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Injection Mold Design

Dr. Naresh Bhatnagar


Mechanical Engineering Department
Indian Institute of Technology-Delhi
Basic Structure oI an Injection
Mold
SIGN PROCSS
FING SYSTM (Sprue, Runner,
Gates)
COOLING SYSTM (Channel, Coolant,
Temp)
CTION SYSTM (Pins, Stroke,
Actuation)
Mold Types
iIIerent types oI molds:
(a) the cold-runner two-plate mold
(b) the cold-runner three-plate mold
(c) the hot-runner mold
(d) the insulated hot-runner mold
(e) the hot-manifold mold
( f ) the stacked mold.
Two Plate Injection Mold
Three Plate Injection Mold
Important Phases in Designing
Injection Mold
Parting Lines
Weld Lines
Meld Lines
Sink Marks
Vent, Trapped Air, and Ejector
Undercuts
Blind Holes
Runner Design
Mold-Cooling Design
Gate Design
Parting Lines
Vent, Trapped Air, and Ejector
UNDERCUT
ample oI an
undercut made
possible by using
an ejector pin
Multiple-Cavity MOLDS
Partially Iilled
cavities in an eight-
cavity balanced
runner mold
Types oI Runner Systems
NaturaIIy BaIanced ArtificiaIIy BaIanced
Types oI Runner Systems
4Id Runners
2-PIate M4Id 3-PIate M4Id
1
2
1
2
3
Types oI Runner Systems
4t Runners
MeIt
Shut-Off
Pin
Gate Gate
avity avity
MeIt MeIt
N4Ie N4Ie
Fr4en Fr4en
Layer Layer
artridge
eater
MeIt
eater
InsuIated InternaIIy
eated
ExternaIIy
eated
hat is the Best Runner
iameter?
Allows the Mold to be Filled Quickly
Minimizes Scrap in the Runner
elivers the Melt as UniIormly as Possible
hat is the Best Runner
iameter?

