Defects in injection molding?

Preventive measures?
controlling factors in molding of plastic?
mold functions and elements(feed, ejection, cooling)?

How is sheet metal components formed?

Sheet metal components are generally metal formed through various forming processes
majorly involving Bending, deep drawing, Roll forming, Stamping, Punching, Piercing etc.
The sheet metals are initially received as Rolls and cut into plain blankets and then formed
into desired shape using above mentioned processes mainly bending and stamping.

What are precision sheet metal components?

Sheet metal components that are made using high precision dies with sheet of close tolerance
in machines with high stability are generally called as precision sheet metal components. The
precision of the component has to be decided based on the purpose that the components is
going to serve,

What is the standard bending radius followed during sheet metal fabrication?

Sheet metal enclosures are usually fabricated by 'cold forming' technique, where the metal is
clamped and bent in machines called 'press brakes'. Because of this, metal typically cannot be
formed into a true 90 degree corner. Instead, the corners are curved or filleted in practical
which is technically denoted as bend radius,

Different degrees of curvature can be achieved and Note that bend radius is specified as the
radius of the INSIDE surface of the bend

What common methods of Welding, would be associated with sheet metal fabrication?

Depending on your sheet metal design, you may desire spot-welded enclosures or fully seam-
welded enclosures. With many enclosure designs, such as our standard U-shape (clam shell),
no welding is required. One section of the enclosure contains small flanges with self-
clinching nuts and the other section of the enclosure is fastened using mechanical fasteners
such as machine screws or sheet metal screws.

Spot welding would be used in cases where disassembly is not required. Fully seam welded
edges may also be a requirement, especially if the application requires a more tightly sealed
enclosure.

What is meant by Bending allowance in sheet metal fabrication ? How to calculation

bending allowance?

Bend allowance comes from the fact that when sheet metal is bent, the inside surface of the
bend is compressed and the outer surface of the bend is stretched (elongated)//.

So, when we want a 90 degree bend in which one panel side has a length of A, and the other
panel side has a length of B, the total length of the flat piece will NOT be A+B, but rather
equals A+B plus a bend allowance or A+B minus a bend deduction(depending on how we
measure A and B).

So bend allowance is a term which describes how much material is needed between two
panels to accommodate a given bend. Determining bend allowance is commonly referred to
as bend development or simply development.

What is K-factor in sheet metal fabrication?

As explained in bend allowance, when sheet metal is bent, the inside surface of the bend is
compressed and the outer surface is stretched, but somewhere within the thickness of the
metal lies its Neutral Axis, which is a line in the metal that is neither compressed nor
stretched.

The location of the neutral line varies depending on

the material itself,

the radius of the bend,
the ambient temperature,
direction of the material grain,
and the method by which it is being bent, etc.

The location of this neutral line is referred to as the K-factor.

Many CAD programs also work out bend allowances automatically by using K-factor
calculations.

K-factor is a ratio that represents the location of the neutral line with respect to the thickness
of the sheet metal.

What are all the surface finish processes used for sheet metal fabrication?

Powder coating is a commonly used surface finishing technique. It is a type of coating that is
applied as a free-flowing, dry powder.

What are some common parameters , to be considered while material selection for sheet
metal fabrication?

Good corrosion resistance

Formability
Weldability

What are all the reinforcement techniques followed to improve the strength of the sheet
metal component?

