where D = Diameter of runner (mm)

M = mass of moulding (g)
L = Length of runner (mm)
Material typical runner f ( mm)
A B S, SAN 4 - 10
Acetal 3 - 10
Acetate 4 - 10.5
Acrylic 7.5 10
Impact Acrylic 8 12
Nylon 1.5-10
Poly Carbonate 4 -10
Poly estenrene 3 -10
PVC. Plasticise 3 -10
67
Long runners required increased diameter all main runners of mould

should be equal diameter f of all Secondary runner should be atleast
0.75 less than f of the main runner mass of the runner System in gram
for mal density 1 gm / cm3
Dia mass per 10mm Trape 20 idol

(Mm) (Round)
2 0.0314 0.0366
3 0.0704 0.0823
4 0.1256 0.1463
5 0.1963 0.2286
6 0.2826 0.3292
9 0.6359 0.7407
12 1.1304 1.13167
15 1.7663 2.0574
18 2.5434 2.9626
mass of runner for other material can be obtain by multiplying the

above values by the relative density of the particular material
Gate calculation:
The cross Sectional area of the gate ( h x w) controls the rate of fill of
material into the impression the depth of gate controls time for which
the gate remains open this gate open time must be Sufficient for the
mat to reach the extreemity of the impression
68
h=nxt
Where h = depth of a gate in mm

t = wall thickness in mm
n = the mat constant
Material n
P E, PS, PA, PC 0.6
PP 0.7
PA and cellulose acetal 0.8

acrylic
PVC 0.9
The width of the gate controls the flow rate
The flow rate
W = n Ö4
30
Where W is width of the gate in mm

A is Surface Area of the cavity in mm 2
n is material constant.
The land length of gate is approximately equal to the gate is

approximately equal to the gate depth
69
9 Parting Surface
The parting Surfaces of a mould are those positions of both mould

plates adjesent to the impression which butt together to from a seal and
prevent the loss of plastic material from the impression parting surface
are classified as flot and Non flat. the nonflat parting surfaces include,
Stepped, profile and angle Surface the nature of the parting surfaces
depends entirely on the shape of the component the parting Surface
must be So Choosen that the moulding can be ejected out easily from
70
the mould if the parting Surface are not p roperly meshed the material
from the impression will escape through the gap this wafer of material
is called the flash
Complex edge forms
components where the edge form is not constant leads to complex

parting surfaces
Local step and profile parting Surfaces
It is necessary to provide a stepped or profile parting surfaces for

component with few small irregularities which other Wise is a regular
from this is achieved by localising the change in parting Surf ace to permit
the major portion of the surface to be kept flat
Relief of Parting Surfaces:
Bedding down a parting Surface over the entire Surface is not

practicable because it would be extreemly expensive and would also
affect the efficient functioning of the mould, effect of injection pressure
and locking Force with respect to the area of contact between two
surfaces
P=f
A
Where P = theoretical injection pressure in megha newton /m 2

f = applied force in Megha newton
A= Area of the injection ram m2
The actual pressure exerted with in the impression will be considerably
less than this theoretical value for the following reasons
(1) The melt is nonneutenion
71
(2) The viscosity of the melt progressively increases as it passes through the
mould due to cooling
(3) The actual pressure with in the impression depends on the length of
the flow path i.e Spure , runner etc in practice 25% to 45% of this
value is used the effe ctive injection pressure is transmitted to projected
area of the imp ression runners and the gates and produces a force which
tend to open the mould this tendency to open is resisted by locking
force this clamping force should exceed t he opening forces developed
due to flash the parting Surface adjestent to impression and runner is
beded down on a relatively Small area and the surrounding surface is
relive this small area adjesent to impression and runner is beded dow n on
a relatively small area and the surrounding surface is relive this small
area and the surrounding surface is relive this small area adjesent to the
impression and the runner is termed as the “land” the corners of the
mould are left high in order to with stand large clamping forces
Venting:
When the plastic mat enters in impression air is displaced normally the
air can escape between the two mould plates but if the plates are
perfectly flat the air may be trapped With in the impression resulting in
discoloration Sinks, in complete filling etc Vents are provided in the mould
to allow air to escape freely . The vent is a Shallow slot not more than
0.05 mm deep and 3 mm Wide If the dept is more the plastic material
can pass through the gap and live a flash mark the position Where the
vents required are
(1) At the point forther most from the gate on symetrical mouldings
(2) At the point Where flow paths are likely to meet
(3) At the bottom of the projections. in the third case it is necessary to
provide the vent through the mould plate this is achieved by
incorporating and ejector pin in the required positions the air escapes
through the minute gap between the ejector pin and the mould pate are
hole
10 Temperature controlling of moulds
The fundamental principle of injection moulding is that the hot mat

enters in mould Where it cools rapidly to a temperature at which it
solidify Su fficiently to retain the shape of the impression after ejection
72
the temperature of the mould govern the portion of the over all
moulding cycle and is impartant while the melt flows more freely in a
hot mould a greater cooling period is required before the Solidified
moulding can be ejected and while tnelt Solidifies quickly in a cold
mould it may not reach the extreemty other impression there fore the
compromise between a two extreem must be excepted to obta in the
optimum moulding cycle .
The oparating temp for a particular mould Will depend on a no of factors

like type and grade of the material to be moulded, length of flow with
in the impression Wall Section of the moulding length of t he feed
System etc it is advantageous to use the slightly higher temperature than
is required just to fill the impression as this tends to improve the surface
finish of the moulding by minimising weld lines, flow mark and other
blemishes.
To maintain the require temperature water is circulated through the holes or

Chanels with in the mould these holes and chanels are termed as water
ways and the completer System of water ways and the completer
System of water ways and the completer System of water ways is termed
as circuit unit for circulation of water are cometially available these
units are connected to the mould by flexible hoses the moulds temp can
be maintained with in close limits w ith these units close temp Control
is not possible using a alternative system in which the mould is
connected to a cold water Supply
The drilling for Circulation of coolant must not be position too close to
the impression as this c auses a marked temp varation across the
impression resulting in moulding problems
Cooling Integer type mould plates
A temp of a mould plate of a integer type is controlled by circulating

the water through holes bored in the plates the holes are normally inter
73
connected to form a Circuit the circuit may be act at one or more level
the no of circuit will depend upon the depth of the mould plate.
Cooling Integer type cavity plate
The Simplest is to drill two water ways one on either side of the cavity
and to connect these at one edge by means of a flexible hases the
external connection can be avoided by inter connection the two water
ways by means of an internal drilling this forms a ‘u’ circuit and is
useful for cooling long and narrow cavities for their internal drillings
ensure the water ways are in close proximity to all four walls of the
cavity in case of the large area shallow cavity the circuit can be
positioned directly below the cavity the mould plate is drilled plugged
and baffled this forms a flow path of ‘z’ configuration for cooling deep
Integer cavity the multilevel System is adopted fig Shows separate
circuit and partially inter connected circuit fig ( 169 170, 171, 172)
Cooling Integer type core Plate
When the dept of the core is fairly shallows the ‘Z’ type Single level
System can be adopted for deeper cores the Single level circuit is not
Sufficient to permit the coolant to transfer heat away from the core
Surface at the faster rate
ANGLED HOLE SYSTEM:
Water ways are drilled at an angle from the Underside of the core plate
So that they inter connect at a print close to the Surface Each hole is
plugged and inlet and outlet holes are drilled into the angled Waterways
BAFFLED - STRAIGHT HOLE SYSTEM
74
Relatively large diameter holes are bored at right angles to the rear
face of the core plate , plugged and baffled . The borings are inter
connected
STEPPED CIRCUIT
In this System holes are drilled through the side wall of the core , parallel
to the core face These holes are carefully plugged and finished as they
form part o f the impression For narrow cores, the above three circuits
can be used Singly for Wider cores a number of identical circuits can be
used at intervals along the core
COOLING INSERT –BOLSTER ASSEMBLY
Cooling of insert –bolster assembly is classified in to two
(1) Cooling the bolster

(2) Cooling the insert
COOLING BOLSTER
The water ways are drilled through the bolster and are interconnected
either externally or internally to permit the circulation of a coolant These
water ways are positioned close to the insert A rectangular or ‘z’ shaped
circuit is also used.
COOLING CAVITY INSERTS
The method adopted for cooling cavity inserts depends upon the shape of
the insert This is broadly classified as rectang ular and circular
Rectangular cavity insert circuit includes ‘u’ circuit System and copper
pipe System ( Fig ……….) For a circular cavity insert an external
annulus method can be adopted an external annulus method can be
adopted An alternative method is coolout sleeve method
75
COOLING CORE INSERTS
The important designs of cooling system are
(1) Deep chamber System

(2) Deep chamber With central support system
(3) Helical channel System
(4) Baffled hole System
(5) Baffled hole System for small core inserts
(6) Chamber cooling system for Small core inserts
(7) Coolant annulus System
WATER CONNECTIONS
ADAPTORS
Moulds are drilled to provide a flow path through which a coolant can
be circulated These drillings are connected to the supply and return
lines via adaptors ( Hose connector ) Hose connector is a standard pipe
fitting which can be obtained in serval sizes Two methods of fitting the
adopter are shown In method ‘a’ the tapping hole s ize for the adopter
governs the diameter of water way used This permits the
76
11 SPLIT CAVITIES
A moulding which has a recess or projection is termed as an undercut

moulding An undercut moulding necessitates the re moval of that part of
the impression which forms the undercut prior to ejection
External undercut components
Any recess or projection on the out side Surface of the component

which prevents its removal from the cavity is terme d an external
undercut .
There are 2 Forms of undercut
(1) The undercut which is local - the recess or projection occurs in one
position only
eg : The hose connector
In either case it is necessary to split the cavity insert in to two par ts and
open these at right angles to the line of drawn to relive the undercut
before the moulding is removed .
Since the cavity is in two pieces the joint line will be visible on the finished
product.
Position of a joint line
The joint lin e can be positioned on only Centre line for a Symertrical
component For unsymmetrical components there is only one possible
position For example the joint line for pen cap can only occur on the
centre of the projection An incorrect joint line will restrict the free
opening movement of the split which will result in scored cracked
components. The joint line should be as invisible as possible on the
moulding
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Splits:
It is necessary to make the cavity insert in two parts for moulding which
incorporate an undercut In fig the cavity form is machined in to the
cavity plate when the mould is opened the core can withdrawn but the
undercut makes the removal impossible In fig the same cavity form
machined into two separate blocks these split cavity blocks are called
splits The moulding can be extracted by opening the splits are retained
on the mould plate and actuated automatically there are moving parts
and its is necessary to
(1) Guide the splits in desired direction

