Mass of Component:

Volume of component : 25.68 cc

Density of Polymer 1.48 gm/cc Ref. Table 4

Mass 38.00 gm 27.5362

25.6757
Runner dia calculations:

Formula:
Full round runner Dia (d) = (m x

m  Weight of one comp. + Feed (gm)

Wt of one component 8.00 gm
Feed ( % of component wt) 15 % Ref. Table 2
Runner Length (L) 155.00 mm
9.2
Full round runner Dia 2.89 mm
Semi circular Runner Dia 4.09 mm 6

LENGTH OF UNDERCUT
Cam pin Length : CAM PIN ANGLE :
FORMULA:
CAM PIN ANGLE - LENGTH OF UNDERCUT / HEIGHT OF SLIDER

LENGTH OF UNDERCUT 15 HEIGHT OF SLIDER

Formula: 40
HEIGHT OF SLIDER
Cam pin Length (L) = (M/sin ) + (2c/sin (2 CAM PIN ANGLE 20.556045

Movement of side-core / split req. 50 mm

Cam angle 25 deg.
Clearance per side of cam pin 0.50 mm

Cam pin Length 119.62 mm 55

CAM PIN ANGLE

Wedge Locking Force:

Formula:
Force = (a x p) / (1000tan ) Tonne

a  Projected area of side-core / Split (cm 2)

Projected area of side-core/split 17.00 sq.cm
Cavity Pressure 500.00 kgf / sq.cm Table 4
Wedge angle 0 deg. Average 5 deg. More than Cam angle

Wedge Locking Force: #DIV/0! Tonnes 8 #DIV/0! ANGLE OF LIFTER:

13.53
#DIV/0!
Wedge Thickness FORMULA :
ANGLE OF LIFTER =UNDERCUT LENGTH/EJECTION STROKE

UNDERCUT LENGTH 10
Formula: EJECTION STROKE 40
Wedge Thickness = 3(12pah) / (8Eb y) cm ANGLE OF LIFTER 14.036243
p  maximum Cavity Pressure kgf/cm 2
= 1/3rd of Injection Pressure for Amorphous Material.
= 2/3rd of Injection Pressure for Crystalline Material
(Refer Table 4)

Projected area of side-core/split 21.50 sq.cm

Cavity Pressure 500.00 kgf / sq.cm Refer Table 4
Height of wedge 2.80 cm
Breadth of split 27.20 cm
Allowable deflection of side walls 0.001 cm

Wedge Thickness 0.85 cm 20

Cavity Insert Wall Thickness

a. For Rectangular Inserts

Formula:
Wall thickness t = 3(C p d4) / (E y)
C  Refer table3
p  maximum Cavity Pressure kgf/cm 2
= 1/3rd of Injection Pressure for Amorphous Material.
Value of ' C ' 0.111 Ref. Table 3
Maximum Cavity Pressure 500 kgf/sq.cm Ref. Table 4
Total depth of cavity wall 0.40 cm
Allowable deflection of side walls 0.015 cm

Wall Thickness 0.04 cm 20

b. For Cylindrical / Round Inserts

Formula:
Maximum Cavity Pressure 800.00 kgf/sq.cm Table 4
Radius of cavity 4.50 cm
Fatigue Strength of Insert Material 420.00 kgf/sq.cm Table*******

Outside Radius of cavity Insert (R) 9.87 cm

Wall Thickness 5.37 cm

Support Plate Thickness

Formula:
Support plate thickness t = (6WL/bf)
Maximum Cavity Pressure 500 kgf/sq.cm Table 4
Projected area of cavity 27.00 sq cm
Width of ejector plate 22.00 cm
Permissible Working stress 3600 kgf/sq.cm Constant for Mild Steel = 3600 kg/sq.cm
Width of cavity plate 35.00 cm

Support Plate Thickness 3.76 cm

GUIDE PIN DIAMETER

Formula:
Guide Pin Diametr(d) = (4 a h p /  f n)
maximum side of core 3.90 cm
maximum height of core 0.80 cm
Cavity Pressure 800.00 kgf/sq.cm
Shear strength of pillar 1600 kgf/sq.cm Constant for Steel = 1600 kg/sq.cm
No of guide pillars. 4

Guide Pin Diametr(d) 0.70 cm

Cooling Water Flow rate

Formula:
Flow rate (Q) = (3.6wQ poly) / (Kt t) lit/hr
w  Weight of molding + feed system in gm
Wt of each Component 8.40 gm
No. of cavities 4
Feed ( % of component wt) 15 %
Total heat content of polymer 100.00 Cal/gm Ref. Table 1
Approximate Cycle Time 30 sec.
Constant K 0.64 0.64 for Direct in Insert & 0.5 for Indirect (in Plate) type
Difference in Temp of Inlet & Outlet Water 3.0 deg C

