EDUTECH NTTF

FORMULAS
TOOLING

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 EDUTECH NTTF

2007 04 03
Kochi

A formula book for tool engineers was that we NTTF was

longing for.

We are thankful to our Director Training for gathering all the

centers Designers during the Designers meet at NTTF,
Bangalore on 2007 01 23 and assigning me the responsibility
to compile the TOOLING FORMULAS related to tooling
industry which will be helpful for our trainees academically
and professionally. I also wish to thank my unit head for his
co operation extended in all ways.

With the help of NTTF Staff from different centers and from
reference books we could come out with this book.

We could compile tooling formulas related to:

a. Mould technology
b. Press Tool Technology
c. Jigs and fixtures

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MOULDS FOR PLASTICS

Injection Moulds- Thermoplastics

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1.0 No of Cavities calculation:

The essential considerations are:

Shot capacity
Plasticizing capacity
Clamping force
Injection pressure

1.1 Shot Capacity:

The plunger machine is often rated in terms of maximum shot weight (gm)
with polystyrene. The rating terms of another material can be determined
from the following relation:

1.1 Shot capacity with material B =

Shot capacity Density of B Bulk factor A

With matl.A X Density of A X Bulk factor B

Matl.A = Plastics Matl. Used for specifying the rating of press (polystyrene)
Matl.B = Plastics Matl. Actually to be used.

The screw type machine is normally rated in terms of swept volume

of the injection cylinder (Cu.Cms)

Shot capacity (g) = swept vol. (Cm) x x c

Density of plastic at normal temperature (g/cm), (As given in

manufacturers literature)

c = 0.85 for crystalline materials

c = 0.93 for amorphous materials.

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1.2 Plasticizing Capacity =

Plasticising rate of Plasticising rate of QA

Matl.B.(g/hr) = matl.A (g/hr) X QB

A - Polystyrene
B - Material actually to be used
Q - Thermal capacity of the material (cal/g)
(Heat content)

Alternatively

Plasticizing rate of Plasticizing rate of

Material.B (g/hr)
= matl.A (g/hr) X
Sp. Heat of A Moulding temp. of A
Sp. Heat of B X Moulding temp. of B

The machine selected should be capable of plasticinsing sufficient

material to maintain the expected moulding cycle.

Plasticizing rate (g/hr) = Wt. of moulding (g) x No. of mouldings /hr.

For max. Efficiency, The machine should not operate above 80% of
its plastering capacity.

1.3 Cycle time =

Cycle time; when machine is limited by plasticizing capacity.

tc mx3600
= pxK

Where tc = Minimum cycle attainable (sec)

m = Wt. of shot (OZ of g)
p = Plasticizing capacity of machine with particular polymer being
moulded (lb/hr or Kg/hr)
K =16 (with British units)
1000 (with Metric units)
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1.4 Clamping force =

The clamping force required to keep the mould closed during injection
must exceed the force given by the product of the opening pressure in the
cavity] and the total projected area of all impressions and runners.

[Projected area of moulding

Including runners ][ X
1//2 to 1/3 of injection
Pressure (Tons /sq. cm.) ]
Thin sections need a high injection pressure to fill and therefore
require more clamping force.
Easy flowing materials like high melt index polyethylene and
polystyrene fill more readily and hence require a lower clamping force.
In the case of screw injection x to of injection pressure should be taken
for clamping purposes. Max. Injection pressure may be obtained from press
manufactures data sheet.

1.5 Injection Pressure =

The injection pressure may be obtained from the following relation:

Injection pr. (Kg/Sq. Cm.) = Injection hydraulic di

Line gauge pressure X dp2
(Kg./Sq.Cm.)

di = Dia. of injection cylinder (Cm)

dp = Dia. of heating cylinder ram (Cm)

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2. Determination of number of cavities:

The number of cavities in injection moulds is determined in most
cases by the machine performance, but some times by the moulding shape
or the mould locking pressure.

2.1 Determined by Shot Capacity =

(Based on 85% of rated shot capacity)

Ns = 0.85w
M

2.2 Determined by Plasticizing Capacity =

(Based on 85% of rated plasticizing capacity)

Np = 0.85 p. Tc
3600 m

2.3 Determined by clamping capacity =

Nc = C
Pc x Am

Where
Ns = No. of cavities based on shot capacity
W = Rated shot capacity for particular polymer (g)
M = Moulding weight per cavity (g)
Np = No. of cavities based on plasticizing capacity.
P = Rated plasticizing capacity for particular polymer (g/hr)
Tc = Over all cycle time (sec)
Nc = No of cavities based on clamping capacity
C = Rated clamping capacity (tons)
Pc = Clamping pressure in Ton.1/cm of projected area (0.630 T/Sq.Cm.)
Am = Projected area of moulding (sq.Cm.) including runners

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The weight of sprue and runners related to the moulding generally

must not be neglected. This should be considered in the formula when
determining the moulding weight. The moulding weight per cavity (m)
should be substituted in the formula multiplied by the following factors:

Moulding wt. (g) Factor

0.3-0.5 1.5
0.5-1 1.4
1-3 1.3
3-5 1.25
5-10 1.15
10-20 1.10
Above 20 1.05

Multiplication factors of small mouldings processed in multi-

impression moulds are even higher than those quoted above.

Typical temperatures =

Material Cylinder Mould c

c
ABS 230 50
Acetal 225 100
Nylon 66 280 70
Nylon 66 GF 300 130
Polythene 230 30
Polypropylene 250 60
Polystyrene 200 30

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3. Strength of cavities:

3.1 Rectangular Cavities =

The maximum deflection commonly allowed is 0.13-0.25mm
depending upon the size of the tool. Of this 0.1-0.2mm may be due to
clearances between the blocks of the built-up mould and elongation of the
bolster or register faces. For stress design purposes, therefore, a maximum
deflection of 0.025-0.05mm is usually taken.
The approximate thickness of the side wall required may be
calculated from the following formula

t = C. p. d4
E.

Where = Max. deflection of side walls (Cm)

C = Constant
P = Max. Cavity pressure; say 630Kg/Cm
d = Total depth of cavity wall (Cm)
E = Modulus of elasticity for steel (2.1x10 Kgf/Cm)
t = Thickness of cavity wall (Cm)

Values of C (Constant).

