19P602 - JIGS, FIXTURE AND DIE DESIGN

DESIGN OF PLASTIC INJECTION

MOULDS

ROLL NUMBER NAME

20P108 JAYAPRADAA A

21P403 HARISH RAGAVENDRA

21P410 VARUN M

21P437 SELVA GANESAN P

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19P602 - JIGS, FIXTURE AND DIE DESIGN

DESIGN OF PLASTIC INJECTION

MOULDS

ROLL NUMBER NAME

20P108 JAYAPRADAA A

21P403 HARISH RAGAVENDRA

21P410 VARUN M

21P437 SELVA GANESAN P

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TOPICS

● MOULD MATERIALS
● MOULDING DEFECTS
● TYPES OF MOLD
● EJECTOR SYSTEM
● COOLING SYSTEM
● CALCULATIONS

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Mould Materials
Based on critical properties,
● Tensile (or compressive) strength
● Toughness
● Wear resistance
● Hot hardness
● Corrosion resistance
● Thermal conductivity
● Ease of machining
● Ease of polishing
● Ease of welding
● Cost
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Mould Materials
● P-20 Pre-hard steel. Rc 29-36. The most common tool steel used, it is a favorite
among mold makers for its durability and machining qualities.
● H-13 Air hard steel. Rc 46-54 Great for high production cavities and cores, slide
bodies, lifters, and gibs.
● S-7 Air hard steel. Rc 54-56 Used for many of the same applications as H-13
however somewhat less stable and more prone to cracking. Great for long wearing
gibs and guides.
● M-2 High speed steel. Rc 60-62 used where tough rigidity is required such as tall
thin core pins or blades.

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 Mould Materials
● 420 SS stainless steel. Rc 49-53 Best for achieving high polish finishes. Also for
corrosive polymers such as PVC.
● Beryllium Copper. Primarily used for inserting small areas in tools that may be prone
to over heating. The thermal characteristics of beryllium copper make it the best
choice for wicking heat out these areas.
● 7075 T-6 Aluminum. Generally used for short run or prototype tooling, however the
hardness, wear resistance and ability to take a good polish has caused many a short
run mold to outlast its projected life.
● Lamina. "Lamina" is a name brand material that is used for wear plates. This material
is a bronze over steel laminate that imparts long life to moving part with a minimum
of lubrication.
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TWO PLATE MOULD

● Consists of two active plates

(cavity and core plates) into which
cavity and core inserts are
mounted,
● Runner system, sprue, runners,
and gates solidify with part being
molded and are ejected as a single
connected item.

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 TWO PLATE MOULD

Two-Plate Mould: The two plate mould is

simple in design, yet versatile. It consists of a
front and stationary half. The cavity or core can
be mounted on either half, depending upon the
part design and the location the knock-out pins.
This mould is easily adapted for different
designs and all part ejection methods.

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Mould Defects

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Distribution of defect causes

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 Moulding Defects

● Flash - excess plastic attached to part along mold

parting plane
● Weld Lines - marks on molded part made by the
meeting of two flow fronts during filling
● Short Shot - mold cavity not completely filled
● Sink Marks - depressions on the part surface due to
internal shrinkage
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 Moulding Defects

● Shrinkage - change in dimensions of molded part

caused by cooling of material (also caused by
formation of crystalline structures with semi-crystalline
plastics [more shrinkage])
● Warpage - dimensional distortion (due to uneven
shrinkage)

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THREE PLATE MOLD

HARISH RAGHAVENDRA
21P403

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THREE PLATE MOLD

Consists of:

1. Stationary or runner plate, which contains sprue and half of

runner.

2. Middle or cavity plate, which contains other half of runner,

gates, and cavities and is allowed to float when mold is open.

3. Movable or core plate, which contains cores and ejector

system.

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THREE PLATE MOLD

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THREE PLATE MOLD

● This type of mould is used primarily to centre gate or submarine gate

parts in multiple cavities.

● It consists of the standard two plate design with the third movable
between the two.

● Automatic degating is possible with three-plate moulds, but runner

scrap is increased.

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WORKING:

Three-plate molding process still includes common steps such as

Injection.
● Colling.
● Opening.
● Product removal.
Three-plate mold opening sequence:

● Runner opening
● Runner stripper plate opening
● Product opening.
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ADVANTAGES AND DISADVANTAGES

ADVANTAGES DISADVANTAGES

● Cheaper to build than a hot-runner ● Higher cycle time due to ejection of the

mold runner system

● Less likely to break down than a hot- ● More material is wasted

runner mold ● Greater injection pressure is required to

● Thermally sensitive materials are less fill the mold
likely to degrade

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EJECTION SYSTEM
AND
COOLING SYSTEM
BY
VARUN M
21P410

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EJECTION SYSTEM

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EJECTION SYSTEM

• Ejection system is driven by power system separate from the one that opens and
closes the mold.