Changing the geometry : Including beads, flanges, notches in weaker cross section.
The weaker cross sections of the sheet metal component can be identified using Hand
 calculations considering the loads acting on the component and evaluating the stress,
displacement and vibration throughout the component.
Changing the material : Introducing higher grade or different material than the
existing one may sometimes results in improved strength of the component. The cost
of the material should have been considered while proposing for an alternative.
Reducing the load acting on the component.
1. What is a tool ?
Anything which is necessary to make a product is called tools.
2. What are the classification of tools ?
Press tools, Moulds, Jigs and fixtures, Cutting and assembly tools ,gauges and
measuring instruments.
3. What is a press tool ?
Press tool is a custom built tool in which we make sheet components that not readily
available in the market.
4. What do you mean by stampings?
The sheet metal which makes with the help of press tool is called stampings.
5. Name the different types of rolling ?
Hot rolling, cold rolling.
6. What is Stock materials ?
Sheet metal from which stampings made is called stock material.
7. What are the press tool operations ?
Cutting, non cutting and combination of both.
8. What is strip?
Each piece of sheet metal called strip.
9. What do you mean Blanking ?
In this operation, cut out material or slug will be the component.
10. What is piercing?
Process of making opening on sheet metal is called piercing. The cut out material will
be waste.
11. What is called cutting off ?
Material is going to cut in a single line, there wont be any waste.
12. What is parting off ?
Double line cutting material in between the line will be waste.
13. Describe about a side cam tool?
Transforms vertical motion of the press ram into horizontal motion of the tool. It is
used for side piercing.
14. What is perforating ?
Making no. of holes at a time.
15. What is dinking ?
Press tool cutting operation for soft materials like paper, leather, wood etc.
16. What is trimming ?
Removing large amount of material from the edge of the piece part.
17. What do you understand shaving ?
Removing small amount of material from the previously blanked part.
18. What is broaching ?
Series of teeth profile removes metal from blanked part.
19. Describe bending?
Bending can be explained as shaping of material around straight line axis. Result is a
new plane which is at an angle to the mother plane.
20. What is lancing ?
 Combination of cutting and bending.
21. What is forming ?
Press tool non cutting operations in which material is formed into different shapes.
22. What do you mean drawing ?
Process of making cup or vessel is called drawing.
23. What is curling ?
Rolling the edge of sheet metals.
24.Define bulging?
Internal forming operation to expand portions.
25.Name the common medias of bulging ?
rubber, urethane, oil etc.
26. What is swaging?
Opposite of bilge. External forming operation also called as necking.
27. What is extrusion ?
Operation to produce collapsible tubes, shell etc.
28. Define coining?
Making depression and corresponding projection wont be there.
29. What is an assembly tool ?
Assembling of two or more parts by riveting, press fitting etc.
30.Describe flaring, lugging, collar drawing ?
Making collar so that no. of threads can be provided.
31. What is Planishing ?
Flattening of material is called Planishing.
32. What is progressive tool ?
Multi stage tool in which perform work at number of stations.
33. What is compound tool ?
All cutting features of the component perform at one stroke of the ram.

34. What do you meant by combination tool?

Small press operated in large one. Blank and form very small parts.
35. What is notching ?

Small amount of material cuts from the edge of the component.

36. What do you understand by sub press tool ?

Small press operated in large one, blank and form very small parts.
37. What is louvering?

Combination of cutting and forming.

38. What is shearing?

Method of cutting sheets without forming chips.

39. What are the stages of shearing ?

Plastic deformation, penetration, fracture.

40. Result of plastic penetration stages is ?

Cut band

41. Result of plastic deformation stage is ?

Edge radius or roll over.

42. Result of fracture stages is ?

Break edge.

43. Name the types of shear load ?

Internal and external loads.

44. What are the types of external shear load ?

Compressive load and tensile load.

45. Define tensile load ?

Force acting on opposite direction in same axis.

46. What is shear load ?

Load which is acting on same direction but not in same axis.

47. What is compressive load ?

Forces acting on same direction in same axis.

48. Name the types of force based on speed ?

Impact force (quick force)

magnetic force

49. Describe about stress ?

Load acting on a material per unit area.

50. Formula of stress ?

load /area

51. What is cutting force?

The force which acts on sheet metal to cut the blank.

52. Formula of cutting force ?

Fc = LSTmax
L : Length of periphery to cut in mm.

S : sheet thickness in mm

TM ax : shear strength in n/mm^2

53. Shear strength is . % of tensile strength.

80%

54. Equation to calculate press force ?

Press force = cutting force + stripping force

55. Normal stripping force is ?

10 to 20 % of cutting force .

56. What are the methods to reduce cutting force ?

Using stepped punch.

Grind the face of the punch or die to a small sheared angle

57. For blanking shear angle will be on ?

Die.

58. For piercing shear angle will be on ?

Punch

59. Briefly explain the capacity of the press ?

Maximum amount of force can be given on the press . It is determined by KN or TONS.

60. What is the shear strength ?

Ability of material to resist shear stress.

61. 1 TON =. Kgf

1kgf.