Ratio of the length of cavity wall Value of C

to the depth of cavity wall (L/d)
1.0 0.044
1.5 0.084
2.0 0.111
3.0 0.134
4.0 0.140
5.0 0.142

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3.2 Cylindrical Cavities =

Increase in radius due to the internal pressure of injected material

can be determined from

= ( )[{(
Re
E r+R )/ (R- r)} +m]

= Increase of inside radius (Cm)

r = Original inside radius (Cms)
R = Original outside radius (Cms)
m = Poissons ratio (=0.25 for steel)
p = Cavity pressure; say 630 kg/cm

3.3 Suggested minimum wall thickness for mould cavities

and retainer plates (for quick reference)

Inside dia Wall thick Wall thick Wall thick Wall thick for
Of inserts for round for retainer for rectangular retainer plates
(mm) inserts plates inserts (mm)
(mm) (mm) (mm)
30 8 30 12 30
30-50 10 35 12 35
50-75 12 37 15 37
75-100 12 40 16 40
100-125 15 45 18 48
125-175 16 48 21 54
175-225 19 50 25 64
225-300 22 57 35 71
Over 300 25 64 45 76

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Note:-Add 3mm on wall thickness when depth exceeds twice the

basic wall thickness indicated in table.
4. Strength of guide pillars:
The decision as to which size of the working diameter of guide pillar
to use depends on the size of the mould and whether or not a side force is
likely to be exerted on it. The moulds with deep and heavy cross-section at
cores exert side thrusts, and the guide pillars should be strong enough to
absorb them without any damage.

Side thrust (Q) can be calculated from the equation.

Q = 2/3 d.h. Pf (Kg) for circular core.

Where
d = Max.dia of core (cm)
h = Height of core (cm)
Pf = Cavity pressure causing side thrust taking into consideration the

effect of clamping force (Kg/cm) say 300 kg/cm

Q = a.h. Pf (kg) for rectangular core.

Where
a = Max. Size of core (cm)
h = Height of core (cm)
pt = Say 300 kg/cm

Working diameter (d) of guide pillar

d 4Q
N fs

Where
Q = side thrust (kg)
N = No. of pillars
fs = Shear stress; say 16 kg/mm
Mould plate bore & fitting dia of pillar H7/n6
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Mould plate bore & fitting dia of bush H7/n6

Working Dia (d) H7/g6 Size of mould

(mm) (mm)
10 100x100
13 100x150
16 150x200
19 200x250
22 250x300
25 300x400
32 400x600
38 600x700

5. EJECTION:

Force required to strip a moulding off a male core may approximately

be determined from

P= St .E. A.
d (d / 2t d / 4t) )

P = ejection force required (kg f)

E = elastic modulus (kgf/cm)
A = Total area of contact between moulding and mould faces in line
of draw (cm)
= Co-efficient of friction between plastic and steel.
d = diameter of circle of circumference equal to length of perimeter
of moulding surrounding male core (cm)
t = thickness of moulding (cm)
= Poissons ratio of the plastic (0.4 to 0.5 on average)
S = thermal contraction of plastic across diameter d =co-efficient of thermal
expansion X temperature difference between softening and ejection
temperature X d (cm)

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Material Co-efficient of Thermal expansion /c Softening

friction of x 10-5 point c
plastic with
steel
ABS 0.5 6 - 13 85
Acetal 0.25 8.1 175
Acrylic 0.4 5-9 90
Nylon - 6 0.4 8 - 13 Melt point 200-
220
Polycarbonate 0.55 7 165
Poly ethylene LD 0.4 16 - 18 86
Poly ethylene HD 0.25 11 - 13 125
Poly propylene 0.33 11 150
Poly styrene 0.4 6-8 90
Poly styrene 0.5 3.4 - 21 88
toughened
PVC 0.55 5 82
SAN 0.5 6.8 94

Although there is no proven method of determining in advance

the number of ejector pins required, a rough rule of thumb is to provide one
Sq.cm of ejector pin bearing surface for every 100Sq.Cm of side wall
contact (not projected area).

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6. Determination of support pillar requirements,

Stress calculation:

W = 8 ZS ; Z = LB ; A = W
M 6 P

W = Permissible load on support plate (Kgs)

S = Per = co-efficient of thermal expansion X temp. difference between
softening point and ejection temp. xd (cm)
missible working stress (Kg/cm) 840 kg/cm
M = Distance between supports (cm)
Z = Section modulus (cm)
L = Length of support plate (cm)
B = Thickness of support plate (cm)
P = Max.unit pressure on support plate (kg/cm) 630kgs/cm
A = Permissible projected area of moulding / impression (cm)

If the calculated permissible projected area (A) is found less than

actual projected area of moulding then it denotes that additional support
pillars are required to withstand the stresses.
Placement of one row of additional support pillars equally, dividing
the span (M) in the ejector grid will quadrupie the permissible projected
area.

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Similarly two rows of additional supports dividing the span (M) in to

three equal parts further strengthen the support plate and will give nine
times the permissible projected area.
The support pillars should be placed as close as possible to the
points of maximum stress, and can be made use of for guiding the plate
assembly.

7. Feed system
7.1 Sprue Bushing =
The maximum dia of the sprue should be at least 6 mm and should
be greater than nozzle orifice as short as possible and never over 100mm
long. Long reach nozzles have to be made use of prevent excessively long
sprues. The sprue included angle has to be 4-5.

Sprue sizes for polystyrene:

Wt. of moulded part (g) Minimum sprue diameter

(mm)
10 3.5
10 - 20 4.5
20 - 40 5.5
40 - 150 6.5
150 - 300 7.5

For other materials the sprue diameter should be multiplied by the

following factors:

Material Factor
Acrylic 2.0
Softened PVC 0.8
Nylon 0.8
Cellulose acetate 1.0
Polyethylene 0.5

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7.2 Runners
To calculate runner diameter

D = W x 4L
D = Dia of runner (mm) 3.7
W = Wt.of moulding (g)
L = Length of runner (mm)

MATERIAL TYPICAL RUNNER IN mm

ABS,SAN 4 10
Acetal 3 10
Acrylic 4 10 . 5
Impact acrylic 7 . 5 10
Nylon 8 10
Poly carbonate 4 10
Polyethylene 1 . 5 10
Polypropylene 4 10
Polystyrene 3 10
Poly (plasticized) 3 10

MAIN RUNNER POLYSTYENE ABS , SAN

LENGTH FROM MAIN 2 ND MAIN 2 ND
SPURE RUNNER RUNNER RUNNER RUNNER
upto 75 5 4 6.5 5.5
75 - 150 6.5 5.5 8 7
150 - 225 8 6 9.5 8
225 - 300 9.5 8 11 9.5
300 & above 9.5 8 12 11

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Main Runner length (mm)

Longer runners require increased diameter. All main runners in a
given mould should be equal in diameter, while the diameter of all the
secondary runners should be at least 0.7mm less than the diameter of the
main runner.
Intersection of secondary runners with the main runner should be filleted
with a 3mm radius on the upstream or sprue side of the intersection.
Similarly the intersection of the sprue with the main runner should also
have a 3mm fillet radius.

Weights of runner systems in grammes for material density 1g/cm

Dia. weight per cm

(mm) Round Trapezoidal
2 0.0314 0.0366
3 0.707 0.0823
4 0.1256 0.1463
5 0.1963 0.2286
6 0.2826 0.3292
9 0.6359 0.7407
12 1.1304 1.3167
15 1.7663 2.0574
18 2.5434 2.9626

For other materials multiply the above figures by the relative density.

