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Heat conduction
Heat transfer Convection heat transfer (Heat delivery)
Radiation heat transfer
Above three occur in a complex manner, but one normally dominates others.
1-1-1 Heat conduction
Characteristic of heat conduction is that the conductor does not move. Thus heat transfer in a
solid object is considered to be the result of genuine heat conduction. To a certain extent heat
conduction occurs in gas and liquid but the conductivity there is prohibitively small in
comparison with that of solid body. Transfer of heat is made from high temperature area to low
temperature area and the transfer rate is proportional to the temperature gradient and the cross
section area of heat passage. This is called Fourier’s Heat Conduction Law and the formula is
shown below (Fig. 1-1-1.1).
∆T1
Q = λ• • A1 ................................................................. Formula (1.1.1.1)
S
Where Q: Heat transfer rate: Heat flow (kcal/h)
ΔT1 : Temperature difference between 2 points (℃)
S: Distance between 2 points (m)
A1: Cross-section area perpendicular to heat flow (m2)
λ : Heat conductivity (kcal/m•h•℃)
In the case of heat transfer from resin to mold in the molding process, both heat conduction and
heat convection occur simultaneously during the injection process but heat conduction
dominates during cooling process under holding pressure after the injection process. Heat
transfer from cavity surface to wall surface of cooling water pipe is made under genuine heat
conduction because it is a heat transfer in a solid body.
Incidentally, heat conductivity of S50C steel, which is often used as mold material, is about 46
kcal/m•h•℃, while heat conductivity of HDPE, which has rather high heat conductivity among
resins, is 0.4 kcal/m•h•℃ and that of GPPS, lower heat conductivity among resins, is about 0.1
kcal/m•h•℃. The ratio to S50C is 1:115 and 1:460 respectively (Fig. 1-1-1.2).
Section Area
Section A-A
S = Distance
Heat "Solid"
Flow
Temperature
Gradient
Temperature
Difference
Air
Water
Pure
Copper
Where A2: Heat transfer area between solid and liquid (m2)
ΔT2 : Temperature difference between solid and liquid (℃)
α : Heat transfer coefficient (kcal/m2•h•℃)
Difference between heat delivery and heat conduction is that in the heat delivery heat
transfers along with moving liquid media and heat transfer coefficient α is not a specific
constant for material like λ (formula 1.3.8.1) and varies depending upon flow condition.
It is considered that there exists a stable film of liquid (or gas), named boundary film,
between solid and flow media. This film is not subject to convection heat transfer but
conduction heat transfer only. As heat conductivity of flow medium is small in
comparison to solid, this boundary film can be treated as a kind of insulation layer made
of flow medium (Fig. 1-1-2.1).
Accordingly if a flow makes the film thinner, the heat transfer coefficient α becomes
greater and the heat transfer rate becomes faster. Generally in the case of slow flow
velocity, the flow forms so called laminate flow in which liquid is not mixed. In this case
the boundary film is thicker. On the other hand the film is thinner if the flow is under
turbulent flow with high velocity where liquid is well mixed.
As explained, heat transfer coefficient α is the one having a boundary film in between
and influenced substantially by the film thickness. Thus it may be called as boundary
film heat transfer coefficient. It is important how to determine α in the convection heat
transfer. One way is to determine α on the basis of Nusselt Number (Nu) which
represents magnitude of heat transfer between solid and flow medium.
Convection heat transfer can be classified by two. One is natural convection heat transfer and
another is enforced convection heat transfer. Heat discharge from mold to atmosphere is mainly
influenced by natural convection heat transfer together with radiation heat transfer to be
explained later. While, heat transfer from mold (internal wall of cooling water tube) to cooling
medium (water or oil) is mainly affected by enforced convection heat transfer.
Solid Liquid
Temperature
Difference
Boundary Film
Thermal energy from the sun is brought to the earth through a space without any transfer
media. This is because heat transfers as electro magnetic wave as same as light and
electric wave. This sort of heat transfer is called radiation heat transfer or simply
radiation.
Any material radiates heat unless its temperature is 0°K (-273℃) in absolute
temperature. The radiation is mutually absorbed, reflected or passed trough. The heat
transfer rate in radiation is proportional to difference of the 4th power of absolute
temperature (Kelvin’s temperature). It is shown below (Fig. 1-1-3.1).
Proportion constant k includes various elements. This k is not given based on physical
property like heat conductivity (λ) but calculation like heat transfer coefficient (α). In
the case of radiation from a mold, a formula is given below considering object a (mold)
is surrounded by object b (air) and radiation area ratio (AA/AB) is negligibly small.
