HO CHI MINH CITY UNIVERSITY OF

TECHNOLOGY AND EDUCATION

FACULTY OF MECHANICAL ENGINEERING

DESIGN - PLASTIC MOULD

MANUFACTURING

SECTION I: BACKGROUND OF
TECHNOLOGY INJECTION
1. Plastic Materials:
a. Distinguish between plastic and rubber.
plastic

rubber

Origination

Oil (crude oil)

Rubber tree

Application

Technical, industrial, Tires,

living.
comdom

bubble,

b. Characteristics of thermoset resins and thermoplastic

Thermoplastic

Thermoset

nature

When heating is
plasticized.

When heated to
harden.

shape

Types (grain, flour ...).

Maybe when heated
blanket 2nd.
short

Fixed, it can not be

a blanket when
heated 2nd
long

Molding cycle

Classification of plastic crystalline and

plastics
amorphous

are amorphous
plastics.

c.The types of additives in injection molding technology

Increased toughness PLUB NA21
liquid

Reschedule plastic circuit

HD, PP increases its
resistance
to
impact,
helping the fresh color,
glossy, easy to break the
mold ..

Increased toughness PAO A4085

and increased impact DF840
DF740

Traction circuit absorption

of PAO products help
improve impact resistance,
improves the flow of plastic

c.The types of additives in injection molding technology

create white

TIPURE R103
K -828

Create porcelain white

background (light blue)
as well blazing color,
yellow
shading
regeneration.

Super
bleach OB-1, OBN -1,
(optical
OB-129, OB-X
bleaching)

Absorbs light and the

green light conjugates,
to help cover the yellow
light of the state
components,
which
enables color brighter.

c.The types of additives in injection molding technology

Liquid bleach

CZ- 35
CBS -NF

Stiffener, reduced NU11

shrinkage, reduced PLUB NA21
warping

Optical
bleaching
agent is a liquid used
to
save
space,
dispersed ...
Increasing the density
of
crystalline,
homogeneous
crystallization
and
shorten the time to
crystallize

c.The types of additives in injection molding technology

Increase
(PP)

increase ball

in PCLEAR 383
PCLEAR DM
XT 386

As part of the crystalline

polymer with continuous
center, helps regulate the
crystallization of PP plastic
circuit with both full size,
small, uniformly distributed,
the product helps in hard

PA 500
PALWAX

Increase
surface
gloss
products, favorable diffuse
color

c.The types of additives in injection molding technology

fresh color

PLUB26
AnTiOX

Disperse the color, the color

of the flame retardant
processing

mold release

HP -M

Helps reduce the affinity

between the hot and the
plastic mold, help get
favorable product

UV resistance MASTER UV
and aging
AnTiOX

Durability and resistance to

the environment.

d. The viscosity of the resin and the relationship

between temperature - pressure, volume.
The viscosity of a fluid is a parameter representing the
friction of flow. When the fluid flow adjacent different
movement speeds, in addition to collisions between matter
particles also have the momentum exchange between them.
For plastic materials greatly viscosity

e. Dimensions of a plastic element.

2. The type of error when pressed plastics

products
a. Product assembly bias full size
. Cause: shrinkage of the material
. The formation of error: in the cycle, when taken out of the
mold.
. Remedial measures : rational design thickness, adjusting the
parameters of temperature and pressure for reasonable

2. The type of error when pressed plastics

products
b. Products warping
The formation of error : the distortion and twisting
Cause : change throughout the product shrinkage or a small
part of the product, take out too early, do not fit the mold
design
Remedial measures : increasing time pressure, temperature
control, check the mold design, to avoid internal stress

2. The type of error when pressed plastics

products
c. Products are porosity
The formation of error: The gas bubbles formed inside the pores
or make the product does not fill completely.
Cause: line focus, the air filled mold is kept in place filled final
Remedial measures: product redesign, change positions
injection port, optimized exhaust system, reducing speed
injection

2. The type of error when pressed plastics

products
d. Products with indentations
The formation of error: when the material cools the
shrinkage put a dent
Cause: result of the shrinkage of the material. Crust
products are not strong enough to shrink, the product will
form part of the hollow inside.
Remedial measures: Change the crushed material shrinkage
smaller,, redesigned products, the mold

2. The type of error when pressed plastics

products
e. Products is missing plastic
The formation of error: Plastic products are not filled
completely.
Cause: Melting temperature, mold temperature and injection
speed is too low. Plastic is not entirely of plastic, lack of raw
materials or low-pressure spray, ...
Remedial measures : temperature increase flow, injection
volume, channel navigation system full size ....

2. The type of error when pressed plastics

products
f. Products are bavia
The formation of error: Bavia are formed on the side parting
or placement in the exhaust system.
Cause: Mold clamping force is too low, not sealed shut
mold, mold incorrect.
Remedial measures : hybrid adjustable mold, reduce heat
flow, mold temperature, select the appropriate position ...

2. The type of error when pressed plastics products

h. Products are line connecting
The formation of error: sunspots at the end of the flow
Cause: currents meet, the atmosphere is no place to escape,
the design of the entrance to the path of plastic were
unreasonable.
Remedial measures: check the exhaust system, using lowviscosity materials, identification by analyzing the
characteristics MOLDFLOW

2. The type of error when pressed plastics products

i. The product line of plastic
. The formation of error : into the thick irregular
. Cause : into the thick irregular, low injection pressure, high
temperature molding, resin canals - the entrance with full
size too small, the entrance with full size too large
. Remedial measures : as a thin, many tendons, avoid
sudden changes in the thickness of the product

2. The type of error when pressed plastics products

i.