7.3 Gates:
The cross sectional area of the gate ( h x w ) controls rate of fill of
material into the impression.
The depth of gate controls the time for which the gate remains open.
This gate open time must be sufficient for the material to reach the
extremities of the impression.

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The depth of the gate.

h = n.t

Where h = depth of gate (mm)

t = wall section thickness (mm)
n = material constant

Polyethylene; polystyrene n=0.6

Polyacetal; polycarbonate, polypropylene n=0.7
Cellulose acetate, Acrylic, Nylon n=0.8
PVC n=0.9
The width of the gate controls flow rate

W = n A
30

Where W = gate width (mm)

A = surface area of cavity (mm)
n = material const.

The land length of the gate is approximately equal to the gate dia or
gate depth.

8. Drafts and Tapers:

Draft should be allowed within the tolerance given by the part
drawing. Good design practice is to provide one degree side wall draft,
when moulding rigid thermoplastics having a long elongation at yield. For
the more resilient polymers a side wall draft of half degree is sufficient. The
polish on the side walls should be specified in line of draw.

9. Venting:
Ground recesses on the parting line of 0.05 deep, 6 to 12 mm wide,
extending fully from the cavity to the mould exterior help efficient venting.
The depth of vent should increase slightly as it diverges from the cavity, so
that the vent will be self cleaning. Ground flats of 0.05mm deep on ejector
pins parallel to its long axis, or clearance of 0.025 to 0.05mm around
ejector pin would improve venting in the deep areas of impression.
Installations of vents on the parting line at points of weld lines improve
moulding quality.

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10. Tolerances:
Cores, projections and other male parts of the mould are calculated
by subtracting of the total allowable tolerance from the maximum
dimension permissible. Then add material shrinkage. Tolerance on mould
is given in minus direction.
Cavities, depressions, grooves, and other female parts of the mould
are calculated by adding of the total allowable tolerance to the minimum
dimension permissible. Then add material shrinkage. Tolerance on mould
is given in plus direction.
Dimensional tolerances, as given on mould drawing should amount to
no more than the desired tolerance for the mould part because the
mould variation is only one of the factors influencing the final dimension.

11. Mould Cooling:

The temperature of the mould must be maintained at some constant
temperature below the heat distortion point of the plastic, in order to chill it
to a rigid state. Differential cooling strains are set if the mould surface
temperature is not uniform and those strains may cause distortion of the
moulding after ejection. The heat input supplied by the injection heating
cylinder to plasticize the material must be removed from the mould to
permit ejection.

11.1 Heat to be transferred from mould per hour (Q)

Q = ma

Where
Q = Heat to be transferred per hour (cal/hr)
M = Mass of plastics material injected in to the mould per hour (g/hr)
a = Heat content (cal/g)

Alternatively

Q=m [Cp (Tmat-Tmould) +L]

Where
Cp = Specific heat of material (cal/g deg.c)
L = Latent heat of fusion of plastics material (cal/g)
Tmat = Injection temperature of material (C)
However a value less than this is used in practice.
Tmould =Temperature of mould (C)
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11.2 Weight of water to be circulated / hour to dissipate the heat (m1)

Qw = K.m1. (Tout Tin)

Where
Qw = Rate of heat extracted (cal/hr)
K = Constant to allow for heat transfer efficiency.
m1 = weight of water passed (g/hr) (Tout-Tin) 3 - 5C

Values of constant K k
Cooling channels bored in cavity plate or male core 0.62
Cooling channels bored in back plates 0.50
Cooling channels using copper pipes 0.10

Since Qw = Q

m1 = m.a
K (Tout-Tin)

11.3 Solidifying time:

The solidifying time is proportional to the square of the wall thickness

T = g.a d
.

p (t mat - t mould)
X 8

Where
T= Solidifying time (sec)
= Specific weight (g/cm)
a = Heat content of material (cal/g)
The heat of solidification
p = Thermal conductivity of plastics (cal/cm.Sec. C)
= Wall thickness of the moulding (cm)
tma t = Injection temp. of material ( C)
tmould =Temp.of mould (C)

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11.4 The solidified heat released when the material is stiffening (Qs) is
transferred by the water circulating in the cooling pipes located
at a distance Z from the surface.

Qs = s. A (t mat - t mould)T
Z

= g . A .d. a
Where
Qs = Solidified heat (cal)
A = Moulding surface (cm)
Z = Distance of cooling line from the moulding surface (cm)
s = Thermal conductivity of steel
0.115cal/cm.sec c
Hence

( t mat t mould ) = Z g. . A
[ s.T

The temperature difference between the material and mould wall is

proportional to the distance between the cooling pipe and the
moulding.Therefore to achieve uniform mould temperature on the working
surface of mouldings with uniform wall thickness, the cooling pipes have to
be located at equal distances from the moulding surface.
For mouldings with various wall thicknesses, the distance of the
cooling pipes from the moulding should be inversely proportional to the wall
thickness where possible.

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11.5 Total length of the channel.

L (cm) = Q1. Z .
s (T mat T mould). 2Ac

Where
Q1 = Q/3600 cal/sec i.e. heat transferred per second
Ac = Area of cross-section of cooling channel, (cm)

Length of each channel can now be decided by dividing the length of

channel L by the number of channels selected depending upon the
moulding configuration ,mould shape, size, location of ejector pins and
return pins, and runner geometry.
The flow of coolant should always be turbulent through the cooling
channels in order to obtain the best heat transfer. Therefore check for the
Reynolds number which should be greater than 3000 to ensure turbulent
flow.

Reynolds number = 98.285xq

Xd

q = Flow rate (Cm3/sec)

= Viscosity of the liquid in centistokes (water=1)
d = Diameter of the cooling channel (cm).