(2) actuate the splits and
(3) Securely lock the splits in position before the material is injected into the
mould
Sliding Splits
The Splits are mounted in guides on a flat mould plate and are actuated
by mechanical or hydraulic means the splits are positively locked in their
closed position by heels sliding Splits can be mounted on either the
moving or the fixed mould plate
Guiding And Retention of Splits
There are three main factors
( i) Slide movement must be prevented to ensure that the split halfes

always come together in the same place
( 2) All parts of the guiding system must be of adequate strength to

support the weight of the splits and to with stand the forces applied to
the Splits by the operating mechanism
(3) The two halves must have a smooth unimpeded movement.
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The guiding function is accomplished by providing a ‘T’ Shaped slot on
the mould plate and using a shouldered Split
Mould plate Designs
A T – Shape can be produced by one of the following methods
(1) By using a T – slot milling cutter
(2) By attaching Separate guide Strips to a flat mould plate and then
attaching flat steel Strips
( 3) By machining a ‘U’ Shaped Slot on mould plate and then attaching

flat Steel Strips
Type 1 Fig Shows the two types of basic Shouldered Split design s
The two part construction is advantageous for larger Splits
Type 2 In this design, a male T – Shaped projection is provided below

the base of the Split The guiding arrangement is directly below the split
which permits a narrower mould As the side of the split is in the line
with the edge of mould plate a cam plate can be fitted close to the split
for actuation
Type 3 Splits are provided with a projection from the base which
Slides in the slot on mould plate General Splits retention is achieved by
splits Shoulder and T-slot on the mould plate
Methods of operation
The splits are actuated by various types of cams like finger cam, dog
leg cam and cam track method. As the mould is opened , the cams
attached to the fixed half cause the splits to slide across the moving
plate and when the mould closes the spits are progressively closed .
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Another method of actuating the split is by the use of compression
Spring s but as these can be used only to open the splits the locking
heels are used to close t he Splits The Splits can also be actuated
hydraulically.
Finger Cam Actuation
Finger cams are hardened pillars mounted at an angle in the fixed

mould plate the Splits have corresponding angled circular holes to
accommodate these finger cams
As the mould opens finger cam forces the splits to move outwards split
movement cases as the contact with the finger cams is lost Further
movement of moving half causes the ejector system to operate on
closing the finger cams re -enter the holes in the split and forces the split
to move inwards The final closing is done by the locking heels. The
traverse by each split across the face of the mould plate is determined
by the length and angle of the finger cam.
The movement
M = ( L Sine ) - ( c/cosq)
Finger cam length
L = ( M /sin q) + ( 2c/sin 2q)
Where M = Split movement

q = angle of finger cam
L = Working Length of figure cam
C = clearance
The split movement must be kept to a minimum The clearance “C” has two
purposes.
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(1) It ensure that the force which is applied to the split during the
injection is not transferred to the relatively Weak cam
( 2) It permits the mould to op en a small amount before the Splits are

actuated In certain cases this movement can be used to with drawn the
core from the moulding. The amount of delay movement ‘D’ can be
determined by the relation Ship
D = c/sine
An angle of 10° is Suitable for finger cam. A maximum of 25 ° is permissible

for excessively longer cams. The diameter increase with the angle The lead
angle at the front is normally ( q + 5°)
One or two finger cams are used to operate each splits depends on the
split Size
Dog –Leg + Cam Actuation
This method of actuation is used where a greater splits delay is required

the dog leg cam is of a general rectangular Section mounted in the fixed
mould plate the split incorporates hole the ope rating face of which has
corresponding angle to that of the cam. in this design the splits do not
Start to open immediately When the mould is opened because of the
straight portion of the dog in the Splits will be pulled from the st ation
moving half causes the actuation of the Splits there by releasing the
moulding.
CAM TRACK ACTUATION
This method of actuation utilises a cam track machined in to a steel

plate attached to the fixed mould half A bass fitted to both Sides of the
split runs in thin track As the mould opens the bosses follow the cam
track and open the split
The Distance traversed by each Split
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M = La tan q - C
angled length of cam: La = M +c
tan q
Delay period D = Ls+c + r (1__ - 1

tan q tanq Sinq
Where q = can lack angle

C =clearance
r = radius of the boss
Ls = Straight length of the cam
SPRING ACTUATION
Compression Springs are used to force the splits apart and angled faces
of the chase bolster is used to close them This design is limited to
moulding With shallow Under Cuts.
The Splits opens immediately as the mould parts and no delay is possible
The moulding must remain in the moving half in order to eject positively
HYDRULIC ACTUATION
In this design the Splits are actuated hydraulically and is not dependent
on the opening movement of the mould The sp lits can be operated at
any Specific time
SPLIT LOCKING METHOD
It is essential to hold the splits rigidly during the actual injection Phase
as the high pressure developed With in the impression will tend the force
them a part Sliding Splits can be conveniently locked in position by the
use of a chase bolster Each split will have a sloping or angled face
accurately matching the angled face of chase bolster Two basic designs
of chase –bolster are
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(1) Open - channel type
(2) Enclosed Channel type
OPEN – CHANNEL CHASE BOLSTER
Simplest of the designs is by machining a channel With angled sides across

the width of a plate The projections formed are called locking heels
wear plates are used to resist wear
Open channel chase -bolster can be made as an assembly by attaching

individual heel block to a plate
ENCLOSED CHASE BOLSTER
An enclosed chase –bolster is preferred for deep splits as it result in a

more rigid structure The chase bolster is made by machining a pocket
which can be of trapped circular or trapped rectangular from The circular
form is less expensive to manufacture But it is easy to fit wear Strips in
a rectangular form.
SPLITS SAFETY ARRANGEMENT
It is necessary to provide certain Safety features in moulds With cam

method of actuation When the mould is fully open the splits are not in
contact with the cam method of actuation When the mould is fully open,
the Splits are not in contact With the cams There fore the Splits may be
moved out of alignment by Shock Vibration or even gravity To Safe
guard against opening by gravity the splits should operate horizontally
with respect to the machine .
To prevent the movement of the splits by shock or vibration the following

methods can be used
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SPRING DETENT METHOD
A Spring loaded plunger is fitted below the surface of the split When
the Splitcal depression which the retains the spli t nominally in that
position The distance between the plunger and the depression is equal to
the movement of the Split
SPRING LOADED METHOD
The Splits are Spring loaded so that after they are actuated they remain
in the open position A Stud fitted to the underside of the split is free to
move in a recess in the mould plate. A Spring is fettled between the stud
and the end of the Slot.
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12 SIDE CORES AND SIDE CAVITIES
A side core is a tool core which is normally mounted at right angles to

the mould axis for forming a hole or recess in the side face of a
moulding This Side core prevents the in line removal of the moulding
The side cavit y is similar to side core in function in that it permits the
moulding of components which are not in line of draw the side Core and
side cavity must be with drawn prior to ejection
MOULDINGS EMBODYING SIDE HOLES RECESSE OR SLOTS
In general any component with a local recess hole or slot Which is not
in line of drawn will necessitate a side core whenever a side core can
be avoided by a Subsequent machining operation it should be
considered This method has the following advantages
(1) The mould is simple and there for cheap
(2) Ease of operation and less production difficulties
(3) No possibility of flow lines developing
SIDE CORE AND SIDE CAVITY
The design requirement
(1) Arrangements for guiding the assembly
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(2) Means for actuating the assembly
(3) The assembly must be Securely locked When in the moulding

position.
THE DESIGN CAN BE CLASSIFIED AS FOLLOWS
(1) Designs for moulding with peripheral under cuts with Slender centre hole
(2) Designs for moulding with holes or slots in one or more Slides
(3) Designs for mouldings With holes or Slots in one or more Sides
(4) Designs for mouldings With Curved holes
INTERNAL SIDE CORE (OR SIDE CAVITY) ASSEMBLY
The Side core assem bly is Similar methods are adopted for guiding
locking and operating it The carriage is mounted in guides which are
securely attached to the moving mould plate The side core element is
secured by the retaining plate to the carriag e The actuation of the carriage
is by means of a finger cam and is locked in forward position by a
locking heel
INTERNAL SIDE CORE (OR SIDE CAVITY) ASSEMBLY DETAILS
The assembly consists of a carriage and either a side core element or a

side cavity element These elements are Secured to the carriage either
directly or by means of a retaining plate The carriage is guided in the
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guide Strip The room for the carriage is provided by a pocket machined
in both mould plates
The major part of the carriage is accommodated below the parting

