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MOULD

DESIGN FILE
SUBMITTED BY
GAURAV
03970208610
TH
7 SEMESTER

MOULD DESIGN
COMPONENT DETAIL

A circular plastic component of equal side dimension of 60


mm each. The thickness of the component is 2 mm.

CALCULATIONS
Projected area
max. length * max. width.
P.A. = 3.14*30*30 sq. mm.
= 2826 sq. mm. ~2850 sq. mm.
Weight of the component
W

P.A. * thickness*specific gravity.


2850*2*0.92
5.1998 gm.
Since it is a two double impression mould total weight of the component =
10.400 gm.
Injection Pressure( I.P.)
Injection pressure for polypropylene(PP) = 450 g/ cubic cm.
Clamping Force
C.F. = P.A. * I.P.
1000
= 2850* 450
1000
= 1.3 tonn.
Runner Diameter
D= (W)1/2 * (L)1/4
3.7
= 3.639*2.340
3.7
= 2.5 mm.

Gate Dimension
Gate height
h=nt
h= 0.7*2
h= 1.5 mm.
Gate width
W= n*(A)1/2
30
0.7*60
30

= 1.5 mm.

Standard Mould Dimensions ( SERIES 2025)


1. Top plate
246 X 246 X 22 ( in mm)
2. cavity plate
246 X 196 X 22 ( in mm)
3. core plate
246 X 196 X 22 ( in mm)
4. core back plate
246 X 196 X 27 ( in mm)
5. risers
246 X 37 X 47 ( in mm)
6. bottom plate
246 X 246 X 22 ( in mm)
7. ejector plate A
246 X 120 X 16 ( in mm)
8. ejector plate B
246 X 120 X 12 ( in mm)

BILL OF MATERIAL
14

SPRUE BUSH

H 24

T 22- 16/15

13

S.H.C.S.

STD. PART

M 10

12

TUBULAR DOWEL

EN 9

T 31

11

REGISTER RING

EN 8

T 121

10

GUIDE BUSH

EN 353

T 21- 20/19

GUIDE PILLAR

EN 353

T 11- 20/19

BOTTOM PLATE

M.S.

246 X 246 X 22

RISERS

M.S.

246 X 37 X 47

EJECTOR PLATE B

EN 31

246 X 120 X 12

EJECTOR PLATE a

EN 31

246 X 120 X 16

CORE BACK PLATE

M.S.

246 X 196 X 27

CORE PLATE

M.S.

246 X 196 X 22

CAVITY PLATE

M.S.

246 X 196 X 22

TOP PLATE

M.S.

246 X 246 X 22

S.NO.

PART NAME

MATERIAL

DIMENSION

Cooling Channel
Channel diameter= dia. 10 mm.
A simple U-channel is designed for both core and cavity plate. The channel
is interconned via hose pipe that permit water/coolant to flow continously
inside the plates. Inlet and outlet holes are connected to adapters of
appropriate size.
Shrinkage Allowance
For polypropylene(PP), shrinkage allowance = 2%- 4%.

Mould Design

Component detail

Above fig. is the detail view of the component with dimension


including shrinkage allowance. The component is a bucket
type having a hole at one of the side wall. The material of the
component is polypropylene(PP).

CALCULATIONS
Projected area
max. length * max. width.
P.A. = 25.4*25.4 sq. mm.
= 645.16 sq. mm.
Weight of the component
W

P.A. * thickness*specific gravity.


645.16*32*0.92
19 gm.
Since its a double impression mould total weight = 38 gm.
Injection Pressure( I.P.)
Injection pressure for polypropylene(PP) = 450 g/ cubic cm.
Clamping Force
C.F. = P.A. * I.P.
1000
= 645.16* 450
1000
= 1.6 tonn.
Runner Diameter
D= (W)1/2 * (L)1/4
3.7
= 3.639*2.340
3.7
= 3.90 mm ~ 4 m
Gate Dimension

Gate height
h=nt
h= 0.7*1.5
h= 1mm.
Gate width
W= n*(A)1/2
30
0.7*25.4
30

= 0.76 mm. ~ 0.8 mm.

Standard Mould Dimensions ( SERIES 2025)


1. Top plate
208 X 196 X 22 ( in mm)
2. cavity plate
196 X 188 X 40 ( in mm)
3. core plate
196 X 188 X 57 ( in mm)
4. risers
208 X 37 X 47 ( in mm)
5. bottom plate
208 X 196 X 22 ( in mm)
6. ejector plate A
122X 119 X 12 ( in mm)
7. ejector plate B
122 X 119 X 16 ( in mm)

BILL OF MATERIAL

17

REST BUTTON

DIA 9 X 15

16

EJECTOR ROD

E.N. 353

DIA. 16 X 90

15

SPRUE PULLER

E.N.-24

DIA. 10 X 100

14

SPRUE BUSH

H-24

T 22- 16/15

13

S.H.C.S.

STD. PART

M 10

12

TUBULAR DOWEL

EN 9

T 31

11

REGISTER RING

EN 8

T 121

10

GUIDE BUSH

EN 353

T 21- 20/19

GUIDE PILLAR

EN 353

T 11- 20/19

8.

CORE INSERT

P-20

120 X 118 X 50

CAVITY INSERT

P-20

120 X 118 X 50

EJECTOR PLATE B

EN 31

122 X 119 X 16

EJECTOR PLATE A

EN 31

122 X 119 X 12

BOTTOM PLATE

M.S.

208 X 196 X 22

CORE PLATE

M.S.

196 X 188 X 57

CAVITY PLATE

M.S.

196 X 188 X 40

TOP PLATE

M.S.

208 X 196 X 22

S.NO.

PART NAME

MATERIAL

DIMENSION

Cooling Channel
Cooling Channel/hole diameter= 7 mm.
A simple U-channel is designed for cavity plate. Inlet and outlet holes are
connected to adapters of appropriate size.
Heat pipes are used for cooling in core plates. A U-channel is designed
which accommodate a heat pipes at the center of the core.
Shrinkage Allowance
For polypropylene(PP), shrinkage allowance = 2%- 4%.