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12. SIDE CORE MOVEMENT CALCULATION

The distance traversed by each split across the face of the mould plate is determined
by the length and angle of the finger cam. Movement can be computed by the formula.
M = [L sin ] [c/ cos ]
As the required movement is known from the amount of component undercut, the
following rearranged formula to determine the finger cam length of greater use, apart
from checking purposes
L = [M/sin ] + [2c/sin 2 ]
Where M = split movement,
= Angle of finger cam,
L = working length of finger cam,
C = clearance.
d

+5
M

M
L
C

Where M = component flange height + 10 mm (for ejecting the component)

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13.0 THERMOSET MOULDING

BULK FACTOR =Volume of loose powder

volume of the moulded part

bulk factor varies from 1.18 to 18

Compression moulding and transfer moulding :

Minimum moulding pressure

Without pre heat :

21.1 Mpa+1.93Mpa per 10mm depth in excess of 25.4 mm(Max 30mm)

With pre heat:7Mpa+0.69per10mm depth in excess of 25.4mm

Mass of mould:
Mt =v x p
mt =total mass of moulding
p =the density of material
v = total volume of moulding including flash(flash factor
10%)

Total volume of loose powder:

Vt =v x bulk factor of compound
Depth of cavity or loading space:
D=vt-vc
A
Where vc=volume of actual cavity space
A=area of cross section of loading space
D= depth of loading space from top of cavity to punch off land

Transfer pot calculations:

The clamping pressure provided by the hydraulic
cylinder is an important consideration .If the total cavity area is greater than
the total pot area the pressure exerted by the plastic compound will tend to
open the mould at the parting line

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To ensure perfect mould locating the pot area should be 25% greater than
the combined area of moulding surface and the are of all runners and sprue
(sprues)

The dimensional of the pot (if it is round or square)

can be calculated once the area is known

Total area of pot Ap=total project area of cavities, runners, gates & sprue
+25to30%of total
projected area
1.25x total projected area
Volume of pot Vp=(total volume of all the piece parts ,the runners ,gates &
sprue +approximate
volume of 0.5to 1mm
thick cullx bulk factor
Depth of pot =Vp
Ap

Minimum cross section area of sprue:

The minimum cross section area of
sprue can be
Calculate from the equation
As=m x n x k-mm2
Where m=mass of moulding (including flash, sprue, runners etc)
n=number4 of cavities
k=flow factor for the type of material being used
Runner & gate dimensions:
The total area of gates fed by one sprue
should be equal to
the minimum cross section area of the sprue

gate area (Ag ) in a multi impression

Mould = As x n
where Ag =gate area of one cavity (mm2)
As = minimum cross section area of sprue (mm2)
n= number of cavities
Width of gate:
Wg=Ag
C
Where Wg = width of gate
C = depth of gate
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14.0 Spure gate dimensions:

Type of plastic Min dia R E C mi nK

Din mm
Wood flour phenolic 4 0.5(d+5) 2.5 0.8 0.28-0.30
Cotton flock phenolic 5-6 0.5(d+5) 3 1.2 0.30-0.36
Fabric filled phenolic 6-7 0.59d+5) 4 1.6 0.37-0.42

The electrical heating elements should be thermostatically controlled by the

use of
Thermocouples
Qtotal = 3Aside +4.5Abasic + covering (KW)
Where Aside = 2(length x height )+(width x heating) m2
Abasic +covering =2(length x Width )m2
The heating body should be capable of maintaining the mould temperature

Qh=(0.165V +Aside )+1.86 Abasic

+covering(KW)
Where V= mould volume (dm3)
X=heating up period
(h)

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15.0 MOULD DESIGN AND BUILD CHECKLIST

Part Name ___________________________________
Part Number _________________________________
Order number ________________________________

Part Print Information

Do we understand the end use of the product?

Are there any mating parts?
Have we evaluated the GD&T requirements?
What are the advanced quality planning issues?
Has the part been prototyped? What were the results?
Is there existing production tooling for this part? What is the history?
Are the part tolerances realistic and achievable?

Moulding machine data

What make and size of Moulding machine is to be used?

What is the tie rod spacing and knockout pattern?
How will the mould be located in the Moulding machine?
How will the mould be loaded into the Moulding machine?
Where is the air, water, electrical, vacuum located?
What type of cooling equipment is to be usedwater, oil?
Is a quick mould change system being utilized? Which one?
Will the Moulding machine K/Os be bolted to the mould?
Are there any special requirements?
Is the identified Moulding machine large enough to keep the mould closed?
Is the maximum/minimum shut height and K/O stroke sufficient?

Resin/Processing Information

What is the specified shrinkage rate? Where did we get the number?
What is the potential for warpage /shrinkage problems? What dimensions will be
affected?
Do we know the optimum processing parameters?
Is the material compatible with the product design?
What are the tooling-related side effects from this resin?

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Part Requirements
Where can we locate gates, parting lines, K/O pins, etc.?
Is the part mouldable? Can we make any suggestions?
What are the assembly/automation requirements?
Is there sufficient draft?
What surface finish is required? Is the part clear?
Where are the potential knit lines, voids, jetting, splay marks, etc.?
How much gate vestige is allowable?
Is there any required artwork, templates, etc.?
Is the part to be textured?
What type of date code is required?

General Requirements
Do we have any special requirements for this mould?
What is the project timeline?
How will we fixture and inspect the part?
Do we require any spare details? Which ones? How many?
Do we require dimensions to be steel safe?

Mould Base General

What type of mould base steel is to be used?
Will the mould fit between tie bars?
Is the locating ring the correct size and style?
Are eye bolt holes in both halves and on all four sides?
Are the right size eye bolt holes specified for the weight?
Will the mould hang level using the eye bolt holes?
Is the mould base large enough to support moulding pressure?
What is to be stamped on the mould base and where?
Has a safety strap been provided?
Are tie bar slots shown?
Are all edges chamfered?
Are all holes countersunk?
Is there adequate pillar support?
Are clamp slots the right size and in the right location?
Is the base to be plated? Which plates? What type of plating?
Are parting line locks required? Straight, tapered?
Are straight locks to be purchased or manufactured?
Do straight locks enter each other before any cavity shutoffs?
Do leader pins enter bushings 25 mm before any shutoffs or cam fingers enter slides?
Do leader pin bushings have clean out shuts?
Has one leader pin and one return pin been offset?

Vents
Are vents detailed?
Are runners vented?
Are vent lands 1.6mm maximum?
Is the vent relief area 0.025-0.05 mm deep?
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Are inserts vented?
Are bushings vented?
Are ejector pins provided for venting where bosses are present in the part?

