p l a s t i c i n j e c t i o n m o l d i n g p a r t 1 p r o c e s s, m o l d a n d m a c h i n e e r i k d e l a n g e
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- Bruce Robbins
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1 p l a s t i c i n j e c t i o n m o l d i n g p a r t 1 p r o c e s s, m o l d a n d m a c h i n e e r i k d e l a n g e H R O R o t t e r d a m B r n o U T j o i n t p r o j e c t 1
2 plastic injection molding = + + Kč 40 / kg 1,50 / kg Kč (for an old one) Kč Kč H R O R o t t e r d a m B r n o U T j o i n t p r o j e c t 2
3 Whose property you think a mold is? In most cases, it s them who own the mold! H R O R o t t e r d a m B r n o U T j o i n t p r o j e c t 3
4 lecture contents industrial product tool (=mold) design design of injectionmolded products mold engineering manufacture injection molding process mold manufacturing H R O R o t t e r d a m B r n o U T j o i n t p r o j e c t 4
5 lecture contents Today Process, mold and machine Getting your product out of the mold Tomorrow Guidelines for designing plastic products H R O R o t t e r d a m B r n o U T j o i n t p r o j e c t 5
6 concept design drawings, CAD-files, production plans designer mechanical engineer mold engineer parts molds assembly department parts production department H R O R o t t e r d a m B r n o U T j o i n t p r o j e c t 6
7 For product designers, having a thorough knowledge in the field of of mold engineering and injection molding is extremely useful! - it prevents throwing over the wall work flow - it helps to design parts with the mold in mind, saving time and money it enables them to: - speak the language of the mold engineer - negotiate with the mold engineer H R O R o t t e r d a m B r n o U T j o i n t p r o j e c t 7
8 lecture outline product tool (=mold) design design of injectionmolded products mold engineering manufacture injection molding process mold manufacturing H R O R o t t e r d a m B r n o U T j o i n t p r o j e c t 8
9 sand casting giant cast-iron ball joints of storm surge barrier in waterway near Rotterdam, cast by Škoda foundries, Plzeň H R O R o t t e r d a m B r n o U T j o i n t p r o j e c t 9
10 annual production volumes > 3 million/year > 12 million/year H R O R o t t e r d a m B r n o U T j o i n t p r o j e c t 10
11 annual production volumes > 500 million/year > 1 billion/year H R O R o t t e r d a m B r n o U T j o i n t p r o j e c t 11
12 metal versus plastic Metal melts and becomes liquid: low viscosity Plastic becomes plastic, not liquid: high viscosity Consequently: A. Casting will take too much time B. Plastic won t fill the corners and small details molten metal plastic H R O R o t t e r d a m B r n o U T j o i n t p r o j e c t 12
13 metal versus plastic To speed up the filling process, the plastic is forced into the mold under high pressure. ( MPa) H R O R o t t e r d a m B r n o U T j o i n t p r o j e c t 13
14 process H R O R o t t e r d a m B r n o U T j o i n t p r o j e c t 14
15 process H R O R o t t e r d a m B r n o U T j o i n t p r o j e c t 15
16 process ejector pins core cavity H R O R o t t e r d a m B r n o U T j o i n t p r o j e c t 16
17 process H R O R o t t e r d a m B r n o U T j o i n t p r o j e c t 17
18 machine clamping mechanism granulate funnel hopper plasticizing and injection unit, melts the granulate and injects it H R O R o t t e r d a m B r n o U T j o i n t p r o j e c t 18
19 machine hydraulic cylinder, providing the clamping force movable platen fixed platen hole for injection unit tiebars, guiding the movable platen H R O R o t t e r d a m B r n o U T j o i n t p r o j e c t 19
20 machine the molding cycle: close the mold inject the plastic into the cavity keep the mold closed until the plastic is cooled and ready for ejection open the mold eject the product the cycle time depends on the wall thickness: thin part (for instance 2,5 mm): 5 secs thick part (for instance 10 mm): 1 min H R O R o t t e r d a m B r n o U T j o i n t p r o j e c t 20
21 mold cooling Due to the hot plastic (for example, 220 C), the mold will get hotter every shot. The time to solidify will become longer and longer; and so will the cycle time. That s why cooling is necessary. cooling channels H R O R o t t e r d a m B r n o U T j o i n t p r o j e c t 21