62. What is reason of drill breakage ?

Due to torsion and compression

63. U channel and angle iron made by .. process

Extrusion
64. 1N =... kgf

9.8 kgf

65. What do you meant by cutting clearance ?

Gap between the side of the punch and corresponding side of the die in single side.

66. Cutting clearance is expressed as ... ?

Mm /side

67. Result of optimum cutting clearance will be....?

Maximum cut band.

68. Result of excessive cutting clearance will be ...?

Maximum edge radius.

69. Result of insufficient cutting clearance will be...?

Maximum break edge.
70. Punch determines....?

Piercing size

71. Die determines ...?

Blanking

72. Calculation of cutting clearance ?

Sheet metal up to 3mm = C*S* root of (TMAX/10)

Sheet metal more than 3 mm=(1.5*s) *(s-0.015)* root of (TM ax /10)

73. What is called land ?

To avoid jamming of material inside the die ,we give straight portion of certain amount from
the cutting edge. That is called land.

74. For sheet metal S up to 3 mm = land will be....?

3mm

75. For sheet metal more than 3 mm = land will be...?

Sheet thickness.

76. Usually ,angular clearance is provided in ... Degree ?

1.5 degree /side.

77. Generally, soft material require... Angular clearance ?

more.

78.What are the types of guide plate tool ?

Open guide plate tool

Stripper guide plate tool

79. Name the basic elements of tool ?

Punch and Die.

80. Punch and die materials ?

Good quality alloy steel(HcHcr ,D2).

81. Hardness of punch ?

58-60 HRC.

82. Hardness of die ?

60-62 HRC.

83. Stripper plate material ?

MS or medium carbon steel

84. Thrust plate material ?

OHNS.

85. Hardness of thrust plate ?

45-48 HRC

86. Top plate and bottom plate material ?

MS or Cast iron.

87. Screws are to the parts ?

hold

88. Dowels are to . the parts ?

align
89. Name the types of cold rolled stock materials used ?

Hard, Three quarter hard, Half hard, Quarter hard, Soft, Dead soft.

90. What is the specialty of hard sheet metal ?

Can not bend.

91. What is the specialty of 3 quarter hard material ?

Can bend 60 degree across the grain.

92. Specialty of half hard material ?

Can bend 90 degree across the grain.

93. Quarter hard material ?

Can bend 180 degree across and 90 degree along the grain direction.

94. Soft material ?

Can bend 180 degree across and along.

95. Dead soft material ?

Can be formed into different shapes.

96. What is strip lay out ?

A layout which gives sequence of works and operations.

97. What are the factors effecting a strip layout ?

Shape of the blank, production requirement, grain direction, burr side, stock material.

98. Formula of economic factor ?

(area of the blank*no. of rows )/(pitch*scrap width )

99. What is pitch ?

Distance between two consecutive operations.

100. What is scrap bridge ?

Portion of the material remaining between two adjacent openings.

101. Scrap bridge nearer to the operator called .... scrap ?

Front scrap
102. Scrap bridge away from the operator called .... scrap?
Back scrap
103. What are the types of strip layout ?

Single row layout, double row, gang dies and angular.

104. Name the types of single raw layout ?

Narrow run, wide run

105. List about the types of punches ?

Cutting punch, non cutting punch and hybrid punch.

106. What are the groups of punches ?

Segregated punches and integrated punches.

107. What is segregated punch ?

Self mounted by screwing etc.

108. What are the integrated punches ?

Mounting with the help of punch plate etc.

109. For beveled head punch bevel angle is .........?

30 to 45 degree

110. What is perforator?

Punch of diameter 2mm and below.

111. What is bucking force ?

Maximum force a punch can withstand without bucking.

112. Formula for buckling force ?

Fb =(ii2EI)/LP2

113. Modulus of elasticity of Steel ?

200 to 220 GN/M2

114. Unit of moment of Inertia ?

Mm4
115. The ultimate condition of buckling force is ..?

Buckling force =cutting force require for the operation =shear force on the punch

116. Material of solid die ?

Non shrinking tool steel.

117. Die bushes are inserted in ..?

mid steel retainer plate.

118. Dies having more than one section called ....?

Split dies

119. Material of carbide dies ?

Tungsten carbide

120. What is the function of stopper ?

Arrest the movement of the strip for one pitch length after each stroke.

121. Fundamental principles of stopper ?

Stop position and registry position.

122. What is stop position ?

Actual position of the stopper.