Cooling Water Flow-rate 108.94 Lit/hr

Hydraulic Cylinder Specs

400000 for converting tonne into kg & mm into cm

Formula:
Force required (F) = (0.35 A s (A s/ A

A s  SurfaceArea of Core in mm
A p  Projected Area of Core in mm
2
Surface Area Of CoreLine Pressure (P) =(400000F/d ) kg/cm
500.00 mm sq
Projected Area Of Core 30.00 mm sq

Force required 0.292 Tonne

Stroke Required 50.00 mm

Cylinder dia 30.00 mm

Hydraulic Line pressure 41.26 kg/sq cm

Machine Selection:
a. Clamping Force

Formula:
Force = (a x p) /1000 Tonne

a  Projected area of molding including Feed system (cm 2)

Total Projected Area of Cavity 326.00 sq.cm
Projected area of Sprue, Runner & gate 0.00 sq.cm
cavity Pressure 500.00 kgf / sq.cm Refer Table 4
Total Wedge Locking Force 0.00 Tonne Wedge locking force x nos of wedges- Refer above formula.

Tonnage required 163.00 Tonne 60

b. Shot Size

Formula:
Wt of each Component 38.00 gm
No. of cavities 2
Feed ( % of component wt) 0 % Refer Table 2

Wt. of Polymer/shot (Wpoly) 76.00 gm

c. Plasticizing Capacity

3.6 for converting time in hours & wt in kgs

Approximate Cycle Time 35 sec.

Plasticizing Capacity 7.82 kg/hr

FINGER CAM CALCULATION

ØØ

M = splits movement
Ø = Angle of finger cam, 10-25
L = working length of finger cam
C = clearance (0.75mm)

The finger cam movement can be computed by the Formula

M = (L sin q) – (C / cos q)
If the required movement is known, the following formula used to determine the finger cam length.
L = (M / sin q) + (2C / sin 2q)
Where, M = splits movements,
q = Angle of finger cam, 10-25°
L = working length of finger cam
C = clearance (0.75mm)
Cam diameter is usually 13 mm.

DOG LEG CAM ACTUATED SPLIT MOULD

Formula for calculating the opening movement, the length of cam, and the delay period
M = La tan q - C
La = (M + C)/ tan q
D = (Ls – e) + (C/tan q)
Where M = movement of each split,
La= angled length of cam,
Ls = straight length of cam,
q = Cam angle, C = clearance,
D = delay,
e = length of straight portion of the hole.
 Table1 Table2 Table 3

Ratio of length to depth Value of '

Polymer Total heat Part wt Feed of cavity wall C'

% of part
cal / gm gm 1:1 0.04
wt.
Cellulose Acetate 63 0.3 - 0.5 50 2:1 0.111
Nylon / Polyamide 103-156 0.5 - 1 40 3:1 0.134
PVC 38-56 1-3 30 4:1 0.140
PMMA / Acrylic 72 3-5 25 5:1 0.142
Polystyrene 57 5 - 10 15
ABS 72 10 - 20 10
HDPE 170-190 >20 5
LDPE 170-190
Polypropylene 130 `
Polycarbonate 84
Polyacetal 110
SAN 1.08
 Table 4
Inj.Moulding Inj.Moulding Linear
Density
Material Temp. Pressure Shrinkage
deg.C kg / sq.cm % mm/mm gm / cc

Polyethylene & Ethylene Copolymers (Crystalline)