22 part shaping The simplest type of mold has only two product-shaping parts, often called core and cavity. This is called a straight pull mold. ejector pins core cavity H R O R o t t e r d a m B r n o U T j o i n t p r o j e c t 22
23 part shaping The simplest type of mold has only two product-shaping parts, often called core and cavity. This is called a straight pull mold. ejector pins core cavity H R O R o t t e r d a m B r n o U T j o i n t p r o j e c t 23
24 part shaping The simplest type of mold has only two product-shaping parts, often called core and cavity. This is called a straight pull mold. ejector pins core cavity H R O R o t t e r d a m B r n o U T j o i n t p r o j e c t 24
25 part shaping During solidification, the product shrinks by a few percent. To facilitate the product s ejection from the core, the walls should make an angle of at least 2 with the line of draw. 2 line of draw core cavity H R O R o t t e r d a m B r n o U T j o i n t p r o j e c t 25
26 part shaping Many shapes would get locked in a straight pull mold: undercut This part will draw from the core, but won t draw from the cavity, due to undercuts. H R O R o t t e r d a m B r n o U T j o i n t p r o j e c t 26
27 part shaping This product requires a mold with side actions. side action line of draw side action H R O R o t t e r d a m B r n o U T j o i n t p r o j e c t 27
28 part shaping Schematic of a side-action mold. H R O R o t t e r d a m B r n o U T j o i n t p r o j e c t 28
29 part shaping Schematic of a side-action mold slide slide K2010.exe H R O R o t t e r d a m B r n o U T j o i n t p r o j e c t 29
30 part shaping cavity core H R O R o t t e r d a m B r n o U T j o i n t p r o j e c t 30
31 part shaping H R O R o t t e r d a m B r n o U T j o i n t p r o j e c t 31
32 part shaping What if the part has internal undercuts? Exercise: try to make a sketch of a mold from which the part will release. H R O R o t t e r d a m B r n o U T j o i n t p r o j e c t 32
33 part shaping Angled ejection pins H R O R o t t e r d a m B r n o U T j o i n t p r o j e c t 33
34 part shaping Angled ejection pins H R O R o t t e r d a m B r n o U T j o i n t p r o j e c t 34
35 exercise cross section of louvered vent H R O R o t t e r d a m B r n o U T j o i n t p r o j e c t 35
36 exercise H R O R o t t e r d a m B r n o U T j o i n t p r o j e c t 36
37 exercise slide H R O R o t t e r d a m B r n o U T j o i n t p r o j e c t 37
38 exercise parting line (PL) slide H R O R o t t e r d a m B r n o U T j o i n t p r o j e c t 38
39 parting planes The parting line is visible on the product. As a designer, you might have certain ideas where you would like to locate this line. Parting lines can also be curved. This makes the mould more expensive. H R O R o t t e r d a m B r n o U T j o i n t p r o j e c t 39
40 part shaping A side action mold is far more expensive than a single draw mold. How can the costs be kept low? H R O R o t t e r d a m B r n o U T j o i n t p r o j e c t 40
41 part shaping A side action mold is far more expensive. How can the costs be kept low? H R O R o t t e r d a m B r n o U T j o i n t p r o j e c t 41
42 part shaping A side action mold is far more expensive. How can the costs be kept low? H R O R o t t e r d a m B r n o U T j o i n t p r o j e c t 42
43 part shaping A side action mold is far more expensive. How can the costs be kept low? H R O R o t t e r d a m B r n o U T j o i n t p r o j e c t 43
44 part shaping A side action mold is far more expensive. How can the costs be kept low? H R O R o t t e r d a m B r n o U T j o i n t p r o j e c t 44
45 part shaping Tapered shut-offs should make an angle of at least 5 with the line of draw, for two reasons: to avoid collision to avoid clearance, which would cause flash tapered shut-off H R O R o t t e r d a m B r n o U T j o i n t p r o j e c t 45
46 part shaping The minimum angle of shutoff planes impacts the shape of your product. In our case, it influences the size of the holes. 5 H R O R o t t e r d a m B r n o U T j o i n t p r o j e c t 46
47 determining the appropriate draft angle Draft may spoil the perfect shape you had in mind as a designer. Which factors determine the required draft angle? 0,2º 4º H R O R o t t e r d a m B r n o U T j o i n t p r o j e c t 47