123. Describe registry position ?

Exact position where strip has to be established.

124. Types of strippers?

Fixed and traveling

125. Function of stripper ?

Strip the stock material off the punches after each stroke.

126. Tunnel width formula ?

X=w+f

w = stock strip width at maximum tolerance

f = desired horizontal feeding clearance

127. Hook pins are made from .?

Cold drawn steel rod

128. Gauge thickness for the material up to 1.5 mm is .... ?

3mm

129. Gauge thickness for the material more than 1.5 mm is ... ?

Sheet thickness +1.5 mm

130. Prevention of wrong loading can be done by... ?

Fool proofing

PLASTIC

1. What is the important characteristics of plastics?

It can be molded into finished product by application of heat and pressure.

2. What are the advantages of plastics over metals?

Low weight
Corrosion resistance
Insulation properties
Electrical properties
Cheaper
Easy to handle
Surface properties
Reusable

3. Explain the disadvantages of plastics?

Low strength
Low heat resistance
Poor mechanical properties
Difficulty to repair

4. How to classify the plastics?

Natural : milk of rubber tree, cellulose

 Semi synthetic
Synthetic

5. Types of plastics based on chemical behavior?

Thermo plastics
Thermosetting plastics

6. Difference between thermo set and thermo plastics?

Thermoplastics:

Can be re softened and reused

No chemical changes during heating.
In granular form
Needle structure
Hard but not brittle

Thermo set plastics:

Cannot be re softened and reused

Chemical changes during heating etc.
In powder form
Cross linked structure
Hard and brittle

7. Give Example of thermoplastics

ABS, PP, CA, PMMA, PS, PC, POM etc.

8. Perspex is the trade name of ---- ?

CA

10. Perspex is the trade name of ---- ?

CA

11. Nylon is the trade name of ---- ?

PA

12. Delrin is the trade name of ---- ?

POM

13. Teflone is the trade name of .?

PTFE

14. What is MFI?

Flow capacity of different grades of thermoplastics are inversely proportional to molecular
weight.

15. About ABS?

Shrinkage 0.5%. It is heat resistant, provides good insulation and exhibit electrical properties.
Examples are general purpose safety helmets, pipe fittings, television, radio etc.

16. About CA ?

Shrinkage 0.3-0.8%. Its main properties are transparency and surface texture. Examples are
Tool handle, goggles, TV screens.

17. About HDPE?

Shrinkage 3-4%. Main features of HDFE are high density, rigidity, strength, hardness and
chemical resistance. Examples are milk bottle crates, fish boxes etc.

18. About LDPE?

Shrinkage 0.8-1.5%. It is crystalline and not available in transparent form. Examples are
shopping baskets, waste baskets etc.

19. About PA?

Shrinkage 0.7-1.5%. It is tough and high rigid. Examples are light duty gears, sprockets,
bearings etc.

20.About PC?

Shrinkage 0.5-0.7%. It is known optical transparency, rigidity and toughness. Examples are
goggles, lenses, safety helmets etc.

21.About PP?

Shrinkage 1-3%. It is flammable and degradable in sun light and stable. Examples are air
cleaner, garden furniture etc.

22.About PS?

Shrinkage 0.2-0.8%. It is clear, brittle and it can be easily molded. Examples are toys, house
hold appliances, electronic housings etc.

23.About PVC?

Shrinkage (FLEXI 1.5-3%,RIGID 0.2-0.4%). It is rigid and not very tough and very low cost.
Example - Pipes fittings.

24. Examples for thermosetting materials ?

Alkyds, epoxies, pf, mf, urea, polyester

25. What is fillers and additives?

Adding of small molecules to plastics to get some characteristics (color, flexibility etc.).
Fillers are commonly used with thermosetting plastics. Additives are of two types,

Physical means such as plasticizer

Chemical means--- stabilizer.

26. What are the mold release agents?

1. External with mold surface e.g. Polyvinyl alcohol

2. Internal with resins eg. Silicon oil

27. What are the types of injection molding machines?

Plunger injection cylinder

Two stage plunger injection cylinder
Pre plasticizer two stage screw injection cylinder
Reciprocating screw injection cylinder

28. What are the divided sections of screw of injection molding machines ?

Feed zone
Compression zone
Melting zone

29. What do you meant by nozzle ?

Nozzle connected to the end of the barrel through which soften materials inserted in the
mold.