Products may scratch the

surface stain.
. The formation of error: in mixed
plastic debris is not compatible
with plastics.
. Cause: high stress sliding layers
formed, the dirt is not compatible
with thermoplastics.
. Remedial measures : increased
temperature and reduced flow rate
of injection

2. The type of error when pressed plastics products

m. Products cracked
The formation of error:
Cause: product-force, stress free, internal stress due to
improper molding parameters
Remedial measures : reduce the force acting on the staff, to
review the design, reducing pressure injection-compression
molding, mold cooling, check the temperature uniform
mold, the mold surface temperature rises and the
temperature of the resin flow

2. The type of error when pressed plastics products

n. Products with black burn marks
The formation of error:
Cause: injection pressure is too high, the temperature of the
resin is too high, the air trapped in the mold
Remedial measures : reduced injection pressure and
injection speed, check the exhaust system, the material must
be dried before molding material moisture <1%

3. geometric requirements for plastics injection site

3.1 The thickness of the product:
The thickness of about 0.5 - 4 mm, some special cases, it
may be larger.
In fact, the thickness of the product is made as thin as
possible as well, as evenly as possible
But if the product is not durable enough: increase the
thickness, using different materials have higher durability,
creating or reinforcing tendons to glide to increase
durability.

3.1 The thickness of the product:

correct
the
To
warping, the need to
design
uniform
thickness,
the
following are some
design
work
for
thickness uniformity:

3.2 round off

The radius of in the range of 0:25 to 0.6, preferably 0.5
times the thickness of the product.
The outer radius equal to the radius of the product plus the
thickness

3.3 tendon
The thickness of the tendon should not exceed half the
thickness tendon place.
The ribs should be designed in parallel, the distance
between the tendon should be at least equal to 2 times the
thickness.
Deformed reinforcing: hard to increase the corners, sides,
protruding lugs of the product.

3.3 tendon
In addition to increased strength ribbed design can replace
corrugated folds to increase the rigidity and aesthetics.

3.3 tendon
When designing the cross-junction near the seat forward so
as to ensure a hardness and resistance to stress for the
product.

3.3 tendon
The ribs should be placed along a direction to achieve good
rigidity.

3.4 the paw protruding

The thickness smaller the paw protruding 0.7 times the
thickness of the paw set.
The transition zone between the the paw protruding and
product design radius should bo, bo should choose a radius
0.25 times the thickness of the product.
to increase the stiffness can put the the paw protruding ribs,
the distance between the the paw should be greater than
twice the thickness of the product.

3.4 the paw protruding

The thickness of less than
0.75% the paw to put the paw
thickness.
Outer radius transition with
0:25 to put the paw%
thickness or at least equal to
0.4 mm in order to reduce
stress
The outer taper angle on the
side should be a minimum of
0.50 and smallest taper angle
should be 0250 to ensure the
mold exit

The design parameters of the

the paw protruding

3.4 the paw protruding

To last longer, put away the protruding the paw of products,

designed to add stiffening ribs (at least 3mm)
For products not dent the foot of the paw need to create a
ring at the base of the recess paw to Avoid The
Concentration of material.

3.5 Hole on products

a. holes did not penetrate
. The depth of the hole should not exceed 3 times the diameter.
. if the hole has a diameter of less than 5 mm (3/16 inch
approx), the depth of the hole should be twice the diameter
. the thickness of the bottom of the hole should be equal to 0.2
times the diameter of the hole to eliminate defects for the
opposite side.
. A good design is the thickness of the hole is always equal and
no sharp corners where the concentration of stress.

3.5 Hole on products

b. through Hole
The distance between two holes or between the outer edge
of the hole should be equal to twice the thickness of the
product or twice the maximum size is to measure the
circumference of the hole.

3.5 Hole on products

b. through Hole
As between the hole is too small or complex affect the
molding process can change the design to fit better.

3.9 Corner exit mold

At the core mold cavity short or shallow (less than 5 mm)
taper angle of at least 0.25 per side
the cavity and core depth increased from 1 to 2 inches (25.4
50.8 mm) taper angle should increase to 2 per side
Taper angle needed for plastic Polyolefins and Acetals and
small size is only 0.5 bevel angle, but for the large size,
taper angle may require up to 3 .
Vi vt liu cng hn nh Polystyrene, Acrylic, ngay c
i vi sn phm c kch thc nh, gc cn ti thiu cng
phi l 1,5 .

3.9 Corner exit mold

Note that the smaller the

taper angle, the greater
thrust requirements; so can
damage the product if the
product is not fully
hardened.

3.9 Corner exit mold

A: wide beveled
corner
C: depth beveled
corner
B : cornered

Graphs choose bevelled corner on the height of the

3.9 Corner exit mold

Or can be calculated by the formula
tan=A\C
A: wide beveled corner
C: depth beveled corner

3.10 Lace on products

Foot radius of lace and lace top to the greatest possible to
reduce stress.
Clips all lace creating a smooth passage to prevent
smuggling lace lace lead to damage during use.

false

right

3.10 Lace on products

When designing threaded taper should be designed as
shown below to bond more tightly assembled:

false

right

3.8 Under - cut

Avoid overly complex design undercut.
Thickness no greater than 0.7 times undercut the thickness
of the product in the place where the undercut.
The edges of the mold containing boron undercut should be
inclined to undercut the supply and can easily escape.
Part undercut when removing hot enough to need to be able
to stretch and then return to normal.

3.8 Under - cut

You can change the texture detail to easily remove the
product more

Products originally designed product can not be removed from

the mold

3.8 Under - cut

Products designed to easily remove the product from the mold

However during trinhg avoid mold design mold design

undercut to reduce complexity and cost savings