Surface in a pocket The Width of this pocket is Sufficiently to
accommodate the guide strips The portion of the carriage which projects
above the parting surface must be accommodated in a pocket in the fixed
mould plate The face of this pocket is angled to form the locking heel
GUIDING ARRANGMENT
The guiding arrangement for the internal Side Core ( or side cavity ) is
similar to that of guiding Splits The assembly is relatively small unit
METHODS OF ACTUATION
The internal side core ( or side cavity ) assembly can be actuated by

means of a finger cam other methods like dog leg cam actuation and
spring actuation are commonly used The finger method of actuation is
used when a short delay period is required The amount of clearance
between the can and cam hole determine the actual delay period The
finger cam must be of sufficient len gth to with drawn the side core
from the moulding completely The dog –leg cam method of actuation is
Specified if a longer delay period is required it is desirable to with draw
the moulding with shallow undercuts or projections.
LOCKING THE CARRIAGE ASSEMBLY
The final closing movement and locking of the carriage assembly are
by means of a locking heel
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13 MOULDING INTERNAL UNDERCUT
Any restriction which prevents a moulding from being extracted from

the care in line of drawn is termed as internal undercut. The method
adopted for relieving internal undercuts depends upon the shape and position
of the restriction.
If the under cut is local the restriction can be incorporated on a form pin.
When an undercut extends comp letely along one internal wall of a

component it can be molded by incorporating a core which is of two
parts The moving part is termed as split core
FORM PIN
The undercut form is provided on a f orm pin The form pin can either
have a straight action as for an ejector pin or it can have an angled
action.
STRAIGHT ACTION FROM PIN
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This design is used for components with an undercut on one internal wall
only
ANGLED ACTION FORM PIN
The Working face of the pin is caused to move inwards relative to the
core during ejection This design is used for component which
incorporate internal undercuts on one or more walls
SPLIT CORES
A Split core design is used for c omponents Which have extensive

internal undercuts that cannot be incorporated on a form pin. A split
core can be moved forward for ejection either in a straight plane or an
angled plane
SPLIT CORE - (STRAIGHT ACTION)
This design is used for components with an External undercut on one wall
only
SPLIT CORE ANGLED ACTION
In this design the split core is caused to move inwards during the
ejection withdrawing the restriction and allowing the moulding to be
extarted in line of drawn it is used for components With undercuts on
opposing faces
SIDE CORES
Components with internal undercuts can be moulded using a conventional

Side core
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STRIPPING INTERNAL UNDERCUTS
A Simple and effective method for stripp ing an internal undercut is to

strip the moulding off the core This type of moulding and stripping
depends on
(1) Shape of the undercut

(2) The elasticity of the material and
(3) Whether the external form permits Expansion during ejec tion
MOULDS FOR THREADED COMPONENTS
Thread in the moulding is a form of undercut and this increases the

intricacy of the design The extent of complection depends on the
following factors
(1) Type of thread
Internal External or discontinuous.
(2) Method: Thread form moulded or incorporated by the use of a metal

insert
(3) TYPE OF PRODUCTION: Manual Semi automatic or fully automatic
(4) Other consideration: Does the required thread form allow for stripping
etc
MOULDS FOR INTERNALLY THREADED COMPONENTS
(1) Fixed threaded core design
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The core with thread form is fixed to the moving mould plate The
moulding remains on the core and is unscrewed by the operation mould
cost is considerably cheape r mould maintanance costs are kept to a
minimum
(2) Stripping internally threads
The internally threaded component can be stripped from the core using
stripper plate provided a roll thread is required and the moulding is free
to expand during ejection to permit the moulded undercut to ride over
the restriction on the core
(3) Loose threaded core
The loose threaded core is ejected with the moulding and the threaded
core is unscrewed from the moulding by the operator it is necessary to
use minimum two sets of loose cores during production
(4) Unscrewing moulds
The threaded core is rotated in an axially fixed position with respect

to the cavity the moulding is progressively ejected provided the cavity is
maintained stationary
(5) ROTATING CAVITY
Rotating of cavity inserts Causes the moulding to be progressively

unscrewed Power and transmission systems :
The Power System used are
(1) Manually powered
91
(2) Machine powered
(3) Hydraulically or pneumatically powered
(4) Electrically powered
TRANSMISSION SYSTEMS USED ARE
(1) Chain and Sprocket

(2) Rack and pinion
MOULDS FOR EXTERNALLY THREADED COMPONENTS
(1) Fixed threaded cavity design
The moulding is unscrewed from the mould plate This operation be mannual
or power assisted
(2) Automatic unscrewing:
In this the core shaft is rotated and the moulding is progressively unscrewed
from the cavity
(3) Stripping External threads
External threads can be stripped from the cavity provided the component
has a rolled thread form and the material is Sufficiently elastic to return
to its original Shape after being deformed
(4) Threaded splits
When automatic production is required for an externally threaded

component and where the thread form is such that it cannot be stripped
the Split design is used.
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14 MULTI DAYLIGHT MOULDS
when a basic mould consisting of two parts is op en there is only one

space or daylight between the two moulds halves This is called a Single
-day light mould In a Stripper plate mould Which Which consists of a
fixed mould plate the moving mould plate and the Stripper plate there
are two daylight when opened This is called a double -day light
Stripper plate mould Another type of mould which also consists of
three main parts a feed plate a floating cavity plate and a moving mould
plate has two day lights and is termed as double day light underfeed
mould or three plate moulds This design permits a particular feed
technique know as underfeeding
A combination of Stripper plate and Under feeding results in a triple –day

light mould
UNDER FEED MOULDS
An Underfeed mould is one in which the feed System is arranged to

feed into the underside of the component The Under feed mould is
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basically a two -part mould With an additional plate mounted on the
front This pla te termed the feed plate incorporates the runner Which
can be directed to any point on the cavity plate.
The main uses of the Underfeed type of moulds arc
(1) Mouldings produced on multi impression moulds can be centre fed
(2) Off centre feeding can be achived for both Single and multi impression
moulds
(3) Multi – Point feeding can be accomplished on both Single and multi –
impression moulds
The moving half consist of the moving mould plate assembly Support
blocks back plate ejector assembly and the ejection System
The floating cavity plate is located on guide pillars fitted into the feed
plate Guide bushes are fitted into the moving mould plate and the
floating cavity plate the movement of the f loating cavity pl ate is
controlled by stops bolts Sufficient space between the feed plate and
floating cavity plate is maintained for easy removal of the Feed System
the desired operating sequence is for the first daylight to occur betw een
the floating cavity plate and the feed plate This ensure that the spure is
pulled From the Spure bush immediately mould is opened To active
this Sequence springs are provided between feed plate and floating
cavity plate Extra length bolts are also included to pull the plate the
remaining distance if the floating cavity plate stops before completing
the required movement .
Since a major part of the feed System is accommodate in the feed plate
the runner Should be of a trapezoidal form for easy extraction if a round
runner is for easy extraction if a round runner is for easy extraction if
a round runner is used there are chances of it remaining in floating
cavity plate preventing the falling of feed System
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OPERATION CYCLE
The impressions are filled via the feed System and after a Suitable
dwell period the machine platens start opening An immid iate force
exerted by the compression Springs causes th e floating cavity plate to
move away With the moving half the spure is pulled from the spure
bush by the spure puller movement of floating cavity plate is arrested
by the stop bolts at a pre determined distance the moving half co ntinues
to move back and the mouldings are with drawn from the cavities The
pin gate breaks The spure puller is pulled through the floating cavity
plate and the feed System is released to fall free The moving half
continues to move back untill the mouldings are ejected
TYPES OF FEED
The Shape of the Component effects the design of the floating cavity
plate Which in turn determine the form of feed System The depth of
Steel Situated below the cavity impression should be sufficient to with
stand the applied injection force with out deflection
A group of depth of steel required below the cavity impression plotted

against the cavity diameter is given in fig . Reuleaux’s formula for
circular flat plate Screwed all around the edge With a uniformly
distributed load over unsupported area
t=
3
(PR4/ 6Ed)
Where
95
t = thickness of the plate (m)
P = the pressure (N/m 2) (Pa)
R = the deflection (m)
d = the deflection ( m)
E = the modulus of elasticity (N/m 2)
SECONDARY SPRUE GATE
This Spure gate connects the runner to the impression instead of the
nozzle exit to the impression The Spure gates must be degated in an
extra operation
REVERSE TAPERED SECOND ARY SPURE
This design allows a pin gate to be used the secondary sprue gate termitiates
a short distance from the impression A Standard type of pin gate can be
used . In this method the feed System is not free to fall When the mould
is opened because the secondary Sprues are retained With in the floating
cavity plate The feed System must be removed by hand This can be
avoided by the following methods
UNDERCUT RUNNER SYSTEM DESIGN 1
This design has a runner Which is undercut at either end in the feed plate
and a delayed acting sprue puller The mould opens at P1 and because
the runner is retained in the feed plate by the undercuts the pin gates
break The sprues not pulled at this stage becaus e of the float permitted
by the puller The moving half and the floating cavity plate move back
together Floating cavity plate move back together floating cavity plate
move back together floating cavity plate move back together leaving
the feed System in the feed plate When the puller’s floating distance is
exceeded the spure is pulled and because of the undercuts the runner is
distorted as it is pulled from the feed plate . The floating cavity plate
arrested and the moulding are withdrawn from he cavities the feed
System is released as the puller is pulled through the floating cavity
plate. Continued movement of moving half causes the mouldings to be
ejected.
96
The following points are to be considered in the design
( i) The Float period must be sufficient to permit the reverse tap ered
sprues to clear the cavity plate before the puller pulls the Spure
(2) Considerable runner deflection is necessary to ensure that the

Secondary Sprues are not pulled back into their holes When the puller
is actuated
(3) The diameter of the puller must exceed the width of the runner to
ensure that the puller is pushed back to its position when the mould is
closed
UUNDER CUT RUNNER SYSTEM DESIGN 2
In this design the float period is achieved by Secondary puller When

the mould is opened the spure is pulled immediately by the Spure puller
The entire feed System moves back with the cavity pla te along with
secondary pullers When the floating distance of secondary puller When
the floating distance of secondary puller is exceeded the feed System is
arrested and the secondary spure are with drawn Further movement
causes the distortion of the runner and the feed System is released
Finally the moulding are pulled from their cavities and are ejected The
points to be considered in the design are
(1) The secondary pullers must be keyed in order to prevent their rotating
(2) A front plate is necessary to support the heads of secondary pullers
( 3) There is a tendency for the feed System to be retained by the

secondary pullers when the mould is opened A pneumatically opera ted
Wiper can be used to eject the feed System
97
RUNNER STRIPPER PLATE DESIGN
A positive pulling of the secondary sprues from the floating cavity

plate and a positive ejection of the feed system is achieved in this
design A fixed Secondary puller is fitted directly below each Secondary
Sprue.
A runner stripper plate is used to release the feed System from