30. What are the types of nozzle ?

Reverse taper (melt valve)- for PA, ABS etc.

Removable tip
Standard of general purpose

30. What are the types of nozzle ?

Reverse taper (melt valve) - for PA,ABS etc.

Removable tip
Standard of general purpose

31. Define drooling ?

Leakage of plastic material through the nozzle in between shots.

32. What is injection capacity or short capacity?
Maximum volume material injected by the screw during one cycle of operation.

33. What is plasticizing capacity ?

It is the amount of material that can be processed by the machine per hour. It is expressed in
kg/h.

34. What is injection pressure?

It is the maximum pressure by which the material is injected through the nozzle. It is given in
kg/cm2.

35. What is Injection rate or Injection velocity ?

It is the maximum rate at which the screw can inject or shoot materials from the barrel during
one shot.

36. What do you meant by clamping force?

It is the maximum force that the clamping system can exert on the mold or it is the maximum
force by which the mold halves can be closed together. It is given in ton or kilo Newton.

37. What is maximum daylight?

It is the maximum distance that the machine platen can be separated from each other and it
can be obtained by adding the maximum mold thickness to the maximum opening stroke.

38. What is a mold ?

It is a custom build tool in which we converts plastic raw material into finished product.

39. What are the main elements of mold ?

The main parts of molds are core and cavity.

40. What are the general types of mold ?

Injection molds, compression molds, transfer molds.

41. What are the types of injection mold ?

Two plate mold

Three plate mold
Hot runner mold
Insulated runner mold
Hot manifold mold
Stacked mold

42. What is two plate mold ?

Mold which consists of core and cavity situated in plates. It is logical type tool where
component require large gate. For simple type components there is only one daylight.

43. What is 3 plate mold?

It consists feed plates with core and cavity.

44. What is hot runner mold?

In this, runner kept hot to keep the molten metal into fluid state also called runner less mold.
In this, runner contained in a plate of its own runner section of the mold is not opened during
molding cycle.

45. Note down the advantages of runner mold ?

No molded side products

No separating of gate
Cycle time can be reduced

46. What is insulated runner mold ?

It is a variation of hot runner mold in this type of molding. The outer surface of the material
in the runner acts as a insulator.

47. What is hot manifold mold ?

This is a variation of the heated hot runner and not the runner plate. This is done using
electric cartridge.

48. What do you meant by stacked mold?

A stacked mold is a multiple two plate mold with mold placed one over the other. A stacked
mold construction doubles the output from a single molding machine and requires the same
clamping force.

49. Explain about injection molding?

In this process, the plastic material is injected in to the mold through a sprue bush by means
of a screw plunger. This process can be used for both thermosetting and thermoplastic
materials.

50. What is compression molding?

In this process, the plastic material is placed in the cavity and use a force for compressing the
compound as the mold closes, these molds are generally used for thermosetting materials.

51. What is transfer mold?

In this process, the plastic materials is transferred from a transfer pot and then forced in to the
cavity by means of plunger. This method is used for molding thermosetting materials only.
52. Write a short note about blow molding ?

Blow molding is very much like compression molding because the blow mold generally
closes on a hollow shape that has been deposited in between the halves of the mold. Air or
gas pressure is introduced at the center. This internal pressure causes a flow of the heated
material in to intimate contact with the relatively cold mold sections. Here the plastic material
solidifies and is subsequently ejected.

54. Explain vacuum molding?

The mold used for this process is similar that of the female half of the compression or blow
mold auxiliary equipment on the machine heats the material and drags it over the cavity as
indicated by the precise technique chosen.

55.Elaborate about rotational molding?

The machine provides the means of holding the mold and rotating it about two axis at the
same time. This rotation causes the powdered material that was loaded in to the mold before
it was clamped in to the machine to solidify and cling to the wall of the mold.

56. What is impression ?

Gap between core and cavity is called impression. Impression provides the shape of the
component.

57. What do you meant cavity?

Female portion of the mold and it gives external form.

58. What is core ?

Male portion of the mold and it gives internal form.

59. What is sprue bush?

Connecting member between register ring and runner.

60. What is register ring ?

It is used to align the mold with machine platen.