Low Density 150-300 560-2100 1.5-5.0 0.92-0.925
Medium Density 150-300 560-2100 1.5-5.0 0.926-0.940
High Density 150-300 700-1400 2.0-5.0 0.941-0.965
Ethylene ethyl-acrylate
125-300 560-1400 1.5-3.5 0.93
copolymer
Ethylene Vinyl acetate
125-200 560-1400 0.7-1.1 0.925-0.950
copolymer
Polypropylenes (Crystalline)
Unmodified 200-225 700-1400 1.0-2.5 0.902-0.910
Copolymer 200-225 700-1400 0.9-2.0 0.890-0.905
Inert Filled 180-225 700-1400 0.5-1.5 1.0-1.3
Glass reinforced 225-275 700-1400 0.4-0.8 1.05-1.24
Impact (Rubber
200-275 1050 1.0-2.5 0.890-0.910
modified)
Vinyl Polymers and Copolymers (Amorphous)
Rigid 150-210 700-2800 0.1-0.5 1.30-1.45
Flexible Unfilled 160-190 560-1750 0.1-0.5 1.16-1.35
Flexible filled 160-190 560-1750 0.8-3.5 1.3-1.7
Vinyl Butyral Moulding 150-200 700-2100 0.5-2.5 1.65-1.72
Vinyl Formal Moulding
150-200 700-2100 0.15-0.30 1.2-1.4
Compounds
Chlorinated Polyvinyl
190-210 1050-2800 0.3-0.7 1.49-1.58
chloride compound
Vinyl Butyral Moulding
Compound Flexible 125-170 1050-2100 1.05
unfilled
ABS Modified Vinyl
200.00 560-1750 0.4-1.5 1.35
Chloride rigid Flexible
PP modified vinyl
115-190 560-1120 0.2-0.5 1.28-1.58
chloride rigid
Polysterene (Amorphous)
Unfilled Free flowing
0.1-0.6 (C),
general purpose heat 160-250 700-2100 1.04-1.09
0.2-0.6 (I)
resistant
Impact resistanat, High
175-300 700-2100 0.2-0.6 1.04-1.10
impact Medium imoact
Special heat and
chemical resistance 175-350 700-2100 0.1-0.8 1.04-1.10
type
20-30% glass filled 225-310 1050-2800 0.1-0.2 1.20-1.33
Styrene Acrylonitrile
190-290 700-2300 0.2-0.7 1.075-1.100
Copolymer Unfilled
Styrene-Butadiene (Amorphous)
Thermoplastic 150-210 1050-2100 0.1-0.5 0.93-1.10
 Acrylics (Amorphous)
Moulding 160-260 700-1400 0.1-0.4© 1.17-1.20
Impact Acrylic Moulding
200-260 700-1400 0.2-0.8(I) 1.11-1.18
Compound
MMA(Alphamethyl
175-275 700-2100 0.20-0.6 1.09
Styrene Copolymer
Acrylic Multi Polymer 200-240 700-1400 0.6-1.0 1.09-1.14
Acrylic Resins and Monomers
DAP Moulding
150-180 140-420 0.20-0.06 1.61-1.78
compound glass filled
DAL moulding compounds
1)Mineral filled 0.5-0.7 1.65-1.68
2)Synthetic Fibre Filled 0.9-1.1 1.34-1.39
Compounded With Butadiene Acrylonitrile Copolymers
Wood flour cotton flock
150-180 140-280 0.4-0.9 1.29-1.35
filled
Asbestos filled 155-180 140-280 0.4-0.7 1.57-1.65
Rag filled 155-180 140-280 0.2-0.4 1.3-1.35
Metal filled(iron or lead) 140-160 140-350 0.3-0.4 2.0-4.2
Cellulose Moulding Compounds
Ethyl Cellulose
Moulding compounds 180-260 560-2240 0.5-0.9 1.09-1.17
and sheet
0.3-1.0
Cellulose Acetate
170-245 560-2240 (C),0.3-0.8 1.22-1.34
Molding
(I)
cellulose 0.3-0.9
propionatemoulding 170-260 560-2240 (C),0.3-0.6 1.17-1.24
compound (I)
Cellulose Acetate 0.3-0.9
Butyrate Moulding 170-240 560-2240 (C),0.3-0.6 1.15-1.22
Compound (I)
Chlorinatted Polymer 210-230 700-1400 0.4-0.6 1.4
Ionomers 150-275 140-1400 0.3-2.0 0.93-0.96
Acrylonitrile-Butadiene-Styrene (Amorphous)
Extrusion Grade 0.4-0.6 1.02-1.06
High Impact 190-275 560-1750 0.5-0.8 1.01-1.04
High Heat Resistant 260-275 560-1750 0.5-0.8 1.05-1.08
Medium Impact 220-260 560-1750 0.5-0.8 1.04-1.07
Self-Extinguishing 190-220 560-1750 0.6-0.8 1.15-1.21
20-40%Glass filled 260-280 1050-2800 0.1-0.2 1.23-1.36
Clear 225-260 700-1400 0.6-0.8 1.07
Nylons (Crystalline)
Unmodified 260-310 0.8-1.5 1.13-1.15
Nucleated 260-310 0.7-1.2 1.13-1.16
30-35% glass reinforced 260 0.5 1.34-1.42
Acetals (Crystalline)
Homopolymer 190-235 700-1400 2.0-2.5 1.42
Copolymer 185-240 700-1400 2.0-(Avg) 1.41
 20%Glass Filled 175-240 700-1400 1.3-2.8 1.56
25%Glass Filled
190-240 700-1400 0.2-0.6 1.61
Copolymer
TFE-Fibre Reinforced 185-225 700-1400 2.0-2.5 1.54
Fluroplastics
Polycholorotrifluoroethyl
260-300 1400-4200 1.0-1.5 2.1-2.2
ene
FEP Fluroplastic 310-380 350-1400 3.0-6.0 2.12-2.17
Poly Vinylidene Fluoride 225-275 1050-1400 3 1.75-1.78
Polyphenylene Sulphides
Unfilled 300-350 350-1050 1 1.34
25% Asbestos Filled 300-350 700-1400
40% Glass Filled 300-350 700-1400
Polysulphone 325-375 1050-1400 0.7 1.24
polymethyl pentene
250-280 560-1400 1.5-3.0 0.83
polymer
Phenol Formaldehyde And Phenolfurfural moulding Compounds
No filled 135-160 140-280 1.0-1.2 1.25-1.3
Wood flour and cotton
145-190 140-350 0.4-0.9 1.34-1.45
flock filled
Asbestos filled 145-190 140-350 0.2-0.9 1.45-2.00
Mica filled 135-175 140-350 0.2-0.6 1.65-1.92
Glass fibre filled 135-175 70-420 0.2-0.4 1.69-1.95
Macerated Fabric and
140-190 140-280 0.2-0.9 1.36-1.43
cord filled
Pulp performed and
145-175 145-175 0.18-0.8 1.36-1.42
moulding board
Melamine-Formaldehyde Moulding Compounds
No Filler 150-165 140-350 1.1-1.2 1.48
Alpha cellulose filled 140-185 105-560 0.5-1.5 1.47-1.52
cellulose filled 145-180 105-420 0.6-0.8 1.45-1.52
Flock filled 140-165 280-560 0.6-0.7 1.50-1.55
Asbestos filled 140-170 70-490 0.5-0.7 1.7-2.0
Macerated Fabric filled 140-165 280-560 0.3-0.4 1.5
Macerated Fabric filled
150-175 280-560 0.3-0.6 1.5
(phenolic modified)
Glass fibre
140-170 140-560 0.1-0.4 1.8-2.0
filled(including nodular)
Melamine Phenol
150-175 140-350 0.4-1.0 1.5-1.7
moulding compound
UREA Formaldehyde
140-175 140-560 0.6-1.4 1.47-1.52
moulding compound
EPOXY RESINS
Glass fibre filled 0.1-0.5 1.6-2.0
Mineral filled 0.2-0.8 1.6-2.0
Low density 125-150 70-105 0.6-1.0 0.75-1.00
Type - 6
Unmodified 220-310 0.6-1.4 1.12-1.14
Nucleated 220-310 350-1400 1.12-1.14
30-35% glass reinforced 0.4 1.35-1.42
Type - 6/6
Copolymer 175-200 0.6-1.5 1.08-1.14
Type - 6/12
Unmodified 225-275 1.1 1.06-1.08
(Limited only
30-35% Glassreinforced 225-275 by the 0.3 1.31-1.38
pressure
Type - 6/10 required to
Unmodified 225-275 fill the mould 1.2 1.07-1.07
by the
30-35% Glassreinforced 225-275 capacity of 0.4 1.31-1.38
Type - 11 the
machine)
Unmodified 195-260 1.2 1.04-1.05
Type - 12
Unmodified 180-260 0.3-1.5 1.01-1.02
30-35% Glass filled 225-270 0.3 1.23
Runner  it is a channel Machined into the mould plate to connect the
(gate) to impression.