Mold Design (Advance) Page 5
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⎧⎪⎛ T 4 ⎞ ⎛ T 4 ⎞⎪⎫
Q = ⎨⎜⎜ A ⎟⎟ − ⎜⎜ B ⎟⎟⎬ (kcal/h) ........................................... Formula (1.1.3.2)
⎪⎩⎝ 100 ⎠ ⎝ 100 ⎠⎪⎭
In the formula (1.1.3.2), let us see the influence to heat flow due to radiation of mold
temperature by varying the temperature TA like 40℃, 80℃, and 120℃. Room
temperature TB is assumed to be 25℃. Result shows when TA changes to 2 times and 3
times, resultant Q changes 4.5 times and 9.3 times. This tells you that radiation transfer
cannot be ignored if temperature difference between room temperature and heated object
temperature is big when the object is exposed to atmosphere.
Absorption
Reflection
Let’s take up received heat from resin (QA). When W (kg/h) is resin weight injected per
hour, received heat (QA) can be calculated by applying following formula.
In the formula (1.2.2), temperature at mold separation (TR) can be replaced by thermal
deformation temperature to assure the temperature in the center of the thickest portion of the
product to be lower than the heat distortion temperature. In this case, try to set the
temperature 10~30℃lower than the heat distortion temperature to entertain safety
consideration. A part of the formula {CP(TP-TR) +L•C} can be roughly estimated by resin
material, when the value is represented by total heat amount (Q), formula (1.2.2) can be
shown as below.
Table 1-2.1 shows estimated values of Q by resin material in the safe direction (estimating q
in the bigger side).
QD is calculated as heat passing through composite wall surfaces, but estimation of heat
resistance between mold clamping plate and platen of injection machine is very difficult. QE
is considered as a mixture of convection and radiation heat transfer. It is influenced by
molding conditions such as mold temperature, airflow, mold open time, etc.
Mold Design (Advance) Page 7
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Mold
If receiving heat is more than releasing heat and thermal balanced point is higher than
required temperature range, cooling device is needed. On the other hand, if receiving heat is
less than releasing heat and balanced temperature point is lower than required temperature
range, heating device should be arranged (Fig. 1-3.1).
Here in this section, condition QO< QI, in other words, condition required to cool off a mold,
will be taken and heat to be removed from a mold will be discussed. Removed heat QR can
be expressed in a molding cycle where receiving and releasing heat are to be balanced.
If you understand basics behind the formula (1.3.3), you may simplify the calculation as
follows. In the cold runner mold, QB can be traded off by (QD + QE) because (QD + QE) is
usually bigger than QB. By trading them off, cooling calculation will come to safe side
(increased requirement for cooling). In this way, you may treat heat to be removed (QR) is
equivalent to received heat (QA) from resin.
In the heat transfer calculation, you may apply formula (1.3.4) for approximate result
because q in formula (1.2.3) and table (1-2.1) are given in the safe side. However if you
intend to apply formula (1.2.2), it is advised to incorporate 1.5 times safety factor taking
account of possible requirement of cycle shortening and expected deterioration in the heat
exchanger performance.
QR = 1.5 QA
= 1.5 W • {CP (TP – TR) + L • C} (kcal/h) ........................... Formula (1.3.5)
Assuming QR can be applicable to all kinds of cooling medium, following formula can be
derived.
TL in formula (1.3.6) is average temperature of the cooling medium other than that in the
boundary film. In the case of water as cooling medium, (TW–TL) can be regarded as about
2~3℃. WL and VL, required volume of cooling agent can be expressed as follows:
Flow velocity V can be derived from formulae (1.3.4) or (1.3.5), (1.3.6), (1.3.7) and (1.3.8),
as follows:
4W • Q
V= (m / h ) .................................... Formula (1.3.9)
π • D 2 • ρ L • C PL (TW − TL )
4 × 1.5W • {C P (TP − TR ) + L • C}
V= (m / h ) ........................... Formula (1.3.10)
π • D 2 • ρ L • C PL (TW − TL )
Internal diameter of cooling tube (D) in above formulae should be picked up from Table 1-
3.1 temporally, and confirm them if it falls in the range of 10,000~30,000 of Reynolds
number (RE) and then finalize the diameter. Be aware that unit of d is in m.
Next, Nusselt number (NU), important parameter in the convection heat transfer calculation,
will be calculated. Prantle number (PR) in Nusslet number is defined as follows.
Nusselt number is given as follows. Be aware NU formula varies slightly depending upon
where to get the formula from.
