WELCOM TO SEMINAR ON

INJECTION MOULD

By
Mr. Biswaranjan Swain
Mould

MOULD :- It is an assembly consists of an Impression, which is

a recess or gap similar to the Component formed by the two Mould
members termed as ‘CORE’ and ‘CAVITY’ , into which the molten
Plastic Material is Injected under Pressure an is allowed to be cooled
either by water or air till the component gets hard.
CAVITY :- It is female part of the mould, which gives the external
shape of the Component. Pockets, Slots , holes are considered as
Cavities. These are highly polished to a mirror finish ,requires better
finishing appearance on the outer surface of the component.

CORE :- It is male part of the mould, which gives the Internal shape
of the Component. All Projections are considered as Cores. These are
not required high polish as the component is to be sticks on to core .
BUMPER MOULD
PAINT CONTAINER MOULD
 CLASSIFICATION OF MOULD

COMPRESSION MOULD TRANSFER MOULD BLOW MOULD ROTO

HAND TYPE FLASH TYPE POT TYPE PLUNGER TYPE EXTRUSION INJECTION STRETCH

POSSITIVE TYPE
INJECTION MOULD THERMOFERMING MOULD

EXTRUSION

Based on function ACC. 2 CON. ACC..2 RUNNER SYS.

VACCUM PRESSURE
-- HAND
-2-PLATE -COLD RUNNER
-- SEMI AUTOMATIC
-3-PLATE -HOT RUNNER
--AUTOMATIC

FILM EXTR. PIPE EXTR.

 Primarily the plastic is divided in two types
according to their performance characteristics
Thermosetting Type Thermoplastic Type
These plastics undergo a chemical They can be melted and
change during moulding , get solid on cooling,
becoming solid so they can not be They can be reused.
melted
Resistance to chemical Limited resistance
Limited colors Wide colors range

High toughness Toughness with additives

Excellent dimensional stability Very few plastics

 WHY PLASTICS

Why we use plastic material in the first place

instead of traditional such as metal.
In general plastic offers impressive advantages
over metal which are as following.
They are not subjected to corrosion.
They are light in weight with good strength to
weight ratio.
 Very cost effective.
 High production rate.
 Design freedom.
 Good electrical insulation property.

 Availability of wide colours.

 Reduced assembly time
 High toughness if mixed with additives.
 High resilience.

 Vibration damping, like as gears

 Low co-efficient of friction

 Thermal Insulation.
 Applications of plastics
House hold
Industrial application

Consumer goods
Engineering application
Automobiles part
Agricultural uses
INJECTION MOULD

Thermo plastic materials are used in injection moulding.

The thermo plastics soften and become plastic in state

by the application of heat and harden when cooled.

There is no chemical reaction taking place during the

process of heating and cooling.

These materials have linear molecular chains that flow

over each other when heated and solidify into a new shape
when cooled without significant chain breakage
Principle and process of injection moulding :

The process of injection moulding essentially consists

of plasticizing the raw material in a cylinder by the
application of heat and then injecting it under pressure
through a nozzle by means of a ram into a closed mould,
where it is allowed to cool, and then opening the mould
and removing the moulded component.

There are two methods employed to inject the plastic

material into the mould: one by means of plunger and
another by means of a screw which transports the
materials during which time it is plasticized and then it
is injected.
INJECTION MOULDING MACHINE
Typical zones of screw

Feed zone: The screw with large space to carry more

material
Compression zone: The depth of thread reduce,
leading to elevated pressure, and pressure induced
melting

Metering zone: small and uniform thread to provide

uniform controlled quantity. This also serves as final
Mixing.
PARTS OF THE MOULD :-The Mould Consists of the following
9) Locating Ring
1) Top plate
10) Tie Bar
2) Cavity plate
3) Core plate

4) Core back plate

5) Riser or Spacer

6) Bottom Plate
7) Ejector Plate

8) Ejector back Plate

 TOP CLAMP PLATE SPRUE BUSH

CAVITY

IMPRESSION

PARTING
SURFACE
STRIPER
RING

CORE

CORE
INSERT
BOTTOM
CLAMP PLATE
Types of injection mould
TWO PLATE MOULD

THREE PLATE MOULD

SPILT MOULD

UNSCREWING MOULD

HOT RUNNER MOULD

2-PLATE MOULD

3-PLATE MOULD
THREE MAIN SYSTEM IN INJECTION MOULD

FEED SYSTEM

COOLING SYSTEM

EJECTION SYSTEM
 FEED SYSTEM
A flow way in the injection mould to connect the nozzle to each impression.
This flow way termed as feed system
The feed system in a mould consists of a sprue, runner & gate
SPRUE
RUNNER

COMPONENT

GATE
SPRUE
The plastic material which remains in the tapered flow path in sprue bush
when It is delivered to the impression is called sprue.
The sprue is the extension of the injection nozzle into the mould.