Secondary pullers as the mould opens the secondary pullers retains the
feed System causing the gates to be broken and the secondary Sprues to
be with drawn The feed System is Stripped from the puller by the
Stripper plate. and cavity plate is arrested Now the final opening occurs
and the mouldings are drawn from the cavities and are ejected .
DESIGN FEATURES
1 The runner stripper plate must be of the same Size as the other mould
plates and is mounted on the main guide pillars
2 A bush can be used in the Stripper plate for the spure bush This
permits the replacement of bush when wear occur In order to avoid wear
the sprue bush can be tapered at the front and a corresponding angle
should be provided in the Stripper plate hole
3 The Spure must be kept as short as possible by Si nking the head of

the sprue bush well into the feed plate An air jet arrangement is used
to blow the feed System clear
98
4 Extra length bolts should be used to pull the floating cavity plate
positively to the correct position
There are two alternative designs:
1 Underfeed /runner stripper plate design with an extended nozzle
2 Underfeed /runner Stripper plate design With a heated Sprue bush
In the type (1) a heated extended nozzle protrudes into the front fac e of
the mould and touches the front face of the floating cavity plate The
nose of the nozzle fits into the Stripper plate In type ( 2) a heated spure
bush is used as a part of the mould Structure
TRIPPLE DAYLIGHT MOULDS
The 4 basic plates in the assembly are
(1) The feed plate
(2) The floating cavity plate
(3) The Stripper plate and
(4) The moving mould plate
99
A combination of stripper plate design and under feeding design results
in a triple day light mo uld There fore the location and number of guide
pillars must be considered
The guide pillar can be mounted in the feed plate for supporting the
cavity plate and alligning the cavity and core The Stripper plate is
supported on the r ods Which connect the Stripper plate to the ejector
assembly Tie rod bushes are provided in the core plate. In an alternative
design the guide pillars are mounted in the core plate for supporting
stripper plate only and secondary guide pillars are used
This design has certain disadvantages
(1) A large mould area is necessary for the extra guide pillars
(2) The temperature control System is more Complex because of the number
of large diameter holes
(3) The guide pillars tend to box in the making its removal difficult
unless Special cave is taken to avoid this feature when mould height is
limited this design advantageous as direct actuation of stripper plates
possible
As the mould opens the spure is pulled immediately by the spure puller
cavity plate when the floating distance of the Spure puller is exceeded
the feed System is arrested and the g ates break and the Secondary sprues
are With drawn continued movement causes the mouldings to be drawn
from the cavity and are ejected.
15 RUNNERLESS MOULDS
Any mould in which a conventional runner less mould is not incorporated

is called a runner less mould A mould which incorporates a direct feed
from the nozzle is a basic runner less mould . This basic arrangement have
been developed in order either the spure all together by using different
types of nozzle designs There are four types of nozzles
(1) Long reach nozzle

(2) Barb nozzle
(3) Antechamber design
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(4) Multi-nozzle manifold
(1) LONG REACH NOZZLE
These extended nozzles protrude into a pocket machined in the mould plate
thus reducing the length of spure gate. The temperature of the nozzle is
controlled by heating it by us ing a resistance type of band heater or
thermo couple
(2) BARB NOZZLE
To reduce the blemish being left at the injection point due to a

conventional sprue gate the barb nozzles are used A reverse tapered
Spure and a pin gate arrangement is possible by using a barb or italian
nozzle The projection of the end of the nozzle incorporates barbs and is
accommodated in the reverse tapered spure
(3) ANTECHAMBER DESIGN
This is also known as the hot w ell design A Small mass of material is
retained in the ant echamber The plastic material adjacent to the mould
partially insulates the central core of plastic material from the cold
mould allowing it to pass through the anthe chamber into the impression
As it is not necessary to remove the spure from the mould flat moulding
cycles can be achieved
(4) MULTI NOZZLE MANIFOLD
Multi-nozzle manifold is used for direct feeding of material for muti

impression mould s it consists of a manifold block Suitables drilled to
provide a flo w path for the material into Which the required number of
nozzle are fitted The manifold block is fitted to the cylinder of the
machine via a nozzle adaptor and a long ring . To permit even filling
of the impression Seperate temperature control of each nozzle is
necessary Each impression will have its own spure bush The barb
nozzle or ante chamber design can be used if pin gating is required The
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number of impression is limited to the number of nozzle which can be
accommodated With in the aperture in the platen in view of this and
other limitations this design is not commonly used
HOT RUNNER MOULDS
Hot runner designs are Systems by which the runner is kept at an

elevated temperature with in the mould This eliminates the necessity of
removing the runner System from the mould as a part of moulding
Cycle The moulds contains a heated runner manifol d block With in its
structure The block Suitably insulated from the rest of the mould is
maintained at a closely controlled elevated temperature to keep the runner
permanently as a melt. The plastic material can be directed to the mo uld
extremities without loss of heat and without the pressure loss of heat
and Without the pressure losses associated with temperature variations
The runner manifold block, termed as hot runner unit, is mounted
adjacent to the ca vity plate and accommodated in a grid The plastic
material enters via a Centrally positioned. Sprue bush, passes through the
internal drillings and leaves the unit via a secondary nozzle in line With
the impression When the mould is opene d the moulding is pulled from
the cavity and the Sprue gate breaks at its Small diameter The
remainder of the feed System remains heated with in the limit ready for
next shot
The advantages of hot runner moulds are
( 1) The locat ion of the impression is not confined to the central region
of the mould There fore the large number of widely displaced
impressions can be fed at the same time
(2) The mould is not restricted to a particular machine
(3) It allows for pin gating of mouldings on multi impression moulds
(4) It allows for multi point pin gating on Single impression and multi
impression moulds
102
(5) It allows for side or film gating of large mouldings
The hot runner unit is insulated from the re st of the mould parts Two
methods are generally used one method is to fit small blocks of
Sindanyo insulating material to all sides of the unit screws second
methods is to provide an air gap of at least 15 mm all around the unit
except Where contact With the rest of the mould is necessary The hot
runner unit is accommodated in a pocket behind the mould plate
VALVE - GATED HOT RUNNER UNITS:
In this design of hot runner unit valves are incorporated With in the
unit to seal off the gates for particular period of moulding cycle A
needle valve is actuated When required by a hydraulic cylinder via a
lever arm In the forward position the front end of the needle valve
Seals against a complete entry tapered orifice with in the secondary
nozzle there by preventing material flow through the gate
In operation the valves are kept closed until the injection screw plunger
has moved forward compressing the melt A high pressure With in the
injection cylinder and hot runner unit is developed The needle valves
are than Suddenly opened by the hydraulic actuator and plastic melt
enters the impression at high velocity After the impression are filled the
needle valves are closed allowing the screw plunger to be with drawn
This technique is known as pre compressed moulding or exposion
moulding
The advantages are
( 1) No material can be drool from the gate as it is positively Sealed
( 2) Faster cycles can be achieved as the screw plunger can be

Withdrawn immediately the gates are sealed The Screw plunger can start
to move forward even before the mould is closed
103
( 3) The mouldings produced by this technique exhibit less stress less
entrapped air less apparent flow marks thus important the Surface finish
and physical properties
( 4) The amo unt of Scrap is reduced Since fewer Short Shots or

Wrapped mouldings are produced
( b) Because of the fast filling rates a lower melt temperature is possible

Thus there is less risk of degrading temperature Sensitive materials
INSULATED RUNNER SYSTEM
This System is based on the principle that plastics can be used With in
the mould as an insulation medium because of their low thermal
conductivity. This design is a modification of the underfeed type the
difference being that lager runners are incorporated and a latch
arrangement is included to keep the feed plate and floating cavity plates
locked together . The plastic material forms an insulating skin of frozen
material adjecent to the runner wa ll ( metal ) While the Central Cor e
remains in the molten State. Larger than normal runners are necessary to
allow for this insulating skin and the diameter of the runner should not
be less than 12mm Quick release latches are necess ary to permit the
runner to be removed from between the feed and floating cavity plates ,
in case the runner because Solid due to inconsistent conditions .
16 INJECTION MOULDING OF THERMOSETS
Thermo set injection moulding With r eciprocating Screw machine often

replaces the conventional compression and transfer methods because of
the considerably reduced moulding cycle time This results in saving of
cost and time and increased productivity Also the compo und is more
homogeneously fused by the Screw action and is transferred to the
104
mould cavities at high temperatures This allows for more Uniform
curing and void free compression more Uniform curing and void free
compression of even relatively thick mouldings Larger variations in part
thickness and complex articles having very thin walls are possible
Because the compound is injected into a closed mould greater
dimensional accuracy is obtained the resulting flash is thin and is easily
removed .
Almost all theremosets can be injected – ion moulded provided that they
have the correct properties With respect to feeding plasticising thermal
stability , curing and mould release
Because o f the Screw rotation the material starts melting and its
viscosity is reduced The heat received from the barrel plasticises the
material faster and the viscosity drops quickly After this the
polymerisation of the material starts an d its viscosity increases the
continuous application of heat and mechanical action of the Screw
increases the rate of polymerisation and the material becomes more and
more Stiffer After this point is reduced the polymerisation is c ompleted
and the entire material becomes Solid But the solid material is broken
up due to the continued mechanical action of the rotating Screw.
The viscosity of the thermoplastics remain more or less constant during