Formula (1.3.13) is effective only for turbulent flow. In the case of laminated flow or
transition flow, in which Raynold’s number is less than 10,000, re-evaluation of mold
temperature and cooling tube diameter must be carried out.
Once Nusselt number (NU) is decided, heat transfer co-efficient α can be calculated by
formula (1.1.2.1). And cooling tube surface area (AL) can be calculated by a converted
formula from (1.2.2).
As cooling tube diameter (D) is known, cooling tube length can be calculated as follows:
As described, total cooling circuit length of cavity and core can be calculated.
So far, all formulae assumed that heat from injected resin W (kg/h) is transferred perfectly to
a mold. Here we should evaluate if such assumption is reasonable or not. Bahlman’s formula
should be effective for the evaluation. It is to evaluate if W (kg/h) is possible by estimating
molding cycle from theoretical cooling time calculation.
H2 ⎡ 4 TP − TW ⎤
TC = • LN ⎢ • ⎥ .............................................. Formula (1.3.16)
π 2 •A ⎣ π TR − TW ⎦
This formula can be used as a guideline because all kinds of condition have to be assumed
for calculation. Molding cycle should be evaluated by estimating injection time, mold
opening time duration, mold take-out time duration.
If you design temperature control system by applying above explained basics on the heat
transfer thermal dynamics, you should be able to provide temperature control system with
improved heat exchanging efficiency comparing with traditional system, which was made
based on past examples.
In the end of basics on thermal transfer theory, a calculation example is shown below for
your better understanding. Try to solve the example before you read the answer to follow.
Mind units are to be carefully treated.
【A calculation example】
Calculate total circuit length of a cooling water system required for a mold for following
conditions.
Resin: ABS
Number of product per mold: 2
Product dimension: 100mm×100mm×2mm
Molding cycle target: 20 seconds
(Calculation)
① To estimate molding conditions along with physical properties of ABS resin.
• Density: ρ = 1030kg/m3
• Specific heat: CP = 0.35 kcal/kg•℃
• Heat conductivity: λ = 0.2 kcal/m•h•℃
• Resin temperature: TP = 220℃
• Mold separation temperature: TR = 70℃
• Internal wall temperature (water tube): TW = 52℃
• Water temperature: TL = 50℃
② To decide mold specification required for heat transfer calculation.
1) Physical property of water
• Density: PL = 988 kg/m3
• Specific heat: CPL = 1.0 kcal/kg•℃
• Viscosity: µ = 5.58×10-4 PA•S = 2.009 kg/m•h
• Heat conductivity: λF = 0.552 kcal/m•h•℃
2) To calculate weight of Sprue runner
• Dimension: (φ5×130) mm = (φ0.005×0.13)m
• Volume: (0.0052×π/4) ×0.13 = 2.55×10-6 m3
• Weight: (2.55×10-6) ×1030 = 2.63×10-3 kg
3) To calculate weight of product
• Volume: (0.1×0.1×0.002) ×2 = 4.0×10-5 m3
• Weight: (4.0×10-5) ×1030 = 0.0412 kg
Injection machine (100~150 ton capacity) to be used for this size of product usually
required additional 10 seconds maximum for other functions than cooling time. Thus
target cycle time of 20 seconds is reasonable. It could be less than 15 seconds.
Balanced Mold
Temperature without
temperature control
Heating
device.
Mold Temperature
Cooling
Nominal Mold
Temperature Balanced Mold Temperature
with temperature control
device
Mold Size
(Binding Fore) Channel Diameter
Reduced pressure suction type of temperature control device will not be treated in this
section because of its specialty in the circuit design. Hereafter, we will discuss about design
concept for standard temperature control device utilizing water, an excellent coolant for heat
exchanging.
Fig. 1-4.1 shows equivalent diameter for various cross sections such as half a round or
square shape.
Channel
Section
(b = 0.5a)
Equivalent
Diameter
η Is a value due to heat transfer loss due to radiation loss or loss due to heater mounting,
etc, and normally it is set as 0.5. If you utilize a heater with higher capacity and with
adjustable power arrangement, you may ensure stable mold temperature by adjusting
heating and radiation conditions in addition to shortened preparation time.
Heater
Heater
Mounting Bolt
Projection area is the area of a product projected in the mold clamping direction (usually
perpendicular to PL). Total area is shown below (Fig. 1-6.1)
In the case of 3-plate mold, notice that projection of cavity and runner overlaps. If separately
calculated, overlapped area will be calculated twice. Assuming mold is of transparent,
project parallel light from nozzle side, and then figure projected area on the movable platen
surface (Fig. 1-6.2).
