Beruflich Dokumente
Kultur Dokumente
BASIC KNOWLEDGE
Table of Contents
2-plate Since parts and their runners are formed on the same flat surface,
simply opening the mold to the stationary platen and movable platen
ejects parts. This system can be applied to almost all gates including
side gates and tunnel gates.
3-plate This system is exclusive to pin gates. Since parts and runners are
formed on the different flat surfaces, the mold needs to open its
sections separately to eject them. It is called “3-plate” because the
mold is divided into three sections when it is open.
molded part
molded part
tension link
Fig. 2.20 3-plate mold. Fig. 2.21 3-plate mold (when the mold is open).
Basic parts:
Stationary Mold that is mounted on the plasticizing unit of the molding machine.
mold The nozzle touches it and melted resin is injected into it.
Movable Mold that is mounted on the ejector side of the molding machine. It
mold keeps molded parts for a moment and then ejects them with the
ejector
Side core Refers to a method of undercut treatment. It is able to open and close
perpendicular to the closing and opening directions of the molding
machine.
Mold base A set of plates forming the outline of the mold. It is also called a
“mold die set.”
locate ring
sprue bush
stationary plate
stationary cavity
guide pin
ejector pin (K.O pin)
movable cavity return pin
knock pin movable plate
spacer block
ejector plate 1 (K.O plate 1)
ejector plate 2 (K.O plate 2)
Return springs Spring to reset the ejector plate faster than mold
closing after part ejection.
Movable retainer Main plate installed on the ejector side of the molding
platen machine. It holds the movable cavity.
Runner Plate to eject the pin gate runners in the 3-plate mold. There are two types: one type is
ejector KO activated by mold opening tension and the other is by the hydraulic cylinder of the molding
plate machine.
Lifter Lifter lifts the hoop and its guide when feeding the
hoop after a cycle of molding. When lifting the
hoop, it needs synchronization with the ejector.
stationary top plate
Hoop hold- Plate installed on top of the lifter to hold the hoop.
down plate It prevents the hoop from lifting up during
insertion.
runner ejector plate
Lifter pin Pin to connect the lifter to the lifter plate. (runner KO plate)
pin gate runner section
stationary plate
Lifter plate
Air Cylinder
Lifter Plate to fix the lifter pins. It is lifted by the ejector plate, keeps being lifted by the
plate air cylinder while feeding the hoop, and resets after molding to insert the hoop.
Runner ejector KO Pin to guide the runner ejector plate. There are two types;
plate guide pin one type is forced into the stationary bottom plate and the bolt
stopper collar
other is forced into the runner ejector plate, but both of them
function the same. It is usually equipped with the stopper
collar that limits the degree of opening.
press-fit section
Runner KO pin Pin to eject the runners when the runner lock is ejected in
force by the runner ejector plate.
Runner lock pin Pin to fix the runner on the ejector plate and to cut the pin
gate with its undercut.
Mold opening spring Spring and bolt to make a gap between the stationary
mold opening spring
Mold opening bolt top/bottom plate and stationary plate for cutting the pin
gates.
mold opening bolt
Tension link Link to connect the movable platen to the stationary plate
and to connect the stationary plate to the runner ejector
plate. It activates the runner ejector plate during mold
opening. It also acts as a stopper for the stationary plate.
runner KO pin
runner ejector plate guide pin runner lock pin
mold opening spring
runner
runner ejector plate
tension link
Stationary plate
3-plate mold
Opening
condition
Structure and mechanism of injection mold gate cut
runner ejector
runner ejection space
Side core
Core to treat undercut such as side holes. It slides perpendicular to
the mold opening direction due to the angle of the angular pin.
Undercut : The shape that is unable to release in the mold opening
direction
Angular pin Inclined pin to slide the side core during mold opening.
Lock block Block to hold the side core during mold opening to prevent the
side core from being opened by the resin pressure.
lock block
side core angular pin
side mold
Side Core Mechanism Stroke S = 5.5 Stroke S = 20.3
side core
Stroke S = 5.5 Mold Opening
After-treatment of gate Set the gate in the point where the product will not distort or chip
Measures to poor Set the gate where the gate is replaceable or the dent can be
appearance of the gate manufactured.
Measures to weld Avoid multiple gates as much as possible. One gate is much better than
multiple gates.
Measures to distortion Note that some molding materials have fluid orientation.
and warping
Stress cracking There are residual stresses in the vicinity of the gate, so gates easily
crack by external forces.
(A) 1 side gate (B) 2 side gates (C) 3 side gates (D) Center sprue gate 3 pin-gates
1 gate 2 gates
Direct gate Gate used for molding a single big article. There is a residual stress in the
vicinity of the gate.
Side gate The most basic gate. It is easy to manufacture a mold, but the gate requires
finishing.
Tunnel gate Gate that is cut by mold opening, but portion of the gate remain depending
on the resin type. On top of that, it cannot be manufactured depending on
the product shape.
Pin gate Gate that is cut by mold opening, but portion of the gate remain depending
on the resin type. 3-plate mold is used.
Shaft-off gate Refers to an automatic cutting method for hardenable side gates, and
requires a special structure. It cannot be used for elastic gates because it
tends to cause thin burrs on molded parts.
Film/Fun gate Film gate and fun gate can reduce distortions and warping of molded parts
caused by fluid orientation.