the melt temperature Thus the time available to work with or mould this
material is more But the time limit for the thermo set material during
Which it can be Worked With is less thee thermo set material for
injection moulding should exhibit a r apid decreases in Viscosity from
the initial maximum followed by a prolonged period of exchanged
viscosity ( the newly attained viscosity due to heating and finally a
steep is increased in viscosity The minimum viscosity should not be tool
low as other wise too little frictional heat would be transfered of the
material during its passage to the mould cavity and during its passage
to the mould cavity and curing would then depended only upon
conducted heat from the mould cavity and curing would then depended
only upon conducted heat from the mould The compound should have
a long flow time so that the cavity filles quickly and cures rapidly but
not so quick as to cause air entrapment
105
Extra fast curing materials are relatively sensitive to frictional heat
and long flow materials behave in the opposite way Thus the
requirements are conflicting
INJECTION MOULDING MACHINES FOR THERMOSETS
The most popular type of machine used for injection moulding thermosets
is the used for injection moulding thermo sets is the inline Screw
machine it is Similar to injection moulding machines used for moulding
thermoplastics The machines produced by various manufactures differ in
such details as method of barral heating Screw and nozzle design
DIRECT SCREW INJECTION MACHINE
This is also know as the direct in line injection machine and is basically
Similar to that used for the thermoplastic moulding The thermosetting
material fed to the machine is pre heated to a plastic state as the Screw
rotates With in the heated barrel it is then injected through the nozzle
at the front of the barrel directly into the heated mould The main
difference between thermoplastics and thermosetting injection moulding
machine is that the screw has a low or no compression length /diameter
ratio in the letter The infusible behavior of the thermo sets is to be
considered in the machine , mould design and in the operation of the
machine the latter factor is opposite to thermoplastic practice in that
barral temperature are lower and the temperature of the mould is higher
The moulding Cycle time for the conventional moulding of thermo sets
are farily long Although the material cost was less because of the
comparatively longer Cycle time it had difficulties in competing with
thermoplastics The Sophisticated injection moulding mac hinery , the
material technology of fering all sorts of blends and fillers helped the
thermoplastics to match the physical properties offered by thermo sets
The Shorter cycle time offsets the higher material cast of thermoplastics
The advent of DST ( direct Screw transfer direct Screw injection

machine reduced the Cycle time for moulding thermo sets The DST
106
moulding process Seprates the initial material heating Which takes place
in a heated Screw and barrel from t he mould clamping and heating
function As the material is metered by the screw there is no need of
charge Weighting or palletising The material is heated uniformly as it
passes over the Screw the risk of local over heating connected Wi th the
conduction heating of a Static charge as in transfer or compression
moulding the heated softened , material from the nozzle zone into the
mould cavity via the Spure and runner System The precision control of
this Whole Sequ ence of operations brings the material up to or near the
final cure temperature of the mould This reduces the residence time in
mould tremendously Since the material heating and mould clamping
functions are Separate a charge of mat erial can be heated in the barrel
during the cure time of the proceeding device
ADVANTAGES AND DIS –ADVANTAGES OF DST
The principal savings Which occur from DST techniques are these
which arise from the Shorter Cycle time These savings can arise only
if the Shortening of the Cycle time is Sufficient to out weight the higher
machine hour rate of the DST process The higher rate is due to the
larger capital higher maintenance costs and the greater complexi ty of
operation In all Sections ( cross Sectional area) time savings are
available but on thinner Sections the Saving is much less
More saving can be made by using DST processing in the area of

tooling capital expendi ture The nu mber of impressions can be reduced
moulds requiring split forms or Side cores become considerably easier
to manufacture When fewer impressions are involved
MOULD DESIGN
Mould design for thermosetting injection materials generall y follow the

similar Principles used for thermo plastic materials But moulds must be
107
heated to 130 - 300° C instead of being cooled Thermosetting materials
are more abrasive than unfilled thermoplastics Therefore hardened
replaceable gates Sho uld be used and runners Should be chromium
plated to reduce the tendency of mouldings to Stick in the cavities and
thus obstruct automatic ejection
MOULD HEATING
Small moulds upto ( 50 mm thickness ) are heated by conduction heat

from hot plates Larger moulds are heated directly by electrical care
should be taken to ensure even heating of all mould cavities Stripper
plates Should be avoided in the design because they make even heating of
the tool difficult and mould locking may occur
SPRUE AND RUNNERS
Sprues and runners should be as Short as possible Sprue pullers of the

‘Z’ or core type are normally used But ‘Z’ type Should be locked to
prevent rotation The minimise Wear the Spure bush Should be hardened
to at least 55 HRC
Runners Should preferably be fully round and 6mm in diameter The

diameter increases by a bout 30% for runners over 100 mm length
Runner diameter must not be excessive or the essential frictional flow
heating of the moulding material will be lost
GATES AND VENTING
Gating generally follows thermoplastic practice cross Sectional areas

can be Calculated roughly from the recommended formulae for
injection moulding of thermoplastics .
Eg Gate area ( mm2 ) = 23/100 of the mass of the moulding in ‘g’
The gates Should be large enough to allow filling of the mould at

about 40 to 85 g per second .
108
(High rate, refers to shot Weights of more than about 227 g)
Special gates are used for Specific type of mouldings
Eg : - Film gates along both the long edges of rectangular mouldings

minimise Warping Ring assist production of compo nents With moulded
in holes.
Fan gates reduces flow marks in mouldings having large flat surface
Adequate venting is essential to obtain full mouldings free from blis ters
relieved ejector pins and inserts should be used to achive maximum
venting and to achive maximum venting and to case mould filling
EJECTION
Liberal draft angles on moulds and an adequate number of evenly spaced

ejector pins are essential to reduce distortion of mouldings on ejection
Ejector pins Should have Surface hardne ss of about 60 HRC and
Should be of as large as possible
INJECTION MOULDING CONDITIONS
Material / mould temperature
To obtain short cure times the material temperature as it emerges from

the nozzle Should be as high as practicable in the range of 100 to 200 °C
In most cases the temperature of the material emerging from the nozzle
will be at about 30 °c higher than that of the material in the baroal The
increase in material temperature is the result of friction al heat Which
varies With the design and aparture Size of the nozzle and with the
injection Speed used
Thee most important factors affecting the temperature of the material in

the barrel or cylinder temperature the back pressure o n the rotating
109
Screw and the Screw Speed . Nozzle and cylinder heating zone are the
most sensitive means of controlling material temperature. Screw speed
Should be kept as low as is consistent With plasticising a full Shot With
in the curin g time of the moulding Back pressure Should not exceed
4.2 Mpa the prevent over heating of the material. Mould temperatures
Should be as high as possible in the range of 150, 180 C ° to obtain
good quality mouldings
PRE PLASTICISING / MOULDING PRESSURES
There are three pressure parameters to be considered, they are
(1) Back or Counter pressure ( the hydraulic pressure applied to the

screw during the plasticising )
(2) Injection pressure
(3) Dwell or hold on pressure during the initial period of cure.
BACK OR COUNTER PRESSURE
Back or counter pressure is used to prevent the screw from moving

through the plastic or Semi plastic moulding material like a bolt
Unscrewing from a nut it ensures that the forward zone of the barel is
fully packed With preplasticised material and hence the next injection
stroke Will deliver the correct injection Stroke Will deliver the correct
quantity of material While the Screw rotates and forces Volatiles back
to the feed section Where they can escape A too high back presssure
exerts an unnecessarily high load on the Screw drive any may cause
excessive wear of the Screw and barrel liner
INJECTION PRESSURE
110
It i s affected by mould dimensions moulding material plasticity and

injection machine capacity It should be controlled to give a mould
filling rate of about 40 to 85 g per Second Excessive pressure Will
cause burn marks on mouldin g and excessive mould and nozzle Wear it
may also result in air trapping and porous mouldings due to the injected
material curing before the mould cavity is completely filled.
DWELL OR HOLD ON PRESSURE
It is the reduced pressure approximately one sixth of to one half the

injection pressure it is applied after the selected shot volume has been
injected until the Spure is cured it prevents porosity and blistering of
the moulding The exact duration of app lication Will vary With the
type of machine, the size of the moulding the nozzle and sprue diameters
as well as they type of moulding material used
CURE TIME
Cure times are variable depending on the moulding material used the
size of the moulding and the moulding temperature and pressure .
17 THE MOULD CYCLE
111
A mould cycle for a typical Screw injection machine is shown in figure

The mould cycle is made up of a number of elements an y one of which
can be shortened or accelerated thus condensing the entire cycle
PREPARATION OF MOULD DIAGRAM
The mould diagram shows the machine condition needed for the
production of satisfactory parts in minimum time Maximum and
minimum processes for various cylinder temperatures are determined the
mould temperature and the other element of the mould temperature and
the other elements of the mould cycle are kept constant starting at a low
temperature and low pres sure a Series of short Shots will be obtained (
Refer figure ) by increasing the presssure several satisfactory shots will
be produced At Some point as the pressure continued to be increased for
each shot the mould will begin to flash or Stick This then becomes one
point on the flash or Stick line.
A Second series of points are generated at a higher temperature. This

procedure is continued With successive temperature increase until a
temperature is reached at which polymer deterioration starts. BY
connecting all the lost Short shot points a curve is drawn Which
indicates the minimum presssure temperature combination at Which
satisfactory parts can be obtained The curve connecting all the flash
stick line indicates the maximum pressure temperature combination at
which satisfactory parts can be obtained The curve connecting all the
flash stick line indicates the maximum pressure temperature
combination Which can be used to produced satisfactory parts. The area
between the two curves is the mould area Theoretically combination of
pressure or temperature Within this area should produce satisfactory
parts The area between the two curves is the mould area Theoretically
combination of pressure or temperature Within this area should produce
satisfactory components But in actual conditions Some of the fill parts
may Show streaking bubbles or other defects it a record is kept of the
conditions of moulding each part It is found that some defects are
consistently present When parts are moulded in the particular area of the
diagram other areas will produce consistently good parts . The optimum
area will be the one ch aracterised by the highest temperature and
112
pressures necessary to produce parts Which are completely satisfactory
The use of highes temperature and pressure will result in a minimum fill
time
The object of determining the minimum cycle tim e is to produce parts

with maximum efficiency The mould diagram will establish the
optimum pressure temperature combinations .
To determine the minimum cycle time the process is started at a given

mould temperature with the with the h ighest pressure and cylinder
temperature Which will give satisfactory parts Series of shots ( at a
constant pressure temperature With decreasing ram forward line is tried
Below a certain point no satisfactory part can be made Dur ing this test
the cooling time should remain constant After establishing the minimum
ram forward time the same procedure is repeated by decreasing the
cooling time The ram forward time is kept at the minimum This will
establish a minim um moulding cycle for any given cylinder and mould
temperature The procedure should be repeated with either higher or
lower mould temperature until an optimum is reached.
The establishment of an optimum fill time and a cooling ti me effects