Cooling System
Has a mould cooling analysis been done?
Have we designed for turbulent water flow?
Are thermocouples used to control steel temperature?
What size are waterlines to be used?
What size quick disconnects are to be used?
Is there sufficient room between disconnects?
Are in and out marked and numbered?
Do in and out interfere with moulding machine tie bars or mounting holes?
Has O-ring use been minimized?
Are all O-rings captured in steel?
Are all water fittings brass?
Are thermal pins required? Do they have enough area in water for efficient cooling?
MOULD DESIGN AND BUILD CHECKLIST
Runner System
Has a mould flow analysis been done?
Do we know the optimum gate location? Are there any potential part blemishes?
What style of gates is to be used? What is the gate size?
Have gate areas been inserted?
Is the runner system balanced?
Are there any potential pressure drops?
At what size is the runner system designed?
Are all runner intersections radiused vs. sharp corners?
Are runner shutoffs required?
Are there enough cold slug wells?
Are subgate K/O pins the right distance to allow for proper gate flex?
What are the required O and R dimensions?
Is the sprue bushing keyed or locked?
Will the runner fall free from the mould (three-plate)?
What brand of hot runner hot sprue bushing is required?
What type of electrical connectors are required? Where are they to be located?
Are all heat and drop zones clearly labeled?
Is all wiring contained and protected?
Is a drool tube included in the design?
Is the sprue puller 0.4mm per side larger than the K/O pin?
Will a sprue picker be used? What will it grab onto?
Ejection System
Will the part stay on the ejector half?
Is top-side ejection required? How is it to be activated?
Is there sufficient ejection to prevent sticking, distortion, cracking?
Are ejector pins as large as possible?
Are blades or sleeves required? Are these purchased items?
Is the stroke enough to eject the part completely from the mould?
Are ejector back plate to be tapped? What size?
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Are hardened flush plugs required?
Are positive ejection returns required? Internal? External? Purchased or
manufactured?
Ejection System(contd)
Is two-stage ejection required? Which design?
Is stripper plate ejection to be used?
Are latch locks used? Which ones?
Are the ejector plates guided? Are the guide pins captured at both ends?UD
Can the guided ejector bushing be lubricated while in the press?
Is the ejection system spring loaded?
Are the springs captured at both ends and supported?
Are lifters used for ejection? Which ones?

Slides
Is there adequate lead-in for the slides?
Are the slides spring loaded open?
Are spring detents or positive slide retainers included?
Are wear plates Lamina, Ampco, hardened?
Do steel types and hardness vary between components?
Is there cooling in the slides?
Is the slide detail on a removable slide nose detail?
Is the cam pin large enough in diameter?
Is the slide travel retained in the mould base?
Do the slide locks interlock between mould halves?
Air cylinder required? What brand?
Do they have switches at both ends of travel?
Do the cylinders require a manifold?
Is slide travel sufficient to clear undercuts?

Cavity and Cores

What steel type and hardness is required?
Are cavities to be plated? Which plating?
Are parting lines and insert lines approved?
Do cavities stand proud .05 mm above mould base plates?
Do we know the location for all engraving?
Is the revision level of the part number inserted?
Have critical dimensions been identified?
Are shutoff surfaces identified?
Are fragile areas inserted?
Are sharp corners in moulding areas avoided?
Is there adequate steel to support cavity pressures?
Is there adequate steel around screw holes, waterlines, and other fragile areas?
What surface finish is required?

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PRESS TOOLS
for
STAMPINGS

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1. STANDARD PUNCH AND DIE CLEARANCES FOR SHEET METALS

STOCK THICKNESS HARD STAINLESS
mm SOFT STEEL MEDIUM STEEL STEEL STEEL PHOSPHOR BRONZE BRASS COPPER ALUMINIUM
0.25 0.02 0.02 0.02 0.02 0.02 0.01 0.01 0.03
0.51 0.03 0.03 0.04 0.04 0.03 0.03 0.02 0.05
0.76 0.04 0.05 0.05 0.06 0.05 0.04 0.04 0.08
1.02 0.06 0.06 0.07 0.08 0.06 0.05 0.06 0.10
1.27 0.07 0.08 0.09 0.10 0.08 0.06 0.07 0.13
1.52 0.09 0.09 0.11 0.12 0.09 0.08 0.08 0.15
1.78 0.10 0.11 0.13 0.14 0.11 0.09 0.10 0.18
2.03 0.12 0.13 0.14 0.16 0.13 0.10 0.11 0.20
2.29 0.13 0.14 0.16 0.18 0.14 0.11 0.12 0.23
2.54 0.15 0.16 0.18 0.20 0.16 0.13 0.13 0.25
2.79 0.15 0.18 0.20 0.22 0.18 0.14 0.14 0.28
3.05 0.18 0.19 0.22 0.24 0.19 0.15 0.16 0.30
3.30 0.19 0.21 0.24 0.26 0.21 0.17 0.17 0.41
3.56 0.21 0.22 0.25 0.28 0.22 0.18 0.18 0.44
3.81 0.22 0.24 0.27 0.30 0.24 0.19 0.19 0.47
4.06 0.24 0.25 0.29 0.33 0.25 0.20 0.19 0.51
4.32 0.25 0.25 0.29 0.33 0.25 0.20 0.20 0.54
4.57 0.27 0.27 0.31 0.35 0.27 0.22 0.22 0.57
4.83 0.28 0.28 0.33 0.37 0.28 0.23 0.23 0.60
5.08 0.30 0.30 0.34 0.39 0.30 0.24 0.24 0.64
5.33 0.31 0.32 0.36 0.41 0.32 0.25 0.25 0.67
5.59 0.33 0.33 0.38 0.43 0.33 0.27 0.26 0.70
5.84 0.34 0.35 0.40 0.45 0.35 0.28 0.28 0.73
6.10 0.36 0.38 0.43 0.49 0.38 0.30 0.30 0.76
6.35 0.37 0.40 0.45 0.51 0.40 0.32 0.30 0.79

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2. CUTTING FORCE

Cutting force F is calculated by

F= A

Where = shear stress

A= Cut Area (Cut length x Thickness of the sheet)

2.1 STRIPPING FORCE

10-20% of F
2.2 EJECTION FORCE
10% of F

3.0 RECOMMENDED DIE PLATE THICKNESS

STOCK FOR DIE BLOCK LENGTH

MATERIAL UP TO 125 mm 125 200mm 200- 400
THICKNESS IN
mm
Up to 1 16 20 24
1 to 2 20 24 28
2 to 3 24 28 32
3 to 4 28 32 36
4 to 6 32 36 50
6 & above 36 38 60

4.0 BUCKLING FORCE

4.1 For a pnch fixed at one end

2
F= E I min
4L
4.2 For a puch fixed at one end and guided at the
other end
2
F= 2 E I min
2
L

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5.0 SHANK LOCATION

From the die plate references to the centroid of different split profiles
of the die cutting area length of which is taken as l1,l2,l3.,,,,

X= (l1x1)+l(2x2)+(l3x3).+(ln xn)
l1+l2+l3.,,,,,+ln

Y= (l1y1)+l(2y2)+(l3y3).+(ln yn)
l1+l2+l3.,,,,,+ln

6.0 SHAVING
It is necessary to provide a small amount of stock on the punched work
piece for shaving operation.

The amount is Delta = D-d

D=die dimension
d=punch dimension
d the diameter of the punch can be calculated by the formula

d=D++ i = d + + + i

d= diameter of the punch

D= Diameter of the hole after shaving
= Production Tolerance of the hole
i= amount of compensation for tightening the hole after shaving

Value of depending on type and thickness of the material

Copper Medium carbon High carbon

Material Aluminium & low steel steel
Thickness in mm carbon steel
VALUE OF
0.5 to 1.4 0.1-0.15 0.15-0.20 0.15-0.25
1.5 2.8 0.15 0.20 0.20 0.25 0.20 0.30
3.0 3.8 0.20 0.25 0.25 0.30 0.25 0.35
4.0 5.2 0.25 0.30 0.30 0.35 0.30 0.40