Projection
Projection
Total Projected
Area (Aa)
Formula (1.6.1) shows that mold-opening force is proportional to projected area if average
clamping force is constant. Let us look into molding pressure.
Injected mold by injection machine fills a mold space against pressure loss caused by
nozzle, sprue, runner, gate and cavity.
Thus there exists a big pressure difference between sprue area and a part of cavity where
resin is filled in the end. Even after resin filling, molding pressure varies from place to place
(Fig. 1-6.3). However, mind that you need to know average pressure, not all in different
parts.
Although average clamping force varies depending upon product shape, molding condition,
mold structure, etc., Table 1-6.1 can be practically used for your guideline. If your
calculation reveals clamping force exceeds average mold opening force, the machine should
be well justified. In practice, the clamping force should be evaluated as 80% of maximum
clamping force against mold opening force compensating estimated average of the opening
force. Required clamping force (FC) then is shown as follows.
If your selected injection machine has a clamping force more than above described force,
you will be able to mold products without burrs on PL surface. But be minded that too big a
clamping force may cause you a trouble such as partial concentration of the force in the
center or ineffective clamping force due to excessive size of locating hole, etc. (Fig. 1-6.4).
Rule of thumb is not to go beyond 20% of above formula.
Binding Force
Table 1-6.1 Various Resin Materials and Average Resin Pressure in Cavity
Average Resin Pressure in Cavity
Resin Material (Kgf/cm2)
【Calculation example 1】
Calculate required clamping force for a product shown in Fig. 1-6.5. Material is ABS and
numbers of cavity are two.
[Calculation]
① Estimate runner layout (Fig. 1-6.6).
Thus, applicable injection machine should be of the clamping force more than 30ton and less
than 110 ton (or 100 ton may be).
(All Circumference)
Fig. 1-6.5
Sprue
Fig. 1-6.6
As screw size is given bigger, maximum injection capacity becomes bigger. But injection
pressure goes opposite direction. In other words, as screw size is given bigger, maximum
injection pressure becomes smaller (Fig. 1-7.1) as long as diameter of hydraulic cylinder is
the same.
Thus under the same clamping force, injection machine with small screw is suited for
precision thin wall products and injection machine with large screw is suited for large
products with thick walls.
Injection capacity is a product of internal cross section area of injection cylinder (screw
cross section area) and injection stroke.
Practically molding is operated by injecting plastic with viscosity and elasticity under high
temperature and pressure. Therefore maximum injection capacity for injecting PS-GP
(General purpose polystyrene) is usually given together with theoretical value.
Actually, internal pressure of injection cylinder is high, but density of the plastic there is
smaller than that under normal temperature and pressure condition because plastic in the
cylinder is expanded due to high temperature (Fig. 1-7.2).
Calculation of required injection capacity has two folds. The first step is to calculate
expanded capacity of plastic per one shot for product, sprue and runner under high pressure
Mold Design (Advance) Page 27
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and temperature condition, then the second step to compare it with maximum injection
capacity assigned for an injection machine. Specifically, total injection capacity can be given
as follows:
To figure volume expansion accurately, we need PVT data per plastic material, but in our
purpose it is not necessary to go to those details. Although there is some variations in
pressure and temperature conditions, we may approximately estimate 90% of density (1.11
times volume expansion) for amorphous resin, of which specific volume is not much
influenced by temperature, and 80% of density (1.25 times volume expansion) for crystalline
resin, of which specific volume is much affected by temperature. Furthermore taking
account of injection efficiency due to back flow and cushion amount, additional safety factor
80% shall be introduced. To make a formula applicable to all resin, regardless of crystalline
and amorphous, density in the injection cylinder is now assumed to be 85% of the value
under normal pressure and temperature condition. Then required injection capacity (VS) will
be as follows:
Injection machine with larger injection capacity than above can be utilized, but it should not
be too large. Expected problem is that resin starts decomposition in the cylinder if it stays
too long in the cylinder. As a minor problem, measuring accuracy drops due to small
measuring stroke. Thus similarly to the case of clamping force, calculated injection capacity
(VS) should not be less than 20% of theoretical maximum injection capacity of the injection
machine. Accordingly formulae (1.7.4) and (1.7.5) can be expressed as follows.
【Calculation example】
[Calculation]
① Calculate volume of sprue and runner.
Sprue: (π×0.52) /4×7 = 1.4
(Taper portion is assumed to be cylindrical.)