the total time the plastic remains in the cylinder. The net effect should be
a lowering of the time in the cylinder so that possibley a higher cylinder
temperature may be Feasible another series of test shots should be made
at various increased cylinder temperature may be feasible Another series
of test shots should be made at various increased cylinder temperature
establishing a minimum cycle for each cylinder temperature A graph of
the minimum cycle t ime versus the cylinder temperature is shown in
figure
The minimum cycle diagram will be very useful when establishing

conditions for a new mould or a new reason . The mould cycle time can
be again reduced by the following procedure. The Fi ll time can be reduced
to a minimum by correct choice of gate Size and location.
113
The Screw retract time should be slightly less than the cooling time. This
can be achieved by increasing the Screw spaced or to reduce the back
pressure. The machine with larger Shot capacity can also be tried.
The mould open time can be reduced by keeping the minimum distance for
mould by keeping the minimum distance for the mould to open just
enough so that the part can be ejected or removed from cavity
The two dis-advantages of reducing the mould time is
(1) The total Shrinkage of the part will be more than if a longer Cycle is
used
(2) The component will have higher moulding stresses
114
18 COMPRESSION MOULDING
Compression moulding is a process of heating and compressing the

powdered moulding material ( Pellet or chopped provided in the mould to
flow and fill in the cavity provided in the mould to flow and fill in the
cavity and allow to harden and cure to take the shape of the cavity
usually only thermo set plastics are compression moulded The cavity is
provided With enough space to accommodate the moulding compound
known as bulk factor
BULK FACTOR
Bulk factor is defined as the ratio of the volume of the mould part to the
volume of the loose powder
Bulk factor = Volume of loose powder

Volume of moulded part.
Bulk factor can vary from as low as 1.1 as high as 18 so the cavity
would have to be much d eeper to contain the material of a high bulk
factor. To minimize the effect of varying bulk factors, With respect to the
size of mould cavity, per forms are used.
Performs are small pellets or tablets of moulding material that are

formed to shape in a special performs mould at room temperature , so no
curing takes place , only densification In addition to this other
advantages of performs are
(1) The mould charges are of Uniform Weight and Size
(2) Mould cavities are filled more easily without the waste of loose powder.
(3) Performs heat faster, thus reducing the mould cycle
115
(4) Because the mould cavity can be made Smaller, the mould cost is
reduced.
Performs are usually made in Shape of performs are usually round flat face
disc, rectangular or Spherical Performs are preheated before placing in
the cavity The purpose of pre -heating is to remove the moisture content
from the pellets and to reduce the cycle time by prewarming it
COMPRESSION MOULDING PROCED URE
For optimum result in compression moulding the following factors are to be

considered.
(1) Mould Temperature:
The mould must be heated to the correct temperature for that particular
resin and mould These temperature ranges from 130 - 350°C
(2) Mould pressure:
The mould pressure to be used must be adjusted for each resin and mould
(3) Press closing Speed
Depending on the particular resin and/or mould configuration the press

closing speed is to be adjusted to result in th e fastest closing
commensurate with good resin flow and no mould damage
(4) Degassing or Breathing
Before final closing of the mould it is usually degassed or allowed to breath.

This procedure consists of bringing the mould almost to full and then
opening it slightly one or more times to allow the entrapped air,
moisture , and liberated volatiles to escape This action helps to ensure a
sound part, free f internal blisters, or entrapped air pockets.
(5) Final cure time
116
This final cure time may be as low as 20 seconds for a very small, thin
walled part, 1 -3 min for larger parts, and as long as 24 h for same
massive . thick walled aerospace rocket nozzle
MOULDS
THERE are basically four different types o f compression moulds They

differ only in the amount of compression which can be applied to the
moulding powder and in the methods used ‘ land’ the mate portion of the
mould to obtain an exact size
(1) Flash Mould:
The Simplest mould type is the flash mould it is fairly in expensive to

make and produces uniformly dimensioned parts . The main drawback
of these mould is the fact that the parts produced are not of the highest
density since the moulding material i s never put under Very high
compression Material Wastage is more in these type of moulds so flash
moulds are usually used to produce small thin parts Which are not of
high quality.
(2) Fully positive mould
Fully positive mould is the opposite of flash moulds It produces parts of

highest density , since the full compression load can be applied on the
moulding and not on the mould the dis -advantage of this mould is that,
unless the amount of moulding material is weighted very accurately, the
part will not be the Same Size each time in the direction of the applied
force.
(3) Semi Positive Mould
The Semi positive mould combines Some of the compression loading

possible with fully positive mould With out at the last moment, a flash
117
cut –off and a land to assure good dimensional accuracy. A minor dis
advantage of this type is the fact that, If the land is made very narrow ,
use as to cause a quick, thin cut – off of the flash the land will Very
quickly , thus resulting in dimensional instability.
(4) Landed positive moulds
Landed positive moulds are Similar to Semi -positive moulds except

that the telescoping portion is deeper to allow more Comp ression on
moulding prior to landing Usually this type of mould incorporates
Substantial lands Which will not Wear out quickly
There are two type of landed positive mould
(1) Internally landed positive mould or horizontal flash mould
(2) Externally landed positive mould or vertical flash mould.
Despite the deeper telescoping of the mould portion, the final

compression is not as great as in the fully positively mould However
the dimensional accuracyis better in landed posi tive moulds
PROCESS DIFERENCE
INJECTION AND COMPRESSION MOULDS
The main difference between injection moulding and compression

mould kept at the required temperature for curing to take place The
polymerisation of thermo set plastics t akes place in the mould and the
necessary heat for the chemical action is to be Supplied by the mould .
Thermoplastics have Scored over thermo set because of the availability

of machines Which can control the process pre cisely ad dition of filler
materials Which improves the material properties and the reduced cycle
tiime
118
19 TRANSFERS MOULDING
Transfer moulding is the process of heating the thermo set material in a

Separate chamber provided in the moul d and then transferring the liquid
into the impression under Sufficient pressure , through runner and gate
There are two methods of transfer moulding
(1) Pot transfer Mould
In this design the resin is heated and liquefied in a po t or transfer

chamber provided in the mould the plunger Which forces the liquid resin
in to the cavity is part of the upper Section of the mould and is actuated
by the platen of an ordinary compression moulding press the volume
area of the pot must always exceed the volume area of all cavities, sprues
and runners by at least 15% Since the total force exerted by the pot is
required to keep the mould from opening and flashing when the liquid
resin is injected into the cavities
(2) Plunger Transfer mould
In this design the material is injected by an auxiliary ram or plunger

Which is part of the transfer press the press platen here are used only to
hold the mould halves together at the requ ired clamping force, The
clamping force must be always 20 25% above the total force Which
might be exerted by all the cavities sprues and runners when operating
under full auxiliary ram pressure other wise the mould will tend to open
during Injection.
119
Transfer mould design: -
For the best results in transfer moulding the design should take into
account the type of mould number of parts to be moulded , and the
material to be used other important consideration are
Gates:
The gate Should always be as small as possible so that the degating

mark is less However they Should not be so small that they cause to
serve re restriction in flow
Runners:
Runners should be as Short as possible to minimise the flow restriction

The best and most expensive runners are full round The most popular
are half round or modified trapezoidal
Vents
Vents for air removal are very important they most often are in the form
of small groov es in the parting line of t he mould from the end of the
cavity to the outer mould edge.
Advantages of transfer moulding
(1) Moulding cycle
In going through the runners and gates, the flow restriction can be large
enough to add a sensible quantity of heat to the liquid resin, thus saving
time in the chamber
(2) Tighter dimensional tolerances
120
Since the material is injected to a closed mould , there is little or no
flash , and dimensions across the parting line are hel d closely Also since
there is little flash, finishing costs are less
(3) Insert moulding:
Because the material enters the cavity as a liquid the pressure against
fragile inserts is less and there is less tendency for pins or thin mould
Section to bend
(4) Encapsulation
Transfer moulding is the only feasible method to encapsulate delicate

electronic parts such as capacitors and transistors, Where maximum
density is required with low moulding pressur e
Family moulds
It is well suited for producing parts of different Sizes Which must be

assembled together here ‘one’ shot allows production of several parts
all connected together by runners, and all cured at the same time In
compression moulding each parts should probably be moulded
Separately and cured for different times, which might result in slight
colour difference
Mould cost
The mould cost in most of the cases is less compared to a compression

mould the wear and tear also is less compared to a compression mould
121
So that dimensional accuracy is kept longer and refinishing is not
required as often
Disadvantage of transfer moulding
Mould Cost
In some cases the cost of the transfer mould Will be more compaired to a
compression mould of the same piece part
Material cost
The material cost per piece part will be more in transfer moulding since
the Spure runner and gate cannot be reused
Mechanical properties
Under certain circumstance the physical properties of transfer moulded

parts can be less in particular directions An example might be a
tendency to Crack around inserts or Weld lines .
TRANSFER MOULDING PROBLEM CHECK – LIST
The following table of common moulding faults and their causes is

based on the assumption that the mould in question has adequate runner
and gating provisions. Incomplete filling knit lines burning blisters, can
122
all result from excessive frictional heat, developed when transferring the
moulding compounded through runners and gets which are too small.
A correct mould design is very important
SPECIFICATIONS OF SP 130 V/CTS COMPRESSION
MOULDING / TRANSFER MOULDING MACHINE
( 1) The machine Will have a 130 tonnes ( 1. 3MN) clamping Unit With
a down Stroking movement and will be mounted on a Suitable M.S.
fabricated base structure
(2) General specifications
(a) Working height (top of fixed mould plate from ground : 940 mm
(b) Estimated floor space 1600 x 2300 (approx)
(c) Height of top platform on power –pack from ground 1290 mm
(3) The locking units Specifications will be as follows
( a) mould locking force 130 tonnes by direct hydraulic clamping unit ,

which can be adjusted upto the maximum tonnage to suit the size of the
mould
(b) Size of plates: 880 x 730 mm
123
(c) Distance between the bars = 650 x 500 mm
(d) Minimum mould height = 200 mm
(e) Maximum mould opening = 550 mm
(f) Maximum Day light = 750 mm
(g) Dia of tie bars 80 mm
(h) Mould opening force main ram = 9.5 tonnes ( 95 KN)
(i) Opening and closing Speed 150 mm/s
(j) Slow opening Speed 6mm/s
(4) To control circuits will be So arranged tha t locking unit can be run in
the following 4 manners by selecting the Sequence with a Selector
Switch.
(a) Inching or hand controls
The hand controls for the moving mould plates the top ejector up down
and the transfer cylinder up/ down are arranged for push buttons
operation The hand controls are so arranged that it will be possible to
operate the machine with Safety gate open during mould Setting
operations However this feature is provided with customers approv al
unless other wise informed accordingly
(b) Compression Moulding Sequence without Breathing
Safety Gate close by hand with gate closing as a signal , the following
operations will take place in an automatic Sequence
Moving mould platen fast advance
Moving mould platen slow approach
pressure build up to a pre -moulding value pressure hold as per time Set
on timer ( The pre -moulding tonnage value Will be adjustable between
minimum of 45 tons to maximum of 80% of locking force )
Moving platen goes up by an amount adjustable by limit Switch.