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7.0 MOMENT OF BENDING

MOMENT OF BENDING= M= n (UTS) bT2
4

n= correction coefficient of hardening of the material (n=1.6 to 1.8)

UTS = ultimate tensile strength of the material
b= Length of bending
T= Thickness of the sheet

8.0 FORCES IN BENDING

8.1 FORCE FOR U BENDING

F= 2M (1+ sin )
l
(l=Ri + Rk + T(SEE FIG)
if the bending is in a die with an
ejector then the bending force need to increase by about 30 percent so that
the total bending force for the U die is

F1 = 1.3F

8.2 FORCES FOR A WIPING DIE

Ri= Radius on the wiping punch

F = M (1+ sin ) (l=Ri+Rk+T)
Rk= Radius on the die
l
T=Thickness of the material

8.3 FORCE FOR V BENDING

F = 4M . cos 2
lk - 2 (Rk+Ri+T) sin /2 2

lk= Die Opening, =Bend Angle, M= Moment of bending

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9.0 BEND RADIUS

9.1 MINIMUM BEND RADIUS

R min = c (constant) x T (thickness)

Values of coefficient c
MATERIAL CONDITION
SOFT HARD
LOW CARBON STEEL 0.5 3.0
LOW ALLOY STTEEL 0.5 4.0
ALUMINIUM 0.8 3.0
COPPER 0.25 4..0
BRONZE 0.6 2.5
BRASS 0.4 2.0
TITANIUM 0.7 3.0
TITANIUM ALLOY 2.5 4.0

9.2 MAXIMUM BEND RADIUS

R i(max) < TE
2(YS)

T=Thickness
E= Youngs Modulus of Elasticity For the material
YS = Yield Strength

Value of larger bend radius is normally greater than 5 times the sheet
thickness.
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10.0 RADIUS OF THE NEUTRAL FIBER OF A SHEET

THAT IS BEND

Rn = Ro. Ri
Rn= Radius of neutral fiber
Ro= Outer radius
Ri= Inner radius
11.0 SPRING BACK
Degrees of spring back

Material Degrees of bend

5 10 20 30 40 50 60 70 80 90
Aluminium
2.2 2.7 3.2 3.6 3.8 4.0 4.3 4.5 4.7 4.9
3003-0
CRCA
3.0 3.5 4.0 4.2 4.6 4.7 4.8 5.0 5.1 5.3
(SAE 1008)
BRASS
(DEAD 3.5 4.0 5.0 5.4 6.0 6.3 7.0 7.3 7.8 8.2
SOFT)70/30
304 DEAD
SOFT
4.0 5.0 5.8 6.2 6.8 7.1 7.5 8.0 8.4 8.8
STAINLESS
STEEL

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12.0 BLANK DEVELOPMENT BENDING

Blank length = circumference at neutral axis + straight lengths

Ref fig
L1+ l +L2
Blank length =
l= (R+C). 2
360

Where = Bend angle in degrees

Value of C

For R < 2t, C = 0.33t

R = 2 to 4t, C = 0.4t

R > 4t, C = 0.5t

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13.0 DRAWING CLEARANCE

Drawing clearance c=T+ k ( 10 T )

T=sheet thickness
K= constant

Material Coefficient
k
Steel 0.07
Aluminium 0.02
others 0.04

Punch radious Rp = 3-6 t

Die radious Rd = 0.035[50+(D-d)] t

Or
4 to 8 t

14.0 DRAWING FORCE

F = Dp to (UTS) [ Do - 0.7]
Dp
where
Do = Blank diameter
to = Blank thickness
Dp = Punch diameter
UTS = Ultimate tensile strength of material

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15.0 DIE PUNCH CLEARANCE

For sizing draws. (Per side).
C = t[1+0.035(-1)3 ]
15.1 SUGGESTED DRAW CLEARANCE

Thickness sizing draw 1st draw redraw

<0.5 1.04 1.05 t 1.08 t 1.09 to 1.10 t

0.5-1.25 1.05 1.06t 1.08 1.10t 1.10 1.13t

1.25 3.0 1.06 1.08t 1.10 1.13t 1.13 1.15t

> 3.0 1.08 1.10t 1.13 1.15t 1.15 1.2t

.
16.0 SPEED OF DRAWING
Aluminium = 45-50m/min
Brass = 60-70 m/min
Copper = 45-50 m/min
Steel =15-20 m/min
Stainless Steel =12-15 m/min

17.0 NO. OF DRAWS REQUIRED:

= h/d No. of draws
<0.75 1
0.7-1.5 2
1.5-3.0 3
3.0-4.7 4

Where h = inside height of shell

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D = Mean dia of shell

18.0 SHEAR STRENGTH OF MATERIALS

Material Shearing strength(kg/mm2)

Soft Hard

Low carbon steels 22 60

Med,carbon steel 36 60

High carbon steel 40 70

Silicon steel 27 40

Aluminium 6 15

Aluminium alloy 8 37

Copper 17 24

Brass 15 24

19.0 DISTANCES BETWEEN SCREW AND PLATE

EDGES
Distance between Counter bored counter
centre hole sunk hole
Distance between Counter bored Hole Counter sunk hole
centre of the screw &
1)Shearing edge 1.8 d + 5 1.5 d + 5
2) Hardened plate
1.2 d + 3 d+3
edge
3)Edge of soft plate d+1 d+1

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Scrap bridge

Non-metallic materials

The approximate values of the table C/3 applies to sheets of different materials
mentioned.

Hard paper and such is to be warmed up during the reaping and to cut in tools with
springy low holder.
If these conditions are not given, the approximate values increase by about 50%.

Hard paper and hard fabric on phenol resin base as well as records which contain
Epoxy resins become most in the air circulation stove (Oven) within 5... 10 min on 60...
110 warmed up and in usual guts tools with additional being springy low holder cut.

The spring tension, about 1 / 5... 1/3 of the cut strength, a lateral elusiveness material
prevents during the reaping and raises the exactness of the cut edges.