Runner: (π×0.52) /4×5 = 1.0
Thus VR = 1.4 + 1.0 = 2.4 cm3
Thus you can apply an injection machine of which theoretical maximum injection capacity
is more than 54 cm3 and less than 212 cm3.
Principle
Pi•D2 = Po•Do2
Fig. 1-7.1 Internal Injection Cylinder (Screw Diameter) vs. Injection Capacity / Injection
Pressure
Specific Volume
Mold strength should be evaluated to see if the deformation of the mold due to molding pressure
(injection pressure or holding pressure) stays within allowable tolerance limit. Two considerations must
be highlighted. One is how to estimate molding pressure. Another is how to decide allowable tolerance
limit.
Molding pressure comes from resin. With some exceptions, you need not take up a pressure during
injection but a pressure after injection. This is nothing more than the molding pressure inside cavity
pressure that was explained and calculated in the previous section for calculating required clamping
force. But in this section we choose 500 kgfcm2 with some margin.
Tolerable deformation varies depending upon product accuracy, mold structure, locations, etc. One
practical reference is if the deformed amount results in generation of burr or not. Clearance to generate
burr can be considered as the depth of air ventilation. If burr cannot be a reference, the allowable
tolerance should be looked into from the aspect of allowable repeated stress on the mold or product
accuracy.
Generally allowable deformation amount is 0.1~0.2mm unless the mold is extremely small in size.
1) Side walls of rectangular cavity
There are two types. One is of split type consisting of sidewalls and bottom plate. Another is made
from one block, in other words one-piece cavity.
Split type can be machined easily with high accuracy but weaker in strength. Let us see the
difference in strength between split type and one-piece rectangular cavity.
1-8-1) Split type
In the split type, calculation disregards restraint of bottom plate. Actually sidewalls are bolted
together with bottom plate or mounting plate. Thus calculation results in the value with safety factor
by disregarding binding and friction influence from bolts (Fig. 1-8-1.1).
We apply a model of a beam both side fixed and with equal weight distribution to cavity walls for
strength analysis (Fig. 1-8-1.2). Be minded molding pressure uses cm unit, while strength calculation
uses mm unit. The maximum deformation (δMAX) on the both side fixed beam appears in the middle
as follows:
PAL4
δ MAX = ( mm) ........................................................................ Formula (1.8.1.1)
384EI
Where P: Molding pressure (kgf/mm2)
A: Product height (mm)
L: Product length (mm)
E: Vertical elasticity coefficient (kgf/mm2)
I: Cross section moment of inertia
Cross section of the beam is of rectangular, thus moment of inertia is as follows:
BH3
I= ( mm) .................................................................................. Formula (1.8.1.2)
12
Where B: Cavity thickness (mm)
H: Cavity wall thickness (mm)
Wall thickness (H) is derived from formulae (1.8.1.1) and (1.8.1.2) as follows:
12PAL4
H= 3 ( mm) .................................................................. Formula (1.8.1.3)
384Ebδ MAX
Fig. 1-8-1.2 Model of a Beam, Both Side Fixed, for Cavity Wall
【Calculation example】
Calculate wall thickness (H) of split type cavity shown in Fig. 1-8-1.3. Resin material is
ABS and vertical elasticity coefficient of the mold is assumed to be E = 2.1×104 kgf/mm2.
[Calculation]
Molding pressure (P), allowable deformation (δMAX) is assumed as follows. Then formula
(1.8.3) is applied to calculate wall thickness (H).
12 × 5 × 20 × 100 4
H=3 = 24.6 (mm)
384 × 2.1 × 10 4 × 40 × 0.025
Thus, you may decide the wall thickness 25mm if there is no space available, but if possible,
decide 30mm for safety consideration.
Fig. 1-8-1.3
CPA 4
δ MAX = (mm) ................................................................. Formula (1.8.2.1)
EH 3
CPA 4
H=3 (mm) .................................................................. Formula (1.8.2.2)
Eδ MAX
【Calculation example】
Assuming last example is of one-piece type; calculate wall thickness (H). Other conditions
are the same.
[Calculation]
① Calculate volume of sprue and runner.
Sprue: (π×0.52)/4×7 = 1.4
(Taper portion is assumed to be cylindrical.)
Runner: (π×0.52) /4×5 = 1.0
Thus VR = 1.4 + 1.0 = 2.4 cm3
0.142 × 5 × 200000
Thus, H = 3 = 6 (mm)
2.1 × 10 4 × 0.025
Mold Design (Advance) Page 34
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Wall thickness has come up with 6mm, but it is advised to select 10mm for safety
consideration.
