INJECTION MOULD

GENERAL MOULD
Injection mould is an assembly of
CONSTRUCTION parts containing within it an
impression into which plastic
By material is injected and cooled.
Y.HIDAYATHULLAH
TECHNICAL OFFICER – CAD/CAM
CIPET – MYSORE.

IMPRESSION CORE & CAVITY

The impression is formed by two mould
members:
Impression is defined as the
1.Cavity : Which is the female portion of
part of mould which imparts
the mould, gives the moulding its
shape to the moulding. external form.
2.Core: Which is the male portion of the
mould, forms the internal shape of the
moulding.

CORE PLATE & CAVITY PLATE CORE PLATE & CAVITY PLATE

The plate or assembly which contains

the core is termed as core plate.
The plate or assembly which contains
the cavity is termed as cavity plate.

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 SPRUE BUSH SPRUE BUSH

During the injection process plastic

material is delivered to the nozzle of
the machine as a melt; it is then
transferred to the impression through
a passage. This passage is a tapered
hole within a bush. The material in this
passage is termed as sprue and the
bush is called sprue bush.

RUNNER AND GATE RUNNER AND GATE

Runner is a channel machined into the
mould plate to connect the sprue with
the entrance (gate) to the impression.
Gate is a channel or orifice connecting
the runner with the impression.
Feed system is a flow way which
connect the nozzle of the injection
moulding machine to each impression.

REGISTER RING GUIDE PILLARS & GUIDE BUSHES

To mould an even walled article it is necessary

If the material is to pass without
hindrance into the mould, the
nozzle and sprue must be
correctly aligned. This
achieved by Register Ring.
to ensure that the cavity and core are kept in
alignment. This is done by incorporating guide
pillars and guide bushes. Guide pillars on
one mould plate which enters corresponding
is guide bushes in the other mould plate as the
mould closes. Guide bush is incorporated in a
mould to provide a suitable wear resisting
surface for the guide pillar and to permit
replacement in the event of wear and damage.

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REASON FOR KEEPING
CORE IN MOVING HALF
• When moulding cools, it will shrink on to
the core and remain with it.
• Ejector system to be provided to push the
moulding from the mould is difficult to make
in cavity side and can be easily provided in
core side.
• In case of single impression, under feed
moulding, the cavity must be in the fixed half
and the core in the moving half only.
INTEGER CAVITY & CORE
When the cavity or core is machined from a
large plate or block of steel, or is cast in one
piece, and used without bolstering as one of
the mould plates, it is termed as integer cavity
plate or integer core plate. This design is
preferred for single impression moulds
because of the strength, smaller size and lower
cost characteristics. A 4 ¼ % Nickel-chrome-
molybdenum steel (BS 970-835 M30) is
normally specified for integer mould plates.
FIX HALF & MOVING HALF
The half attached to the stationary
platen of the machine is termed as
fixed half. The other half of the mould
attached to the moving platen of the
machine is known as moving half.
Cavity is situated in fixed half and core
is situated in moving half of the
machine platen.
METHODS FOR INCORPORATING
CAVITY & CORE
1.Integer method: Where the cavity
and core can be machined in from
steel plates which become part of the
structural built up of the mould.
2.Bolster method: Where the cavity
and core can be machined from small
blocks of steel, termed inserts, and
subsequently bolstered.
INTEGER CAVITY & CORE
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 INTEGER CAVITY & CORE INTEGER CAVITY & CORE

INSERT BOLSTER CAVITY & CORE INSERT BOLSTER CAVITY & CORE

A recess or hole is made in the cavity or

core plate to accommodate the insert
which is then securely fitted into
position. For moulds containing intricate
impressions, for multi impression
moulds, it is not preferred to machine
cavity and core plates from single
blocks of steel as with integer moulds.

INSERT BOLSTER CAVITY & CORE INSERT BOLSTER CAVITY & CORE

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INSERT BOLSTER CAVITY & CORE INSERT BOLSTER CAVITY & CORE

INSERT BOLSTER CAVITY & CORE FOR AND AGAINST INTEGER AND
INSERT-BOLSTER METHODS
1. Cost
2. Number of Impression
3. Multi-impression mould alignment
4. Mould size
5. Heat Treatment
6. Replacement of damaged parts
7. Cooling system
8. Conclusions.