Disk/Link gate Disk gate and link gate are used for countermeasures against fluid
orientation problems. However, they need to be pressed after molding.
width of gate
stationary platen side
2 ~ 3 mm
45° ~ 65°
gate land
runner sprue
Pin point gate system (4-point gate). Film gate Fan gate
disk gate face Molded part
Enlarged area
Over flow
Ring gate
tab
sprue
Primary gate
Realize simultaneous Equidistant runners are good, but they increase material
filling loss
Decrease material loss Minimize the pitch between parts as much as possible
Regarding hoop molding Consider the molded parts layout when designing the hoop
Round shaped runner Round shaped runner has the smallest fluid resistance but both
upper and lower molds need to be manufactured.
Trapezoid runner When using bad fluid resins, trapezoid runner is used because
it has an extended width.
Runner shapes.
Basic layouts of runners.
8 parts in-series
8 parts in balance 8 parts in 3 rows
16 parts in 2 rows
“Hot runner” means “runner less molding.” This system can save resources by reducing material loss and
can increase cycles by reducing cooling time.
Types of runner less molding
Hot runner Refers to the runner that can keep melted resin right before the
gate. It produces no loss material.
Mini runner When hot runner is inapplicable, mini runner could be used as a
sub runner.
cylinder
cylinder
spear
thermoelement
After a cycle of molding, there remains half-cooled material at the tip of the nozzle. These half-cooled materials are stored
in the cold slug well and ejected to prevent appearance failure during the next cycle of injection. Cold slug wells are
usually located right under sprues or the ends of runners.
sprue
slug well
sub runner
Slug well combining sprue puller
Air vent
Air vents are grooves that discharge air from cavities during injection. If air is not discharged, the air is insulated,
compressed and overheated. Accordingly, short shot or discoloration will occur. Air vents shall be located on the front of
gates or the ends of runners.
Depth
0.01 ~ 0.05mm
vent
(gas)
PL face
gate 3~
5mm Runner air vent.
Good mold release balance Ejectors should eject molded parts in good balance without causing
distortion.
Thick areas Ejectors should be located at thick areas because they mark on thin areas.
Effect of gas vent Ejectors should be located at the point where resin is filled up and gases
stack.
Good mold intensity Pin insertion should not decrease mold intensity.
Types of ejector
Round ejector pin Pin that is commonly used because of its ease of manufacture.
Square ejector pin Pin used for narrow areas that cannot accept round pins.
Ejector sleeve Sleeve to push thin cylindrical sections. (Set with a core pin)
Stripper plate Plate to push the circumference thin products such as cases. (One
mold base activates.)
Ejector block A simple stripper type block. It pushes the circumference of a
product.
Inclined pin Pin not only works as an ejector but also treats undercuts.
Types of ejectors.
ejector plate
bottom plate
Ejector block
Stripper plate
Inclined pin
Mold temperature control
To realize beautiful surfaceKeep the appropriate mold temperature for the resin to be used.
conditions
To prevent distortion orUniform the temperatures of mold component parts.
deformation
To improve mechanicalWhen using crystalline resins, set the mold temperature high to
characteristics heighten crystallinity.
To improve flowabitily For resins with bad flowability, set the mold temperature high
Hot water or hot oil: Mold temperature controller is used. This is the most popular method.
Cold water: Cold water circulation unit (chiller) is used.
Electric heater: Electric heater is applicable to hardenable resins and engineering plastics.
Core cooling
Cooling holes are usually located on the mold base. For thick or large-size products, cores should be cooled
down to stabilize quality and improve productivity.
Methods of core cooling
V shaped path Refers to the method of manufacturing a reciprocating path in the core. It
is used for relatively big cores.
Partition Partition is used when V shape path is inapplicable..
Heat pipe Pipe that makes use of heat transferability. It is used for big cores.
Logic seal The temperature controller made by Logic Device Co. (USA). Resistant to
leaking since it absorbs cooling water at a lower pressure than
atmospheric.
V shape path
Partition Heat pipe Logic seal
Undercut refers to the section of a molded part that cannot be released from the mold by the regular mold opening direction.
Undercut is designed when the undercut is a part of the part design or when the undercut is necessary to keep the part on the
ejector side.
Side core Core that slides perpendicular to the mold opening direction. Its types vary from a mere part of the
mold to a main part of the mold.
Inclined pin Pin that slides perpendicular to the undercut while ejecting the molded part.
Undercut Undercut makes use of elasticity of resins. This method is not suitable for molded part shapes, so it is
mainly used to hold molded parts on the ejector side.
Angular pin The most popular pin. Many purchased pins are available at reasonable prices.
Angular cum When the stroke of the side core is small, the mold can be compact.
Hydraulic cylinder This method is used when the stroke of the side core is large or when cycle up is
targeted.
Angular pin Angular cum Hydraulic cylinder.
inclined pin
Inclined pin
Applications of undercut
Sprue lock Lock used to keep the sprue section on the ejector side.
Runner lock Lock used to keep the runner on the ejector side after gate cut.
Molded product Make the product uneven to keep it on the ejector side, if no problem.
It is difficult to calculate the actual intensity of movable/stationary plates because they usually have a manufactured hole.
Even so, you should investigate their intensity very carefully because wrong calculation might lead to mold damages or
burrs on products.
Hitachi Metals. Daido Steel Co,. Aichi Steel Nippon Koshuha Kobe Steel, Ltd. Uddeholm
Ltd. Ltd. Steel Co,. Ltd.
High temperature aging 53 Mal aging -steel YAG MASIC KMS18-20 KMS-CF19
steel
43 Non-magnetic steel YHD50FM NAK301 KTSM-UMI