Moving platen comes down after a pre -determined interval set on a process
timer
124
Pressure build up to a locking pressure and hold
Curing interval by process timer
Moving platen opens fully and stops
Open safety gate by hand
Eject components by operating transfer cylinder and/or top ejector by
manual operation
TRANSFER MOULDING
Safety gate closed by hand With the gate closing as a Signal , the
following operations Will take place in an automatic Sequence.
Moving mould platen Fast advance
Moving mould platen slow approach
Pressure builds platen up and hold
Transfer rams up and hold under pressure
Transfer pressure hold as per time set on timer.
(The transfer ram wil l have an adjustable Stroke limiting its upward
movement)
Curing time by process timer.

Moving platen opens fully and stops
Eject component by operating transfer Cylinder and/or top ejector by manual
operation clean transfer chamber by manual operation.
125
20 CALCULATION COMPRESSION AND TRANSFER MOULDS
MINIMUM MOULDING PRESSURE
Without pre heat:
21.1MPa + 1.93 MPa per 10 mm of depth in excess of 25.4 mm ( max

30 mm)
MASS OF MOULDINGS:
mt = V x
Where mt = total mass of moulding

= density of material
V = total Volume of part including flash factor 10%
TOTAL VOLUME OF LOOSE POWEDER
Vt = V x Bulk factor of Compound
126
DEPTH OF CAVITY OR LOADING SPACE
D = Vt – VC
A
Where VC = Volume of actual cavity Space

A = Area of cross Section of loading Space
D = Depth of loading Space From top of cavity to punch off land
TRANSFER POT CALCULATIONS
The clamping pressure provided by the hydraulic cylinder is an important

consideration If the total cavity area is greater than the total pot area
the pressure exerted by the plastic compound would tend to open the
mould at the parting line To ensure perfect mould locking the area ( AP)
Should be 25% greater than the combined area of the moulding
Surface and the area of all runners and Spure ( Sprues)
The diameter of the pot if it is round or square can be calculated once the
area is known
Total area of pot Ap = Total projected area of cavities , runners gates

and Spure + 25 to 30% of total total projected area = 1.25 x total
projected area
Volume of pot VP = ( total Volume of all the piece parts, the runners,
gates and Spure + approxima te Volume of 0.5 to 1 mm thick Cull ) x
Bulk factor
Dept of pot = VP
AP
MINIMUM CROSS SECTIONAL AREA OF SPURE
The minimum cross Sectional area of Spure can be calculated from the
equation
As = m x n x k (mm2)
127
Where M = mass of moulding (including flash, Sprues, runners cull etc)

n = number of cavities
k = flow factor for type of material being used
RUNNER AND GATE DIMENSIONS
The total area of all gates fed by one sprue Should be equal to the
minimum cross Sectional area of the Spure.
Gate Area ( Ag) in a multi impression mould = As x n
Where Ag = Gate of one cavity (mm2)

As = minimum cross sectional area of Sprue
n = Number of cavities
Wg= Ag/c
Where wg = Width of gate
C = depth of gate
SPRUE GATE DIMENSIONING
Type of plastic powder Min Dia D mm R E Cmi K

WOOD FLOUR PHENOLIC 4 0.5(D+5) 2.5 0.8 0.28- 0.30
COTTON FLOCK PHENOLIC 5-6 0.5(D+5) 3 12 0.30- 0.36
FABRIC FILLED PHENOLIC 6-7 0.5(D+7) 4 1.6 0.37- 0.42
MOULD HEATING
The moulds are heated electrically the heating System Should have the
capacity to maintain the mould temperature for Successful operation.
The los ses by radiation convection conduction on the lower and upper
bearing plates.
Q total = 3A sides + 4.5 A basic + covering (KW)
128
Where A side = 2 (length x height) + (Width x height) ( m 2)
A basic + covering = 2 (length x Width) m 2
The heating body Should be capable of maintaining he mould
temperature is
Qh = 0.165 V + A Side + 1.86 A basic + covering ( kW)

x
where V = Mould Volume ( dm 3)
x = heating up period (h)
BULK FACTOR AND SHRINKAGE VALUE OF THE RMO SETTING

PLASTICS
21 OTHER PLASTIC PROCESSING METHODS
A varity of special procedures are widely used in the processing of plastics

in addition to basic procedures like injection moulding compression
moulding and transfer moulding
BLOW MOULDING
Blow moulding is a process of forming hollow articles from a softened

plastic tube The process consists of forming a tube of the melt ( called
parrison) and introducing air into the parsion to expand it, either to a free
blown object or against a mould to form it a definite size and shape.
The equipment used to accomplish this job often consists of an extruder

to plasticize the resin a cross head with die and core to create desired
tube or parsion , an air source to inflate the tube and a press to open and
closed the mould.
129
Theoretically, any thermoplastic resin can be used for a blow moulding
operation However only those materials which show high hot strength
and good stretc h properties at the extrusion temperature and Suitable for
formation of a parsion and the Subsequent blowing can be used In all
cases the extruder should have an L/D ratio of at least 20 : 1 to ensure
complete and through plasticization of the melt.
THERMO FORMING
This is a process where by flat sheet material is converted to a three

dimensional Shape The process requires that the Sheet material be
brought to a thermoplastic state by the addition of heat and then for ced
in to a mould pneumatically or by mechanical means The process is also
called vaccum forming since much of the carly work was done using
vaccum to provide the forming pressure .
There are number of advantages to the thermo forming process on of the

most Significant is that of the tooling In Comparison to the other
methods is relatively in expensive , Since the technique is particularly
Suited to the production of many large parts cost savings can be
impressive many parts With very thin wall thickness can be made only
by this method The process is also ideal for the production of small
number of parts Samples proto type etc The process now is used to
produce such items as refrigerator door liners, automobile dash board
panels cheese containers soft drink cups , signs, packaging etc
ROTATIONAL MOULDING
Rotational moulding also know as roto forming or ratio moulding is a

process in which a pre-determined mass of powder, usually thermo plastics
is charged in a closed mould and caused to Simultaneously rotate into
two. planes While in a hot oven The temperature will be from 260 °-
485°c depending on material and product This cause the powder to melt
and uniformly deposit on the mould Surface When the melting phase is
completed the moulds are moved While Still rotating from the oven in
to a cooling chamber where the moulds are cooled by air circulation or
130
water spray internal c ooling to speed the cycle by means of nitrogen or
water fog is currently being investigated as means of lowering the cost.
After the cooling cycle the moulds are opened, and moulded parts are
removed Gasuline tanks, toy, plastic balls etc are produced by this
method
Advantages of rotational mouldings are
(1) Tooling is Simple and in expensive

(2) Parts produced are strain free
(3) Parts are usually made with uniform wall thickness
(4) No weld lines, sprue marks, gate marks eject ion marks on the parts
(5) No Scrap or very little, is produced
(6) Hollow parts are easily produced with Simple tooling
(7) Usually no Secondary operations are required
(8) Wall thickness change can be easily made with out new tooling or tool
modification.
Dis Advantages are
(1) Not Suited generally for large production runs of small parts
(2) Not Suitable for production of parts With wall thickness less than 0.5
EXTRUSION
Extrusion moulding is used to make continuous Shapes Such as tub es,

rods, Sheets, pipes , Wires, Films, out of thermo plastic materials the
extrusion machine is Similar to an injection moulding machine The
material is fed into the machine through the hopper. The screw compresses
and plasticizes the material until a liquid melt is obtained The melt is then
pumped though the die Which Shapes the extrusion on leaving the die
the extrusion is cooled Sized solidified and drawn off by some type of
131
take off equipment THE final product is then cut to length, reeled up or
coiled.
SURFACE TREATMENT OF PLASTICS PRIOR TO DECORATION
Some plastics notably polyolefin’s and acetals are high resistant to

bonding other media to themselves To over come this deficiency
treatment like f lame treatments such as corona discharge , plasma
discharge and chemical treatment are commonly used
Flame treatment consists of passing the object through an oxidation on

the plastic Surface and enables the adhesion of inks, enamels etc.
In ‘corona’ discharges process high voltage current is used for the

oxidation of the surface In plasma process air at low pressure through an
electrical discharge is used to change the physical chemical
characteristics of plastics In Chemical treatment products are dipped in
acid resulting in an etched surface which makes it respective the point
SCREEN PROCESS PRINTING
The process of printing through a screen consists of forcing ink or paint

through the interstice of a stencilled Screen material is often nylon
mesh or other Synthetic material Metallic Screens Such as stainless steel
are also in common use
HOT STAMPING
Hot stamping by the roll leaf process is a method of decorating plastic

materials The leaf or foil consists of a thermoplastic colour coat applied
to an acetate or cellophane carrier film When a heated die is pressed
132
against the foil carier film the colour coat is release and adhere s to the
product placed beneath it
HEAT TRANSFER DECORATION
It consists of a paper carrier, a fusible release Coat and a thermoplastic

ink hot platen, when it is pressed against the product the ink bonds to
the surface Some of the fusible release coat carrier over With the ink
providing the image with a glossy protective coating
IN MOULD DECORATION
In this method the decoration becomes an integral part of the product

making it most durable and permanent In compre ssion moulding the
mould is loaded With the resin in the usual the mould is loaded With the
resin in the usual manner and closed After a partial cure it is opened
and the Cycle is proceeded after keeping the foil consisting of a pri nted
cellulose sheet and closing it again The foil is fused to the product
during the moulding cycle and becomes part of the mouldings, the foil
or over lay is placed in the cavity prior to the injections. The overlay is
printed in a film of 0.05 - 0.10 mm. thick of the same polymer of that of
the product The ink used to inprint the flim must be heat resistant The
gate location in this case is very important to avoid shifting of the
overlay during injection.
Similar method can be adopted in decorating blow moulded products also
Two colour moulding is an injection process where two colours are