The stamp play amounts according to flat-thick sp 0.04... 0.008 mm, the mole firmness
according to kind of the layer material with 1.5 mm thick flat 70... 120 N / mm2

Table C/3: Approximate values for least Scrap bridge-width and edge-width (extract for
guideline VDI 3367)

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20.0 Scrap bridge and edge-width

Material Metals fibrous Material Hard paper, Hard tissue

Material Width Strip width B in mm Strip width B in mm
thickens to100 100 to 200 to 200 to 200
S Scrap bridge length le or Edge width la mm Scrap bridge length le or Edge width la mm
e < 10 50 > < 10 50 100 < 50 100 150 < 10 50 100 150
mm a 10 to to 100 10 to to to 50 to to to 10 to to to to
i 50 100 50 100 200 100 150 200 50 100 150 200
mm

e 0.8 1.6 1.8 2.0 0.9 1.8 2.0 2.2

a 1.0 1.9 2.2 2.4 1.2 2.2 2.4 2.7
0.1
i 1.5 1.5

e 0.8 1.2 1.4 1.6 1.0 1.4 1.6 1.8 2.4 2.8 3.2 3.6 1.2 1.5 1.7 2.0 2.3
a 0.9 1.5 1.7 1.9 1.1 1.7 1.9 2.2 3.0 3.4 3.9 4.4 1.6 1.9 2.2 2.5 2.8
0.3 i 3.0 1.5
1.5 1.5
e 0.8 0.9 1.0 1.2 1.0 1.0 1.2 1.4 1.8 2.0 2.4 2.8 1.0 1.3 1.5 1.8 2.1
a 0.9 1.0 1.2 1.5 1.1 1.2 1.5 1.7 2.0 2.4 3.0 3.4 1.5 1.8 2.0 2.3 2.6
0.5 i

1.5 1.5 3.0 1.5

e 0.9 1.0 1.2 1.4 1.0 1.2 1.4 1.6 2.0 2.4 2.8 3.2 1.2 1.5 1.8 2.1 2.4
a 1.6 1.9 2.0 2.5 2.8
0.75
i 1.5 1.5 3.0 1.5

e 1.0 1.1 1.3 1.5 1.1 1.3 1.5 1.7 2.2 2.6 3.0 3.4 1.3 1.7 2.0 2.3 2.6
a 1.7 2.0 2.3 2.6 2.9
1.0
i
1.5 1.8 3.0 1.5
e 1.2 1.4 1.6 1.8 1.3 1.6 1.8 2.0
a
1.25 i 1.8 2.0

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Material Metals fibrous Material Hard paper, Hard tissue
Material Width Strip width B in mm Strip width B in mm
thicknes to 100 100 to 200 To 200 To 200
e Scrap bridge length le or Edge width la mm Scrap bridge length le or Edge width la mm
S a < 10 50 > < 10 50 100 < 50 100 150 < 10 50 100 150
i 10 to to 100 10 to to to 50 to to to 10 to to to to
mm mm 50 100 50 100 200 100 150 200 50 100 150 200

e 1.3 1.4 1.6 1.8 1.4 1.6 1.8 2.0 2.8 3.2 3.6 4.0 1.6 2.0 2.4 2.5 2.8
a 1.8 2.2 2.6 2.8 3.1
1.5
i
2.2 2.5 3.0 1.5
e 1.5 1.6 1.8 2.0 1.6 1.8 2.0 2.2
a
1.75
i 2.5 3.0

e 1.6 1.7 1.9 2.1 1.7 1.9 2.1 2.3 3.4 3.8 4.2 4.6 1.9 2.2 2.6 2.8 3.1
a 2.2 2.6 2.8 3.2 3.4
2.0
i
3.0 3.5 3.0 2.0

e 1.9 2.0 2.2 2.4 2.0 2.2 2.4 2.6 4.0 4.4 4.8 5.2 2.4 2.7 3.0 3.3 3.6
a 2.6 3.0 3.2 3.5 3.8
25
i 3.5 4.0 3.0 2.5

e 2.1 2.3 2.5 2.7 2.3 2.5 2.7 2.9 4.6 5.0 5.4 5.8 3.0 3.3 3.5 3.8 4.1
a 3.1 3.4 3.6 4.0 4.3
3.0
i
4.5 5.0 3.0 3 .0
e 5.8 6.2 6.6 7.0
a
4.0 4.0
i

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V la<10

le<10
e
a

le
e
B

a
i

la
la<10
a

le
B

e la
a

Authoritative one splits: la or le upto 10mm.

lm cut stripes are with easy stripes and with coil strips.
a - Edge width in mm,
la - edge length in mm,
b - Strip width in mm,
e - Scrap bridge-width in mm,
le Scrap bridge length in mm,
v - Pitch in mm,
i- Side cutter scrap in mm.

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Approximate values are to be increased for friable and softy materials and coil
strips - about 50% to increase.
1.0 JIGS AND FIXTURES
FORMULA TO FIND THE COST PER COMPONENT

T2-T1
_________
N =
K1-K2

HERE:

N= Number of components.
T1= Cost of tooling without jig or fixture.
T2= Cost of tooling with jig or fixture.
K1 = Cost of component without jig or fixture.
K2 = Cost of component with jig or fixture.

SUPPOSE ,

The total cost without tooling = X1

The total cost with special tooling = X2

For economy of employing a jig or fixture the

condition must be that X1 must be less than X2.

i.e., n x K2+ T2 must be less than n x K1+T1

when X1=X2

n x K1+T1= n x K2 +T2
n x K1 n x K2 = T2-T1
n(K1-K2) = T2 T1

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i.e., n = (T2 T1) / (K1 K2)

1.0 MOMENT OF INERTIA OF DIFF SECTIONS.

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STEELS FOR TOOLING

GENERAL RECOMMENDATIONS-PRESS TOOLS

Part GRADE HRC
1 Die-block AISI 01, A2, D2, D6, M3:2 54-65
2 Die-insert D2, M3:2 58-65
3 Die Backing Plate AISI 1148 ----------
4 Gauges AISI 01 52-54
5 Punch AISI 01, A2, D2, D6, M3:2 54-65
6 Punch holder plate AISI 1020 ----------
7 Punch backing plate AISI 01 52-54
8 Stripper plate AISI 1148 ----------
9 Stripper insert AISI 01 52-56
10 Top plate AISI 1020 ----------
11 Bottom plate AISI 1020 ----------
12 AISI E 9315 50-55 HRC
Guide Pillar
chrd 0.8 deep
13 AISI E 9315 50-55 HRC
Guide Bush
chrd 0.8 deep

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GENERAL RECOMMENDATIONS- MOULD

Sl.no. Part GRADE HRC

1 Top plate AISI 1020
2 Register ring AISI 1020
3 Sprue bush AISI 420 48-50
4 Cavity plate AISI 1020
5 Cavity insert AISI H 13,P 20 48-50
6 Core plate AISI 1020
7 Core insert H 13,P 20 48-50
8 Stripper plate AISI 1020
9 Core back plate AISI 1020
10 Support block AISI 1020
11 Ejector retainer AISI 1020
12 Ejector plate AISI 1148
13 Rest buttons AISI 01
14 Bottom plate AISI 1020
15 Guide pillar AISI E9315 HRC 50-55 chrd
0.8 deep
16 Guide bush AISI E9315 H HRC 50-55
chrd 0.8 deep
17 Centering bush AISI 440C HRC 50-55 chrd
0.8 deep
18 Ejector Pins H13 HRC 48-50

