Advance Mould Design

SPLIT MOULD

SPLIT MOULD

Split design constrains the following factors:

Amount of splits movement required. Whether a delay period is required. Length of a delay period. Ease with the moulding can be removed. Whether a short or long production run is required. Whether the available machines are programmed for ancillary cylinder control. Whether moulding inserts are to be incorporated.

TYPES OF SPLIT MOULD ACTUATION METHODS Finger cam actuation method. Dog-leg cam actuation method. Cam track actuation method. Hydraulic actuation method. Angled-lift splits. Spring actuation system.

FINGER CAM ACTUATION:

 If the required movement is known from the amount of component

undercut, the following formula used to determine the finger cam length.

L = (M / sin) + (2C / sin 2) Where, M = splits movement.

The clearance C provided for

= Angle of finger cam (10-25). L = working length of finger cam. C = clearance.

No direct force on finger cam pin. Permits to open the mould to open a predetermined amount before the splits are actuated. The amount of delay movement D before the splits are actuated I determined by the formula: D = C/sin

DOG-LEG CAM ACTUATION:

The relevant formula for calculating the opening movement, the length of cam, and the delay period are given by M = La tan - C , La = (M + C)/ tan ,D = (Ls e) + (C/tan )

Where

M = movement of each split, La = angled length of cam, Ls = straight length of cam, = Cam angle, C = clearance, D = delay, e = length of straight portion of the hole

CAM TRACK ACTUATION:

M+c La = ---------tan c 1 1 D = Ls + ---------- + r ------- - -------- tan tan sin

Where M = movement of each split, La = angled length of cam track, Ls = straight length of cam track, = cam track angle, 10-40 c = clearance, 1.5 mm D = delay, r = radius of boss

 The permissible angle of the cam track plate is

between 10 and 400. The formula for calculating the distance required for each split, the length of cam track, and the delay period are as follows: M = La tan - c

HYDRAULIC ACTUATION:
The splits are actuated by hydraulic mechanism, The hydraulic actuation system is used for design of large shape split mould components as more locking force is required to keep the splits closed during the injection phase. In this case more delay movement and large split movements can be achieved. The splits having a projection on the underside to which the ram of the hydraulic actuator is attached.

Angled guide dowel actuating systemG:

In this design, the guide dowels are fitted at an angle to the underside of each split. These guide dowels are passes through holes machined at an angle in the chase-bolster. When the ejector system is actuated, the relative movements between the ejector plate and the enclosed chase-bolster causes the guide dowels to move forward at an angle corresponding the splits are get to open, shown in figure

The spring-loaded system:

It is an operating method confined to moulding has very shallow undercuts or projections. AS shown in Figure , a stud is fixed to the underside of the split block and it is accommodated in a slot machined in the mould plate. A spring or springs are fitted to the slot and cause the side core assembly to withdraw immediately the mould opens. The locking heel is used to progressively return the assembly when the mould is being closed

MOULDING INTERNAL UNDERCUTS

These are three types of methods are used for releasing the internal undercuts as follows: (1) Form pin (2) Split cores internal undercuts. (3) Stripping internal undercuts.

FORM PIN:

The amount of withdrawal obtained may be computed front the following relationship: M = E tan Where M = the withdrawing movement. E = ejection movement. = fitting angle of the form pin.

Split Core Actuation :

Split core angled action:

Mould Designs for threaded components:

Basically, thread forms may be moulded by the following methods: Using loose tool inserts Using splits Using collapsible cores Axially moving and static unscrewing cores Using automatic unscrewing techniques

Mould Designs for threaded components:

Typical jump undercut design

Two-segment collapsible core details

Mould Designs for threaded components:

Rotating core unscrewing tool

HOT RUNNER
Hot runner molds are two plate molds with a heated runner system inside one half of the mold. A hot runner system is divided into two parts: the manifold and the Nozzles. The manifold has channels that convey the plastic on a single plane, parallel to the parting line, to a point above the cavity. The Nozzles, situated perpendicular to the manifold, convey the plastic from the manifold to the part.

Manifold:

Rectangular and Circular Manifolds

Types of Profiles for Manifolds

Nozzle types:-

Barb Nozzle

Extended nozzle

Antechamber Nozzle

Advantages & Disadvantages\

The many advantages of insulated runner systems, compared with conventional runner systems, include: Less sensitivity to the requirements for balanced runners Reduction in material shear.

More consistent volume of polymer per part.

Faster molding cycles. Elimination of runner scrap less regrind. Improved part finish. Decreased tool wear. .

 However, the insulated runner system also

has disadvantages. The increased level of technology required to manufacture and operate the mold results in: Generally more complicated mold design. Generally higher mold costs. More difficult start-up procedures until running correctly. Possible thermal degradation of the polymer melt. More difficult color changes. Higher maintenance costs

Gas-Assisted Injection Molding

Introduction
Gas-injection moulding has been developed to save material, shorten cycle times and to improve the surface aspects of thick-walled injection-moulded parts.

General Principles
Gas-injection moulding uses a standard injectionmoulding machine, extended with equipment to inject gas normally (Nitrogen) parallel or in series with the injection of the melt .Gas injection can take place through the same nozzle as the melt (machine nozzle), or via one or more special gas injection needles located at the runner or where there are material concentrations (thicker walls). Special machine nozzle designs are needed to ensure reliability.

Stack mould
The stack mould is used for moulding shallow and small parts in large quantity such as tape cassettes. In this type of mould the cavities are located into two planes corresponding to the parting lines and are filled at the same time. For moulding the stack mould it requires an injection moulding machine with large opening strock and clamping force of 15% higher than a standard mould. Stack mould were originally operated with cold runner design, which has to be the moulded in each shot. Further hot runner manifold is employed to increase the productivity

Reaction Injection Molding RIM was developed with polyurethane to produce large automotive parts such as bumpers and fenders RIM polyurethane parts possess a foam internal structure surrounded by a dense outer skin Other materials used in RIM: epoxies, and urea-formaldehyde