FUNDAMENTAL REQUIREMENTS BOLSTER MATERIAL

OF A BOLSTER
Bolster is normally made from Mild Steel
plate to the BS 970 – 040 A15
1.It must provide a suitable pocket into specification. A Medium carbon steel
which the insert can be fitted. (BS 970 – 080 M40) can also be
preferred.
2.It must provide some means for securing
the insert after it is fitted in position.
3.It must have sufficient strength to
withstand the applied moulding forces.

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 TYPES OF BOLSTER TYPES OF BOLSTER
1. Solid Bolster: Suitable for both Rectangular and
Circular inserts.
2. Strip type bolster: Suitable only for Rectangular
inserts.
3. Frame type bolster: Can be used for both type
inserts. But particularly suited for circular inserts.
4. Chase bolster: This type is used in conjunction
with splits.
5. Bolster plate: This is used in particular
circumstances with both rectangular and circular
inserts.

TYPES OF BOLSTER FITTING INSERT TO SOLID BOLSTER

GUIDE PILLAR & GUIDE BUSH SPECIFICATION TYPES OF GUIDE PILLARS &
GUIDE BUSHES

1.Leader Pin
2.Standard Guide pillar & Guide bush
3.Spigotted guide pillar & Guide bush
4.Surface fitting guide pillar & guide bush
5.Pull back type guide pillar & guide bush

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 LEADER PIN STANDARD GUIDE PILLAR & GUIDE BUSH

SPIGOTTED GUIDE PILLAR & GUIDE BUSH SURFACE FITTING GUIDE PILLAR & GUIDE BUSH

PULL BACK TYPE GUIDE PILLAR & GUIDE BUSH SIZE OF GUIDE PILLARS AND GUIDE
BUSH BASED ON MOULD SIZE

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 LOCATION OF GUIDE PILLARS AND MATERIAL FOR GUIDE
GUIDE BUSH ON MOULD
PILLARS AND GUIDE BUSH
• The surface of the guide pillar and guide bush
must be hard and wear resisting. This is achieved
by machining the component from low carbon steel
(BS 970-080 M15) which is subsequently case
hardened. This process gives a surface which
resists pickup and scoring as the guide pillar
continuously enters and leaves.
• If the guide pillar is likely to be subjected to
bending forces, the use of a carburizing nickel-
chrome steel (BS 970-835 M15) is to be preferred.

MOULD ALIGNMENT MOULD ALIGNMENT

Any misalignment in the mold will have

one wall thinner than the other. In addition
to this material entering the mould will
take the easiest route and flow down the
thicker section first. This will tend to move
the core further out of alignment, and
result in un acceptable mouldings.

TAPER LOCATION TAPER LOCATION

For most small moulds the guide pillars are normally
able to maintain alignment of the two halves within
reasonable close tolerance irrespective of the force
applied during injection. However, moulds for thin-
walled articles require special treatment as even a
slight misalignment can not be tolerated. With some
very large moldings the size of pillar necessary to
maintain alignment becomes excessively large. In
either case the designer must consider means of
maintaining alignment without relying entirely on
guide pillars. A satisfactory way of achieving this is by
the incorporation of a tapered location, normally in
addition to the guide pillars.

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SPECIFICATION OF TAPER LOCATION SPRUE BUSH
Is a connection member between the machine nozzle
and the mould face, and provides a suitable aperture
through which the material can travel on its way to
the impression or to the start of the runner system.
Sprue bushes are made from 1 ½ % Nickel Chrome
steel (BS 970-817 M40) and should always be
hardened.
The internal aperture of the sprue bush has between
2 to 4°included taper, which facilitates the removal of
the sprue from the mould at the end of the moulding
cycle. .

TYPES OF SPRUE BUSH TYPES OF SPRUE BUSH

1.Spherical seating
2.Flat seating

SPRUE BUSH & NOZZLE SEATING REGISTER RING

Register ring also called locating ring or

location ring is a circular member fitted on
to the front face of the mould. Its purpose
is to register or locate the mould in its
position on the injection machine.

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 REGISTER RING TYPES REGISTER RING TYPES

1.Reduced Diameter type

2.Constant diameter type
3.Increased diameter type
4.Increased depth type

LOCATING MOULD WITH MACHINE METHODS OF SECURING SPRUE BUSH

WITH LOCATING RING
PLATEN BY REGISTER RING

MOULD PLATE FASTENINIG MOULD PLATE FASTENINIG

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ATTACHMENT OF MOULD TO MACHINE PLATEN DIRECT BOLTING METHOD

Two methods of attachment of

mould with machine platen are;

1.Direct bolting method

2.Indirect bolting method

INDIRECT BOLTING METHOD

THANK YOU

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