• The ejector plate, to which the ejector pins are attached, advances after the
mold has been opened.

• Ejector pins move through the support plate and the B plate and into the back of
the cavities to push parts out of cavities.

• Stripper plate mold is used when ejector pins are not used to push part out of
cavity by moving against a feature in part.

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EJECTION SYSTEM

Objectives in Ejection System Design

• Allow Mold to Open.
• Transmit Ejection Forces to Moldings.
• Minimize Distortion of Moldings.
• Maximize Ejection Speed.
• Minimize Cooling Interference.
• Minimize Impact on Part Surfaces.
• Minimize Complexity and Cost.

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The Ejector System Design Process

• Identify Mold Parting Surfaces

• Estimate Ejection Forces
• Determine Ejector Push Area and Perimeter
• Specify Type, Number, and Size of Ejectors
• Layout Ejectors
• Detail Ejectors and Related Components

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Ejection Methods

• Pin ejector
• Blade ejector
• Sleeve ejector
• Angled ejector pin
• Valve headed ejector
• Stripper plate ejector
• Air ejector

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Ejection Methods
Pin Ejectors

Reference:https://www.dgmfmoldclamps.com/wp-content/uploads/2020/11/21.-Mold-ejector-pin-launches-
demoulding-reinforcement-DGMF-Mold-Clamps-Co.-Ltd.gif

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 Blade Ejector

Reference:https://res.cloudinary.com/steven-cheng/image/upload/c_scale,w_287,h_217,dpr_2/f_auto,q_auto/v1641183037/G2-
09.gif?_i=AA

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Sleeve Ejector

Cylindrical ejector sleeves provide maximum

ejection contact area along the edge of
circular parts

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Angled Ejector Pin

Ejector pins on angled surface must be

keyed to prevent rotation and often
require grooves to prevent sideways
deflection of the ejector pin

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Stripper Plate Ejection

Stripper plate ejector

In molds with stripper-plate ejection, the
faceplate which forms the edge of the parts
Moves forward stripping the parts from the
core.

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Air Ejector

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COOLING SYSTEM
● Cooling is very important to remove heat efficiently and dissipate the
heat of the molding quickly and uniformly.

● For efficient molding, the temperature of the mold should be controlled

and this is done by passing a fluid through a suitably arranged channel in
the mold.

● Adequate mold temperature control is important consistent molding.

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Cooling Layout

Different types of cooling layouts

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Affects Cooling of Mold

➢Temperature increase (T) of coolant from in to out

➢Flow rate of coolant
➢Chemical composition & thermal conductivity of coolant
➢Thermal conductivity of mold parts
➢Temperature drop of plastic from injection to ejection
➢Runner system size and layout
➢Type of runner system (hot or cold)
➢Cooling channels layout and size
➢Return lines number and diameter
➢Cooling capacity of chiller
➢Mold close time and related cycle time

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Positioning of Cooling channels

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Positioning of Cooling channels

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Positioning of Cooling channels

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Conformal Cooling

1. Shortening the cooling cycle time up to 50% .

2. Reduce warping .
3. Homogeneous heat transfer from the mold cavity.
4. Optimization of the cooling circuit as part.
5. Absolute freedom in the design of the cooling circuit.

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Conformal Cooling

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Cooling Channel layout depends on

● Cooling Channel layout depends on

● Part geometry
● Number of cavities
● Ejector and cam systems
● Part quality,
● Dimensional precision,
● Part surface appearance
● Polymer etc

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Spiral Baffle

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Bubbler

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 EJECTION FORCE
AND
COOLING TIME CALCULATION

SELVAGANESAN P
21P437

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EJECTION FORCE

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PROBLEM-1

A single impression cover moulding is required to be moulded in polystyrene on a 250-tonne

injection moulding machine. If the stated ejection force is 30 kN, estimate whether or not the
machine is suitable for the intended purpose. Use the following data:
• Component dimensions = rectangular box 12 cm x 23 cm x 9.5 cm deep
• Component wall thickness = 0.3 cm
• Material to be moulded = PS
• Coefficient of friction (PS on steel) = 0.4
• Poisson’s ratio = 0.35
• Modulus of elasticity (PS) = 30 x 104 N/cm
• Coefficient of expansion for PS = 7 x 10-5 cm/°C
• Softening temperature of PS = 80 °C
• Mould temperature for PS = 20°C

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SOLUTION:

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COOLING TIME CALCULATION:

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PROBLEM-2

To calculate the heat required to take a 400 kg steel mould to 80°c

from an ambient of 20°c the equation is as follows:

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