Successively moulded to create their portion of the finished parts The
Shell is moulded first and then it is transferred to another cavity where
the second colour is injected to complete the product.
ELECTRO PLATING OF PLASTICS
Plating is done on many plastics to provide a hard wear and corrosion

resistant surface physical properties su ch as tensile strength , heat
133
deflection temperature etc are also enhanced in plated plastics . The
surface to be plated are to be properly conditioned and Sensitized The
proper choice of resin for products to be plated are also very important
many parts like knobs, light reflectors, name plates etc are made out of
plastics and plated to give metallic appearance with, light weight and
corrosion resistance plating is done on way plastics including Phenolic,
urea , acetal , A B S, Polycarbonate etc
VACUUM MELTALIZING OF PLASTICS
It is a process Where by a bright thin film of metal is deposited on the

Surface of a plastic moulded product or flim While being Subjected to a
high vacuum The deposite d metal may be gold, Silver or most
generally aluminium Deposition is the result of vaporisation of small
clips of the metal to be deposited attached to an electrically heated
filament . When electrical energy is applied to the filamen t the clips
melt an coat the filament Increased energy causes vaporization of this
coating and plating of the product takes place The deposition is
accomplished at high vaccum In order of 0.5 micron The thickness of the
resulting coating is a about 1 micron
22 FINISHING METAL MOULDS
The finish of a moulding largely depends on the finish of cavity and

core High finish helps easy ejection of the component and improves
flow conditions Dull or sand blasted finishes are specified for the
purpose of minimising light reflection These are produced by grit
blasting or acid etching But all the special surface finish Should be
limited to flat area or to sides Which provide considerable dra ft
Different methods are used for finishing metal moulds .
CHROME PLATING
134
Chrome plating of moulds offer the following advantages of friction and

thus facilititates the flow of plastic in the mould and also the removal of the
moulding.
(2) It has excellent resistance to abrasion and protects the mould from Wear
(3) The bright finish is duplicated on the moulded article
(4) Protects the moulding from rusting during Storage.
The thickness of the plating will be greater than 0.025 mm greate r than
0.025 mm.
POLISHING OF MOULDS:
To bring the surface to high finish the moulding Surface are lapped and
polished Lapping is applied to flat and Shaped inserts, cores and cavity
of the mould if the shape of the components allows lapping Lapping is
done on a plate by a profile. lap or by hand using lapping Sticks.
The Surface to be polished are lapped first With rough grade lapping
paste to remove the machining marks medium and fine grade lapping
pastes a re applied to a give a good finish on the surface the final
polishing is done by chromium powder Diamond pastes of different
grades are also used for polishing the moulds.
The amount of material that can be removed by the lapping paste or

diamond paste is only few hundred this care should be taken to remove
all machining marks from the surfaces in the soft stage itself to save
time and labor in finishing the mould after hardening
135
LESSON 23 PROCESS DESCRIPTIONS
Pressure die casting is a process in which molten metal is forced under

high pressure in to a cavity in a metal die in a fraction of a second and
then allowed to solidify when the casting has solidifie d the die is
opened and the diecasting is removed ( ejected ) The process is and allows
Complex Shapes to be cast as almost finished parts and many thousands
of castings can be produced from a set of dies without significant
changes in casting dimensions.
136
There are two basic diecasting
Processes (1) The hot –chamber process

(2) The cold –chamber process
The hot chamber process is used for diecasting metals that melt at lower
temperatures, Such as zinc an d lead , The cold –chamber process is used
for metals that melt at higher temperature such as aluminium magnesium
and brass
HOT CHAMBER PROCESS
The basic components of a hot chamber diecasting machine and die are
illustrated in fig In t he hot chamber process the plunger and cylinder are
Submerged in the molten metal in the holding furnace The power to
pump Zinc into the die cavity is provided by a hydraulic accumulator by
a hydraulic pump at a rate that will bring t he accumulator pressures upto
the desired operating level each time a casting ( shot) is to be made. the
casting sequence in the hot –chamber diecasting process is illustrated in
fig When a shot is made , the control valve opens causi ng the shot
cylinder to force the plunger down and force molten metal through the
nozzle. past the sprue pin, through the runner and gates and into the
system and some of the molten metal flow through the die cavity and
out through ve nts and/or in to over flows After the cavity is filled, the
metal is allowed to Solidify, the casting is ejected and the cycle is
repeated Since the gooseneck and plunger are Submerged in the molten
metal , the system refills automatically when the plunger is with drawn .
COLD CHAMBER PROCESS
The casting sequence for the cold chamber process is illustrated in fig In
this process molten metal is ladled into the cold chamber and then the
plunger advances to force the me tal into the die Except for the manner
in which molten metal is fed into the shot system and injected into the
die, the casting Sequence for the two processes are Similar
137
CLAMP MECHANISM
Because of the tremendous pressures used to inject the molten metal in

to the die, large forces are required to hold the two die halves together
This holding force is accomplished With the tie bar platen – toggle type
machine construction shown diagrammatically in fig.
The constru ction arrangement not only achieves the required holding (
clamping) force, but it also opens and closes the die rapidly This speed
helps to achieve the high production rates of the diecasting process.
DIECASTING DIES
Die casting dies consists of two Sections

(1) The Cover half and
(2) Ejector half
Which meet art the parting line The basic components of hot -chamber
die casting die are illustrated in fig The cover half of the die is secured
to the front or stationar y platen of the machine The Spure for filling the
die cavity is in this half and it is aligned With the nozzle of the hot
chamber machine The ejector half of the die is attached to the movable
platen of the machine It contains the ej ection mechanism and in most
cases the runners.
The die cavity which forms the part being cost is machined into both
halves of the die block or into inserts that are installed in the die blocks
The die is designed so that the casting remains in the ejector half when
the die opens The casting is then pushed out of the cavity with ejector
pins that come through holes in the die and are actuated
138

Plastic Mould (Theory)

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Plastic Mould (Theory)

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INDO GERMAN TOOL ROOM

PLASTIC MOULD (THEORY)

PLASTIC MOULD (THEORY)

The plastic is a Synthetic Plainer of high made cular Weight composed

(i) Thermo plastics

(ii) Thermo sets

Thermoplastics or thermo resin consist of long molecules each of it

In thermosetting resin the reaction portion of the molecule s forms cross

Ex : Injection moulding of thermo sets some plastics are the members of

These plastics are produced commertially in granular from for optimum

The thermoplastic materials changes from granular from to

Melt Flow Index (MFI)

This indicates the flow capacity of different thermoplastics and is

Spiral flow index (S.F.I)

It is another way of expressing the flow of a particular way of expressing

Grade SFI at 260° cyl temp 17 MPA injection pre

Flow length to wall thickness ratio

M 17.30 1.7 150

M 56 .30 5.6 275

Application : Thin walled rigid container for packing toys , refrigerator s

LOW Density poly Ethyl lene [L DPE]

Trade name Ackathence; Indo thene ; pol ythene it is a crystalline plastic

Trade name koylene

Acryonitrile Butadyne Styrol ( ABS)

Trade Name: polysac ABS OR ABS Polac.

Acrylics ( PMMA) Poly methyl methacrylete Trade name pers pecs

properties : “PMMA” is a hard , rigid material With excellent optical

Poly Venyl chloride [P.V.C]

Trade Name : Nocil P.V. C; caliplast ; Sri Ram venyles Properties

Plasticizer is added to get soft and flexible product Which is easily

Poly carbonates [PC]

P.c is outstanding in transparency toughness and temperature resistance

Uses : Largely used in electronics because of fire resistant, good

Trade name Akulone ; Tufnyl ; Gujlon; Nylon Properties Nylons ( PA)

Uses Transparent parts for mechanical medical use components with

Thermo plastics polyesters :

Poly Urethane (PUR)

Trade name: Foom

It is highly abrasive and impact resistant material it posesses good

Thermo setting Materials.

Among plastic Materials -thermo – setting materials generally provide –one

(i) High thermal stability

(ii) Resistance to deformation under load and high dimensional stability.

(iii) High rigidity and hardness.

( i) A resin System Which generally contain such components such as

( ii) Fillor and or roiin forcements Which may consist of mineral or

( 1) Alkydes : Alkydes are primely electrical materials There mould ability

Typical uses of alkydes includes circuit breaker , insulation capacitor and

Diallyl phthalate [DAP] is most commonly used m oulding material in allylic

( iv) Ureas : [ Urea -for malde hyde ] Excellent colourability moderately

Uses: for producing lighting fixtures, wiring device etc

(v) Phenolics: [ Phenol Formalde hyde]

They posess extreem hardness, excellent and permanent Colourability, arc

Polyesters resin may be formulated as brittle and hard tough and

Fillers and Additives

The Second group of additives active their effect by chemical relations

Fillers are classified as inorganic organic , mineral natural and synthetic

Fillers normally endow the plastic With Specific mechanical , Physical

Large amount of inorganic and mineral fillers increase brittle ness (

( i) Cost, availability and Uniformly

(ii) Competability or melt ability With the resin

(iii) moisture absorption

(iv) Physical absorption

(v) Thermal Stability and mould temperature