F4r PS, ABS, SAN


S

1
1
.
5
2
2
.
5
4
3
3
.
5
4
.
5
5
2 2.5 3 3.5 4 4.5 5.5 6.5 7.5 8.5 5 6 7 8
0
100
800
700
600
500
400
300
200
G
(
g
)
G: Weight (g)
S: Nominal thickness (mm)
D: Reference diameter (mm)
hen To Use a Hot Runner
System?
Long Runner Lengths (High Pressure Loss
in Cold Runner)
Reduce or liminate Scrap in the Runner
System
Minimize Cycle Time Ior Thin alled Parts
etermining the Best Gate
Locations
Should Allow Part to Fill ithin Target
Pressure
Must Properly Place eld Lines
Should Not Be Located in Structural Areas
etermining the Number oI
Gates Needed
ependent on Flow Length
ependent on Part Thickness
ependent on Resin Being Used
Should Promote a Large Process indow
Gate Effects
An eample oI
jetting in an
injection mold
Melt Iront progression during injection molding oI the part. The part is one oI the two covers Ior a 3.5 inch computer Iloppy disk.
The illustration shows the melt Iront just beIore the cavity is Iilled. BeIore the availability oI molding CA, the short shot was
the molding engineer`s Iavorite diagnostic tool.
MOLDFLOW RESULTS
Air traps eld lines
Orientation at skin
Fill time
MOLDFLOW RESULTS
MOLDFLOW RESULTS
Air traps
Fill time
Temperature at Ilow Iront
Clamp Iorce XY plot
FILLING SIMULATION
Mold-Cooling Design
iIIering
temperatures on
opposite sides oI the
mold causes the part
to be concave
towards the hot side
Cooling esign
How Cooling Time AIIects Cycle Time
How all Thickness Impacts Cooling Time
Considerations Ior a Good Cooling esign
Good Cooling vs. Bad Cooling
P44r Part
in L4nger Time
P44r
44Iing
Better Part
in Sh4rter Time
Pr45er
44Iing
Part temperature distribution at ejection shows that initial cooling system does not
provide even cooling oI the part.
Improved cooling system results in more even temperature distribution.
Mold layout with cooling channels and cavity
'olumetric shrinkage distribution across the molded part at the time oI ejection.
Mold wall temperature distribution at the start oI the injection cycle.
alls close to the intersection oI the rib and the base structure are warmer
than other areas. Shrinkage will be higher there.
Cooling line layout with maniIolds. The Ilow rate in each cross channel is diIIerent, ranging Irom
4 liters per second at the channel closest to the inlet and outlet, to halI that Ior the channel Iarthest
Irom the inlet.
Serial connection oI cooling system has equal Ilow in all legs.
Fiber Orientation
Fiber Orientation in a
section oI a Glass-
Iilled polypropylene
part
Tensile stress/strain behavior oI a 30 carbon Iiber reinIorced polycarbonate parallel
and perpendicular to the Ilow direction.
Gate Effect on Flexural
Strength
Edge-Gated part performed but Center-Gated failed
Gate Positions
The eIIect oI Gate
Position on Iiber
orientation
Warpage
arpage oI a T-
section, end-gated
part with and
without Iiber Iiller
Gate effect on Warpage
The eIIect oI
differential
shrinkage on a
Ilat Iiber-Iilled part
that is center-gated
Warpage Tendency
More shrink on the
side with the hole
causes warpage.
Model oI the radiator end cap with a central gate
Cavity Iilling oI the automotive radiator end cap
arpage resulting Irom the Iiber orientation Irom a central gate
arpage Irom the central gate, with the reIerence plane changes to the nodes at one end
arpage predicted Ior the center gated radiator end cap. The upper leIt window shows the model.
The upper right widow shows the warpage reIerenced to a plane deIined by the user to be near the
end oI the cap. The lower right shows the shrinkage in the X-ais direction due to diIIerential area
shrinkage. The lower leIt window shows the shrinkage Irom orientation.
Center gate Ilow directions as the melt Iront passes each element. These can be correlated
with the Iiber orientation.
Resulting Ilow directions and Iiber orientation Ior a part with an end gate
Melt Iront temperature Irom a mold Iilling simulation, showing eIIects oI the melt hesitating
in the thin region.
Figure 10.10: Finite element mesh oI the part, automatically generated Irom CA solids model.
'olumetric shrinkage distribution demonstrates potential diIIerent shrinkage that can
cause stresses between diIIerent regions oI the part. Red areas represent regions oI
high shrinkage; cooler colors represent regions oI lower shrinkage.
istribution oI process-induced shrinkage oI the molded part. Process-induced
warpage includes the eIIects oI both non-uniIorm shrinkage and uneven cooling oI the
cavity Iaces.
Pressure distribution at the end oI the packing phase shows over packing near the gate.
This will also result in lower volumetric shrinkage in this area. Since the time is at the
end oI the packing phase, pressure at these points indicate a residual pressure that time.
Fiber orientation on the skin oI a molded part. The short lines Iollow the direction oI
Iiber or molecular orientation on the surIace oI the part. This layer is oriented by shear
stresses between the layers oI the plastic as the cavity is Iilling. As the plastic touches
the cold cavity wall, it is Irozen with the orientation eIIects in place.
Comparing a mold Iilling simulation to
an actual Iilling pattern in an 8-cavity
mold. The error in the simulation
results Irom the use oI simpliIied 1
beams, which are standard with most oI
today`s state oI the art injection molding
simulation programs.
Hybrid Composites
Hybrid composite materials, incorporating both fiber and flake
reinforcements, have mold shrinkage values that tend to be more
isotropic than conventional fiber-reinforced polymers
SIMULATION
Mold Flow
simulated model
Fill Time
Shear Stress at Wall
Shear stress at wall
at gate location Ior
diIIerent types and
sizes oI gates
Material
TUFNYL S13
maimum allowable shear
stress 0.5 MPa
FILLING SIMULATION
Fiber Effects
Comparison between
flowand cross-
flowshrinkage and
the effect of fiber
type on shrinkage
THANK YOU

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