48 determining the appropriate draft angle Materials having a large shrinkage percentage need a larger draft angle. Also, stickier materials, having a larger coefficient of friction, need a larger draft angle. PVC PS PP HD-PE LD-PE Nylon 66 Nylon 6 PVDF PTFE PMMA Acetaal ABS shrinking percentages (min-max) 0% 1% 2% 3% 4% 5% 6% 7% 8% H R O R o t t e r d a m B r n o U T j o i n t p r o j e c t 48
49 part shaping Surfaces that are being shaped bij the core, need a larger angle than ones being shaped by the cavity. core cavity example: Lego blocks (exaggerated) H R O R o t t e r d a m B r n o U T j o i n t p r o j e c t 49
50 determining the appropriate draft angle core pin Products may even have cores on the cavity side of the mold, around which the plastic will shrink: cavity plate core H R O R o t t e r d a m B r n o U T j o i n t p r o j e c t 50
51 determining the appropriate draft angle Some other factors are: product texture and mold roughness; the deeper the roughness valleys are, the larger the draft angle must be whether or not you are willing to accept scratches on the product; how many ejector pins you want to use. H R O R o t t e r d a m B r n o U T j o i n t p r o j e c t 51
52 determining the appropriate draft angle You can negotiate (sjednávat) with mold makers about the draft angle. With special measures very small draft angles are possible. special measures can be a stripper ring and additional ejection pins. H R O R o t t e r d a m B r n o U T j o i n t p r o j e c t 52
53 filling the mold runner gate gate sprue bushing H R O R o t t e r d a m B r n o U T j o i n t p r o j e c t 53
54 filling the mold De runner is uitgefreesd in de achterste The runner vormholteplaat, has been milled of in in beide the vormholteplaten core plate, alternatively, in both plates. runner in core plate only A-A A A runner in both plates; better, more expensive H R O R o t t e r d a m B r n o U T j o i n t p r o j e c t 54
55 filling the mold A fraction of the plastic solidifies in the filling sytem. In some cases it can be ground and re-used. runner gate sprue cone 4-fold runner H R O R o t t e r d a m B r n o U T j o i n t p r o j e c t 55
56 filling the mold Advantages: multiple cavities possible gating on the parting line causes a modest vestige Disadvantages: manual separation of parts and runner loss of plastic due to the runner hard to make perfectly round products in this way H R O R o t t e r d a m B r n o U T j o i n t p r o j e c t 56
57 filling the mold Spuitneus komt rechtstreeks in de holte uit Advantages: simple and low-cost central gating ensures round products to stay perfectly round Disadvantages: only one cavity sprue cone needs to be manually removed leaves a clearly visible vestige on the product H R O R o t t e r d a m B r n o U T j o i n t p r o j e c t 57
58 central gating and multiple cavities Spuitneus komt rechtstreeks in de holte uit If you would like to have central gating AND multiple cavities, a three plate mold is necessary. This has two parting planes, the second one serving to release the runner. H R O R o t t e r d a m B r n o U T j o i n t p r o j e c t 58
59 filling the mold: heated filling system Spuitneus komt rechtstreeks in de holte uit heated sprue heated runner hot runner H R O R o t t e r d a m B r n o U T j o i n t p r o j e c t 59
60 filling the mold: heated filling system heated filling systems have numerous advantages: only a pinpoint vestige no loss of material central gating possible also in multiple-cavity molds Spuitneus komt rechtstreeks in de holte uit Disadvantages costly (hot runner manifold > Kč / 5000) will clog if granulate contains impurities H R O R o t t e r d a m B r n o U T j o i n t p r o j e c t 60
61 submarine gating Spuitneus komt rechtstreeks in de holte uit idea When the mold opens: the product will stay on the core (goes to the left) the small steel triangle (which is part of the cavity plate) separates the product from the runner, cutting through the small conical gate. H R O R o t t e r d a m B r n o U T j o i n t p r o j e c t 61
62 submarine gating Spuitneus komt rechtstreeks in de holte uit H R O R o t t e r d a m B r n o U T j o i n t p r o j e c t 62
63 submarine gating Spuitneus komt rechtstreeks in de holte uit Pin acting as a sprue-puller H R O R o t t e r d a m B r n o U T j o i n t p r o j e c t 63
64 submarine gating Spuitneus komt rechtstreeks in de holte uit H R O R o t t e r d a m B r n o U T j o i n t p r o j e c t 64
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