61. What is runner?

Connecting member between gate and sprue bush.

62. What is gate?

Connecting member between impression and runner.

63. How can we calculate the cycle time of mold?

Cycle time Tc=m*3600/P
Where ,Tc =minimum cycle time obtainable
M=mass of the shot

P=plasticizing capacity of the machine with the particular polymer being molded (kg/h)

64. What is parting surface?

The surface where top and bottom half closed together and prevents the loss of plastic
material from the impression.

65. What are the types of parting surface?

Flat and non flat

66. Name the types of non flat parting surfaces?

Straight, stepped and angular.

67. What do you meant flash ?

If the parting surfaces are not properly matched, the molding material from the impression
will escape through the gap. This escaped melt is called the flash.

68. Why do we provide vent in mold?

Vents are provided in the mold to allow such air to escape freely. The vent is a shallow slot
not more than 0.05 mm deep and 3mm wide. If the depth is more, the plastic material can
pass through the slot and leave a flash mark.

69. What are the types of runner ?

Fully round
Rectangular
Hexagonal
Trapezoidal
Modified trapezoidal

70. Explain briefly about sprue gate ?

When the molding is directly fed from a sprue or secondary sprue, the feed section is term as
sprue gate.The main disadvantage with this type of gate is that it leaves a large gate mark on
the molding. This sprue gate is used only for single impression molds.

71. What is rectangular gate?

This is the general purpose gate and it is a rectangular channel machined in on mold plate to
connect the runner to the impression.

72. Write a short note about fan gate?

Fan gate can be considered as the other type of edge gate but it does not have a constant
width and depth. The fan shape spreads the flow of the melt as it enters the impression and a
more uniform filling is obtained with less flow marks and surface finish.

73. What is tab gate?

This is particular gating technique for feeding solid block types moldings. This is mainly
used to avoid undesirable jetting on the molded part.

74. What is overlap gate ?

It can be considered as a variation of basic rectangular edge gate and is used to feed certain
type of molding. In this type of gate we have a better control over the flow rate. Main
disadvantage is that it leaves big remnant mark after degiating.

75. What is diaphragm gate ?

This gate is used for single impression tubular shaped moldings on two plate molds.

76. What is ring gate?

The function of this gate is identical to that of a diaphragm gate. This type of gate is used for
tabular type moldings when more than one impression is required in a simple two mold.

77. What is film gate?

This is a long rectangular type edge gate and it is used for large thin walled components to
assist in the production of warpage free products.

78. What is pin gate?

Used for 3 plate mold and under feed mold. Small degating mark will be there.

79. What is round edge gate?

This gate is formed by machining a matching semi circular channel in both mold plates
between the runner and impression.

80. What is submerged gate?

Automated degating with less mark also called as sub surface gate or submarine gate.

81. What is winkle gate?

This is a curved variation of the subsurface gate and for that reason it is sometimes called a
curved subsurface gate or curved tunnel gate.

82.What are the types of injection techniques ?

1. Pin injection
 2. Sleeve injection
3. Stripper bar injection
4. Blade injection
5. Valve injection
6. Air injection
7. Stripper ring injection
8. Stripper plate injection

83. What is Pin injection ?

This is the most common and simple type of injection. The molding is ejected by the
application of a force by ejector pins.

84. What do you meant by sleeve injection ?

In this method, the molding is ejected by means of a hallow ejector pin which is called
sleeve.

85. What is stripper bar injection?

This method of injection is suitable for thin wall box type moldings because of the effective
injection area obtainable are greater.

86. What is blade injection ?

The main purpose of blade ejector is for the injection of very slender parts such as ribs and
other projections which cannot be satisfactorily ejected by the standard type of ejector pin.

87. What is valve injection ?

A valve ejector is basically a large diameter ejector pin. It is used for the injection of large
components.

88. What is air injection ?

This is the simplest to install. It is easy to connect to the fixed or moving half. The medium of
actuation is compressed air.

89. Explain briefly stripper ring injection?

The stripper ring is a local stripper plate and it is used on molds with one or two impression
only. The stripper ring is made to seat in the mold plate.

90. What is stripper plate injection?

This injection technique is used mainly for the injection of circular box type moldings and for
moldings with thin wall sections.