Table 1-8.2.1 Various Resin Materials and Average Resin Pressure in Cavity
【Calculation example】
Evaluate if the deformation of cylinder type cavity in Fig. 1-8-3.2 can be within tolerance
limit or not. Resin material is ABS.
[Calculation]
Calculate δ of formula (1.8.3.2) and compare it with the clearance 0.03mm to cause burr for
ABS resin.
Calculation result reveals that the deformation is less than minimum clearance (0.03mm) to
cause burr of ABS resin. Thus the wall thickness is appropriate.
In the case of cylinder type cavity, inserts are used in the plate. As the clearance between
inserts and holes on the plate is around 0.01~0.02mm, the plate can share some stress when
deformation exceeds the clearance above.
Fig. 1-8-3.2
Calculation for mold weight and center of gravity is required to determine size and position
of hook bolts for hoisting a mold. Normally the shape of a mold is of rectangular sections.
Thus the volume can be easily figured, so as weight by multiplying specific weight of mold
material. In case of steel, apply 7.87.
Regarding center of gravity, it can be determined by estimating the position in the direction
of mold thickness. Mold is normally symmetrical with a centerline in the injecting direction.
The center of gravity should locate on the centerline.
Calculation proceeds firstly to calculate weight on the center of gravity of each plate and
secondly to find a point where each moment can be balanced.
Referring to Fig. 1-8-4.1, calculate each moment as a product of weight on the center of
gravity of each plate and distance based on fixed side clamping plate. The total moment
should balance with a moment as a product of total mold weight and distance from the
reference point to the center of gravity.
x=
∑W L N N
........................................................................... Formula (1.8.4.2)
w
Fixed Side
Mounting Face
【Calculation example】
Calculate center of gravity of the mold shown in Fig. 1-8-4.2. Mold material is S50C.
[Calculation]
① Specific weight 7.87 is applied for S50C.
④ Calculate distance from fixed side mounting face to the center of plate. (Fig. 1-8-4.3)
221+1475+2242+3186+2394+2926+4204
x= 138.8 ≒ 120 (mm)
Fig. 1-8-4.2
Fixed Side
Mounting Face
Fig. 1-8-4.3
In the case of calculation example 1.3.9.6, center of gravity locates at 120 mm from fixed
side mounting face. If you place a hook bolt at this location, you can hoist the mold without
tilting the mold. But notice this location is near parting surface of movable mold plate and
support plate. Thus a screw cannot be tapped there. Two solutions can be proposed here. One
is to use a lifting bar and another is to move the screw position a bit toward fixed side
clamping plate (Fig. 1-8-4.4). The moved amount should be selected for the mold not to tilt
more than 10°. If it is moved in the opposite direction, workability to position a locating
ring to the nozzle hole of injection machine will be affected (Fig. 1-8-4.5). In our case here,
if the screw position is moved toward fixed side mounting face, it comes to much closer to
the parting surface. Thus it is recommended to apply a lifting bar.
Receiving Movable
Plate Side Mold
Plate
a. By Lifting Bar
Calculated
Gravity Center
Receiving Movable
Plate Side Mold
Plate
b. By shifting screw position
Platen of Platen of
Injection Injection
Machine Machine
Gravity
Center
If the spring force is too weak, the ejector plate cannot fully return to its original position. If
it is too strong, operational balance will be affected and galling may be caused on the return
pin.
Thus we may define the return force of ejector plate should stand weight of ejector plates
(upper and lower) and their friction force.
Friction force is related to friction coefficient of ejector plates (upper and lower). As we
know the maximum friction coefficient is 1, it must be enough to estimate the friction force
2 times of the plate weight. Generally, number of springs to be installed on the periphery of
return pin is 4. Thus you should calculate the shared friction load per spring is 1/2 of ejector
plate weight (2×1/4).
The spring is better to have a smaller spring constant value to assure smoother load transfer
to the spring while stroking (Fig. 1-8-5.1). In addition initial deflection of the spring is better
not to exceed thread length of stripper bolt (normally 10~15), otherwise you will have a
difficulty in installing stripper bolt to female thread hole because of the long spring (Fig. 1-
8-5.2). Following checkpoints may be useful for selecting correct spring from available ones
in the market.
① Internal diameter of the spring should be at least 1 mm larger than return pin outside
diameter.
② Maximum deflection in usage should be within allowable limit.
③ The spring should have enough returning force at the initial deflection.