JIGS AND FIXTURES

Sl.no. Part GRADE HRC

1 JIG BUSH O6 60-63
2 SETTING BLOCK O1 52- 54
3 LOCATING PINS O1 52- 54
4 JIG FEET AISI 1148
5 TENONS AISI 1148

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PROCESSING CHARACTERESTICS / PROPERTIES OF PLASTICS

MATERIAL MOULDING MOULDING LINEAR SPECIFIC

TEMP.OC PRESSURE SHRINKAGE GRAVITY
Kg/cm2 % mm/mm

POLYETHYLENE AND ETHYLENE CO POLYMERS

LDPE 150-300 560-2100 1.5-5.0 0.92-0.925

Medium density 150-300 560-2100 1.5-5.0 0.926-0.940
HDPE 150-300 700-1400 2.0-5.0 0.941-0.965

POLY PROPYLENES

Unmodified 200-225 700-1400 1.0-2.5 0.902-0.910

VINYL POLYMERS
Rigid PVC 150-210 700-2800 0.1-0.5 1.3-1.45
Flexible PVC 160-190 570-1750 0.1-0.5 1.16-1.35

POLY STYRENE
Unfilled free 160-250 700-2100 0.1-0.6 1.04-1.09
flowing general
purpose heat
resistant
Impact resistant 175-300 700-2100 0.2-0.6 1.04-1.10
Special heat & 175-350 700-2100 0.1-0.8 1.04-1.10
chemical
resistant type
20-30% glass 225-310 1050-2800 0.1-0.2 1.20-1.33
filled

ACRYLICS
Moulding 160-260 700-1400 0.1-0.4 1.17-1.20
Impact acrylic 200-260 700-1400 0.2-0.8 1.11-1.18
moulding
component
MMA 175-275 700-2100 0.20-0.6 1.09
Acrylic multi 200-240 700-1400 0.6-1.0 1.09-1.14
polymer

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MATERIAL MOULDING MOULDING LINEAR SPECIFIC

TEMP.OC PRESSURE SHRINKAGE GRAVITY
Kg/cm2 % mm/mm

ABS
High impact 190-275 560-1750 0.5-0.8 1.01-1.04
High heat resistant 260-275 560-1750 0.5-0.8 1.05-1.08
Medium impact 220-260 560-1750 0.5-0.8 1.04-1.03
20-40% glass filled 260-280 1050-2800 0.1-0.2 1.23-1.36

NYLONS
Unmodified 260-310 - 0.8-1.5 1.13-1.15
Nucleated 260-310 - 0.7-1.4 1.13-1.16
30-35% glass 260 - 0.5 1.34-1.42
reinforced

ACETALS
Homopolymer 190-235 700-1400 2.0-2.5 1.42
Copolymer 185-240 700-1400 2.0 1.41
20% glass filled 175-240 700-1400 1.3-2.8 1.56
TFE-fibre 185-225 700-1400 2.0-2.5 1.54
reinforced

FLUROPLASTICS
Polychlorotrifluro 260-300 1400-4200 1.0-1.5 2.1-2.4
ethylene
FEP fluroplastic 310-350 350-1400 3.0-6.0 2.12-2.17
Poly vinylidene 225-275 1050-1400 3.0 1.75-1.78
fluoride

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MATERIAL MOULDING MOULDING LINEAR SPECIFIC

TEMP.OC PRESSURE SHRINKAGE GRAVITY
Kg/cm2 % mm/mm

PHENOL FORMADEHYDE
No filler 135-160 140-280 1.0-1.2 1.25-1.30
Asbestos filled 145-190 140-350 0.2-0.9 1.45-2.00
Mica filled 135-175 140-350 0.2-0.6 1.65-1.92
Glass filled 135-175 70-420 0.2-0.4 1.69-1.95
MELAMINE-FORMALDEHYDE

No filler 150-165 140-350 1.1-1.12 1.48

Cellulose filled 145-180 105-420 0.6-0.8 1.45-1.52
Asbestos filled 140-170 70-490 0.5-0.7 1.7-2.0
Glass fiber 140-170 140-560 0.1-0.4 1.8-2.0
filled
UREA 140-175 140-560 0.6-1.4 1.47-1.52
formaldehyde
EPOXY RESINS

Glass fiber - - 0.1-0.5 1.6-2.0

filled
Mineral filled - - 0.2-0.8 1.6-2.0
Low density 125-150 70-105 0.6-1.0 0.75-1.00

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 EDUTECH NTTF

INFLUENCE OF ALLOYING ELEMENTS ON THE PROPERTIES OF STEEL

Properties of steel Alloying elements

C S P Si Mn Ni Cr Mo W V Ti Co
Strength ++ + + + + + + + + +
Hardness + + + + + ++ + + + +
Tensile - - ++ -- + + -
Elasticity ++ + ++ + + + ++
Impact strength - -- - ++ + ++ ++ --
Corrosion
resistance - -- ++ + + ++ +++ + + + +

Formability -- - -- -- - -- - - --
Machinability - ++ + - - - - - - -
Wear resistance
+ + + + +

Weldability
- - - - +
-
Toughness - + + +

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 EDUTECH NTTF

TYPICAL APPLICATIONS OF COMMON TOOL & DIE MATERIALS

AISI Machinability Hardness (HRC) Characteristics & Applications

rating
Good wear resistance & toughness, good harden ability, used for
A2 70 57 to 62
blanking & forming dies, punches
Excellent size stability in heat treatment, deep hardening, used for
A6 65 57 to 60
blanking and forming dies and punches
Good wear resistance and toughness, superior size stability,
A8 70 56 to 59 suitable for highly abrasive hot work. Used for shear blades, trim
dies& plastic moulds
Medium resistance to wear, solid cold heating dies, die inserts,
A9 65 35 to 56
coining dies, forming dies & punches.
High wear resistance, excellent size stability, deep hardening in
D2 50 57 to 62 air,. Used for blanking dies, drawing dies, shear blades, forming
rolls.
Excellent abrasion resistance, high hardening response,
D3 35 57 to 64 compressive strength. Used for blanking dies, drawing dies,
shearing blades & punches.
Very high wear resistance, size stability, and resistance to
D5 50 59 to 63 tempering. Used for blanking dies, drawing dies, shearing blades
& punches.
Good wear resistance, safe to harden, easy to machine. Used for
O1 90 59 to 61
blanking and forming dies, plastic moulds and shear blades.
Good wear resistance, easy to machine. General purpose tooling
O2 Fairly 57 to 61
with a combination of wear resistance and moderate toughness.
Excellent machinability, outstanding wear resistance, easy
harden.Uses are gauges, punches, cold forming, blanking &
O6 125 45 to 63
trimming dies. Bushings & other machine tool parts. cold forming,
blanking & trimming dies. Bushings & other machine tool parts.

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