91. Name the methods used for actuation of stripper plate?

 1. Tie rod actuation
2. Length bolt actuation
3. Chain actuation
4. Direct actuation

92. Define shrinkage ?

When a hot plastic cools inside a mold, it contracts by an amount depending on the material
being processed and the final product is smaller than the mold size is called shrinkage.

93. What are the factors which affect the increase in shrinkage ?

Increase of material temperature.

Increase of mold temperature.
Increase in wall thickness.
Low injection pressure .

94. What are the factors which effect the decrease in shrinkage ?

Low melt and mold temperature

High injection pressure
Long injection time
Presence of filler materials and its content

95. What is undercut molding?

A molding which has a recess or projection is termed as an undercut molding

96. What do you mean external undercut?

Any recess or projection on the outside surface of the component which prevents its removal
from cavity is termed an external undercut

97. Name the methods of split actuation?

Finger cam actuation

Dog leg cam actuation
Cam track actuation
Spring actuation
Hydraulic actuation

98. How can we calculate finger cam length?

Finger cam length =(M/Sin Q) +(2c) l Sin 2Q

Where

M= split movement

Q=angle of finger cam

L=working length

C =clearance

99. Where we use side core and side cavity ?

A side core is a local core which is normally mounted at right angled to the mold axis for
forming a hole or recess in the side face of a molding. The side cavity performs a similar
function to the side core, in that it permits the molding of components which are not in line of
draw. This element allows the components with a projection or projections on one or more of
their side faces.

100. Where we use form pin straight action method ?

For the components which has internal undercut on one side of the wall.

101. Where we use form pin straight action method ?

We use form pin straight action method for the components which has internal undercut
throughout the wall

102. What is single daylight mold ?

When a basic mold is opened, there is only one space or daylight between the two mold
halves. This is called a single daylight mold.

103. Explain about double daylight stripper plate mold ?

A stripper plate mold consists of a fixed plate, a moving mold plate and a stripper plate.
There are two day light when opened. This is called double daylight stripper plate mold.

104. What is underfeeding mold?

An underfeeding mold is the one in which the feed system is arranged to feed into the
underside of the component.

105. What are the types of injection molding defects ?

Sinkmark, Streaks, Blisters/Bubbles, Weld line, Ejector marks, Cold weld, Jetting, Warpage

106.Define sink mark ?

Sink marks are the localized contractions or the depressions on the surface of the moldings.

107. What is blister or bubbles ?

Hollows created on or in the molded part.

108. What is weld line ?

It is the witness marks of two or more melt flow fronts at their joining zone.

109.What is jetting ?

It is the prominent in-homogeneous snake like strands on the surface of molding.

110.What is warpage ?

Warpage is the deviation of the mold part from its required shape.

111.What is bulk factor?

Bulk factor is defined as the ratio of the volume of the loose powder to the volume of the
molded part.

112. What are the types of compression molds?

Flash mold
Fully positive mold
Semi positive mold
Landed positive mold

113. Write a short note about performs ?

Performs are small pellets or tablets of molding material that are formed to shape in a special
performs mold at room temperature. Curing won't takes place only densification.

114. Name the types of transfer molds ?

Pot transfer mold

Plunger transfer mold

115. What is die casting?

Pressure die casting is the process in which the molten metal is forced under high pressure
into a cavity in a metal disc with in fraction of a second and allowed to solidify.

116. What are the types of die casting ?

Hot chamber process

Cold chamber process

117.Write the differences between hot chamber and cold chamber processes ?

Hot chamber process Cold chamber process

The plunger and cylinder are submerged in the Molten metal is ladled into the cold
molten metal in the holding furnace. chamber.
After shot, plunger is forced the molten metal After ladling, the plunger advanced to
through the nozzle. force the metal in to the die.
Since both plunger & goose neck are submerged in
Each time, we have to ladle the molten
the molten metal, it refills automatically when the
material in to the chamber.
plunger is withdrawn.
For casting metals that melts at high
For casting metals that melt at lower temperature
temperature such as aluminum,
such as zinc and lead.
magnesium and brass.

118. What are the types of die casting defects ?

Cold defects
Hot defects
Miscellaneous defects

119. Example for cold defects ?

Lack of fill, cold shut, severe chill, chill, flow lines

120. Examples for hot defects ?

Soldering, cracks, broken part, bent part, heat marks or shrinkage pits.