④ When spot facing is made for the spring, clearance around return pin can be secured
(two times pin diameter) and there should be no interference with coolant channel.
Deflection
【Calculation example】
Conditions of an ejector plate are as below. Select appropriate length of springs shown in
Fig. 1-8-5.3.
[Calculation]
① Calculate weight of ejector plates.
25×11×(1.3×1.5)×7.87×10-3≒6.1kg
17+8 = 25mm
⑤ Select springs in the list to meet required spring constant and deflection.
From Fig. 1-8-5.3, springs having length (L) more than 45mm and less than 100mm are
appropriate.
In practice, select one of appropriate springs evaluating influence of spot facing and
interference with coolant channel.
\ Price
N
(kgf) Load 1~19
Bending Moment
MMAX = W l
Deflection
Wl3
δMAX =
3EI
π d2
I =Cross Sectional Secondary Moment =
64
E= Young’s modulus
∂
(Vertical elastic modulus) = Ε = = 2.1 x 104 kgf/mm2
∈
∈= Deflection
∂ = Rectangular stress
Wl3
δ MAX =
3EI
Wl3
δ =
π d4
MAX
3E
4
Wl3 . 64
d= 4
3E . π . δ MAX
Example:-
Support pin length = 250
No. of Support pins = 4
Weight of Cavity Plate = 400 kg
E= Young’s modulus = 2.1 x 103
Allowable Deflection = δMAX = 0.01
length of SP 400 mm
Weight of Cavity Plate 220 kg
Young's Modulus 21000 kgf/mm2
Allowable Deflection 0.01 mm
Diameter of SP 102.6792791 mm
Diameter of single SP 25.66981977 mm
`
Mold Design (Advance) Page 51
PITAC
Chapter - 2
Mold
Material &
Heat treatment
2- Mold Material
Limiting our scope to a mold for plastic injection molding, steel is the most popular material.
Particularly JIS S50C and S55C are mostly applied because these are standard materials of the mold
bases in the market.
It is important to select right material to satisfy purpose of the mold and its application on the part
of end users. If necessary, heat-treating or surface finish must be carried out to satisfy requirements.
Here we will take up materials to be used for main parts of the mold, cavity and core.
2-1-1 Basics
Normally users’ specification specifies if the material is of heat-treated (quenched) or not
heat-treated (raw) for cavity and core material. Note that pre-hardened steel, which is heat-
treated when supplied but will not be heat treated after machining, is classified as raw steel.
As-rolled steel → Raw type
Not heat-treated
Materials for Pre-hardened steel → Raw type
Cavity and Core
Heat treated → Heat treatment → Quenched type
Table 2.1.1.1 shows various steel for plastic mold with bland names. Molds made of as-
rolled steel and pre-hardened steel belong to raw type. Pre-hardened steel is heat-treated
having 30~40 HRC hardness and yet having a good machineability. Molds made of pre-
hardened steel are used without heat treatment. Thus the mold processing is the same as that
of as-rolled steel. Cost of a mold is also similar in both cases.
On the other hand, there are two types in quenched type. One is to harden and temper the
mold after machining and to finish the mold just by simple polishing. Another is to finish a
heat-treated mold with a certain deformation clearance by a grinder or EDM (Electric
discharge machine). The former is used for a mold, which does not require high precision
but only erosion resistance. Thus the cost is on the same level as raw type. But the latter
involves time consuming finishing on the hardened steel surface. Thus the cost is much
higher than raw type. Qualified material for mold should satisfy following points.
① Good machineability.
② High abrasion resistance.
③ High corrosion resistance.
④ High toughness.
⑤ High strength.
⑥ Homogeneous property without segregation and pin holes.
⑦ Good heat-treating with less deformation.
⑧ Good heat conductivity.
⑨ Reasonable price.
⑩ Easy procurement.
No single material satisfies all items above. Particularly the extent of abrasion resistance to
determine mold life is deeply related to machineability that affects cost of a mold (Fig. 2-1-
1.1).
Major factors for determining mold material in the user’s specification are number of
injection shot, application and molding material.
Ideal
SKD 11 Mold
Material
13Cr Class QT
SKD 61 I
I
Free-Cutting
Wear Resistance
I I
SCM Class I
SC Class
Machineability
2-1-2-4 SKD-61
SKD-61 steel is normally used for die-cast mold as tool steel for hot processing. But it also
is applicable for plastic mold for relatively large production volume.
Table 2.1.1.1 shows this material under pre-hardened steel with 40 HRC hardness. But
normally raw steel is machined and quenched to 50 HRC hardness after machining. A life of
quenched mold can stand for at least one million shots for usual resins. If conditions are met,
2~3 times longer life can be expected.