SPRUE
 RUNNER
Runner is a channel machined into mould plate to connect
the sprue with the entrance (gate) to the impression

There are some considerations for the designer to keep in

a mind during designing of runner for a particular mould

The shape and crossection of the runner

The size of runner

The lay out of runner

SHAPE & CROSSECTIONOF RUNNER

Round
Trapezoidal
Modified trapezoidal
Hexagonal
SIZE OF RUNNER
The size of runner depends upon the following factor

The number of impression

Distance of the impression from the main
runner sprue

Runner cooling consideration

The range of cutter size available

Plastic material to used
RUNNER LAY OUT
The lay out of runner system depending upon
the following factors
The number of impression

Shape of the component

Type of mould

Type of gate
Runner length is kept as short as possible for rapid
filling of cavity & to reduce pressure loss.
The runner system should be balanced
LAY OUT OF RUNNER
GATE
The gate is a channel or orifice connecting the runner
with the impression
It is the thinest part in feed system

GATE SIZE
The size of gate depend upon the following factor

The flow characteristics of the plastics material

Wall section of moulding

Weight of the moulding

Moulding temperature
 TYPES OF GATE
 Sprue gate
 Edge gate
 Overlap gate
 Fan gate
 Diaphragm gate
 Ring gate
 Film gate
 Pin gate
 Submarine/Tunnel/Sub surface gate
DIRECT SPRUE GATE

RECTANGULAR EDGE GATE

Subsurface/Submarine/Tunnel gate

Fan gate
Overlap gate

Diaphragm or Disc gate

Tab gate

Ring gate
Film gate

Winkle gate
Pin gate
 COOLING SYSTEM
In injection moulding hot material enters into the mould
to matained the required temperature between the mould
and plastics material, water is circulated through holes or
channel within the mould, at which it solidifies sufficiently
to retain their shape of the impression.
The cooling system depend upon the following factor
Type & grade of the material to be moulded

Length of the flow within the impression

Wall section of the moulding

Length of the feed system

Types of cooling

U – Circuit
Z – Circuit
Baffled
Helical
Bubbler type
 Water in

Water out

Water in

Water out
 EJECTION SYSTEM

All the thermoplastic materials contracts as they solidify,

which means that the moulding will shrink on to the core
which forms it.
This shrinkage makes the moulding difficult to remove.

Ejection should be positive in action and ejection pin

also placed in a position that the ejection marks will not
be seen on the product when it is in normal use.
It is advisable, if possible, to use a type of ejection
mechanism ,which does not have any marks on the
moulded product.
 TYPES OF EJECTION SYSTEM

 Pin ejection ( stepped pin, D- pin)

 Sleeve ejection
 Stripper plate ejection
 Stripper ring ejection
 Compressed air ejection
 Valve ejection
Pin ejection
D- Pin ejection
Blade ejection
Sleeve ejection
Stripper plate ejection
 FLOW CHART FOR INJECTION MOULD DESIGN

Part design, requirements, quantity ordered, no. of pieces/time

No. of cavities Selection of injection moulding machine

Type of mould

Two plate mould Three plate mould

Conventional sprue Cold Runner Hot Runner Cold Runner Hot Runner

Cavities layout

Star arrangement Symmetrical arrangement Inline arrangement

Type of gating

Sprue Pin point submarine Film Fan Edge Disc/ Diaphragm

 Temperature control system
Type of ejection
Surface Core & Cavity

Pin Stripper Sleeve Air Valve Ring

Oil Water Oil Water

Type of venting

Parting line Inserts Ejector pins Porous metal pins

Mould material

Mould Base Inserts Plates Anticipated shrinkage

Design Part Design Gating Processing

Advantage of injection moulding
Parts can be produced at high production rate
Large volume of production is possible

Relatively low labor cost per unit is obtained

Process is highly susceptible to automation

Parts require little or low finishing

Many different colors surfaces, design and

finishing are available
For many shapes this process is the most economical
way to fabricate
 Process permits the manufacture of very small parts which
are almost impossible to fabricate in quantities
in other method.

Minimum scrap loss result as runner, gate and

rejects can be reground and reused

Disadvantage
Moulding machinery and auxiliary equipment
cost are high

Lack of knowledge about the fundamentals of

the process cause problem

Quality is often difficult to determine immediately