Gate  it is the orifice connecting runner with the impression.

Full Round runner  it is the cross section of the runner which is in the circular sh

Half round Runner  it is the cross section of the runner which is in the semi-circu

Cam Pin  A hardened steel member fitted at an angle to one mould

operating splits and side cores.

Clearance  it is the clearance given between cam pin & wedge slot to en
not act on the cam pin and to permit mould to open a small
actuated ( This is called ‘Delay’).

Cam Angle it is the angle made by the cam pin with respect to direction
the split / side core outward or inward while mould opening.

Wedge  it is the Bevelled surface used for locking the split / side-cor

Wedge Angle  it is the angle made by the Bevelled surface of wedge

motion of mould.

Projected area  it the area of cavity / core/ side-core/ split in the direction of

Cavity Pressure  it is the pressure exerted by melt on the cavity. (Normally

pressure for Amorphous,2/3 of injection pressure for Crystall

Guide Pillars Hardened steel circular members incorporated in the desig

halves.they may also support the weight of other mould m
plates and floating cavity plates on multi-plate mould.

Clamping Force it is Force required to keep mould closed during injection.

Shot size Amount of material injected per cycle.

uld plate to connect the Sprue with the entrance

the impression.

ch is in the circular shape.

ch is in the semi-circular or disc shape.

n angle to one mould plate for the purpose of

pin & wedge slot to ensure locking force should

mould to open a small amount before splits are

th respect to direction motion of mould to move

while mould opening.

king the split / side-core.

ed surface of wedge with respect to direction

split in the direction of view.

the cavity. (Normally it will be 1/3 of injection

on pressure for Crystalline).

orporated in the design to align the two mold

ight of other mould members such as stripper
lti-plate mould.

ed during injection.