SKD-61 can be nitride to the extent of 0.05mm in depth with 900HV hardness or more. It
means that nitride layer still exists after finishing as much as 0.01~0.02mm. Therefore
nitride SKD-61 is quite effective for a mold that is subject to galling or seizing.
2-1-2-5 SKD-11
SKD-11 steel is normally used for press mold as tool steel for cold processing. But it is also
applicable for mold for plastic with reinforced fiberglass or for mass production.
SKD-11 has high resistance to abrasion. When it is quenched at 58~60 HRC hardness, SKD-
11 can stand for around 5 million shots without special coating on the surface. Weakness
may be poor machineability and toughness. Steel suppliers are developing improved SKD-
11 to cover such weakness.
As Table 2.1.1.1 shows, grains are laid out in dense and homogeneity. Thus powder forging
is made available. SKD-11 is applicable for molds that requires mirror polishing and
abrasion resistance.
Mold Design (Advance) Page 55
PITAC
So far we have discussed about typical mold materials in relation with number of shots
required for a mold. It is advised to analyze available materials, applications, number of
shots, etc. for mold design. a sample of which is shown in Table 2.1.2.6.1
Mold Material Powder Metal SKD-11 (I) SKD-61 (I) P/H Steel (M, T) S50C, S55C AL alloy (HB 150)
Heat Treatment Q/T (62-64 HRC) Q/T (HRC 58-60) Q/T (HRC 48-50) No (HRC 40) No No
Surface Treatment No/PVD No No No No No
Resin for
General
Mold Material SKD-11 (I) SKD-61 (I) P/H Steel (M, T) SCM (I)
Application
Heat Treatment Q/T (HRC 58-60) Q/T (HRC 48-50) No (HRC 40) No (HRC 33)
Surface Treatment No/PVD No/Nitrided No/Nitrided No
Mold Material Powder Metal SKD-11 (I) SKD-61 (I) P/H Steel (M, T) S50C, S55C
Engineering Heat Treatment Q/T (HRC 62-64) Q/T (HRC 58-60) Q/T (HRC 48-50) Q/T No (HRC 40) No
Plastic (Not Surface Treatment No/PVD No/PVD No No No
Reinforced)
Mold Material Powder Metal Powder Metal SKD-11 (I) SKD-61 (I)
Heat Treatment Q/T (HRC 64-66) Q/T (HRC 62-64) Q/T (HRC 58-60) Q/T (HRC 48-50)
Surface Treatment PVD No/PVD No/Nitride No
Engineering
Mold Material Cemented Carbide SKD-11 (I) SKD-61 (I) P/H Steel (M, T)
Plastics
Steel Insert
(Reinforced)
Heat Treatment No (HRA85-90) Q/T (HRC 58-60) Q/T (HRC 48-50) Q/T No (HRC 40)
Surface Treatment No/PVD No/PVD No/Nitride No
Mold Material Powder SUS Class 13 CrSUS Class 13 CrSUS Class 13 CrSUS Class 13 CrSUS Class
Heat Treatment Q/T (HRC 56-58) Q/T (HRC 50-52) Q/T (HRC 50-52) Q/T (HRC 33) Q/T (HRC 33)
Fire Retarded
Surface Treatment No/PVD No/PVD No No No
Grade
Mold Material Cemented Carbide Powder SUS Class 13 CrSUS Class 13 CrSUS Class P/H Steel (T) S50C, S55C
Steel Insert
Transparent Heat Treatment No (HRA85-90) Q/T (HRC 56-58) Q/T (HRC 50-52) Q/T (HRC 50-52) Q/T (HRC 40) No
Product, Optical Surface Treatment No/PVD No/PVD No/PVD No No No
Product
Mold materials for anti-abrasion were discussed in the previous section. Be minded that hard
steel material may cause chipping due to inferior toughness. It may be necessary to lower the
hardness and compensate it by surface treatment such as PVD.
Thus 13Cr SUS can be used for a mold to be mirror polished or to be used for fire retard
resin or fluororesin.
PMMA, PC, etc. are molded. Particularly for photoproducts such as optical discs or lenses,
high grade of transparency is required.
Although JIS provides no specific standard for mold steel for plastic injection molding,
special steel suppliers made such standard available for our application. Referring to such
references select appropriate steel material to be mirror polished for transparent resin
molding. Improved materials are often processed by special smelting processing such as
vacuum process which brings about homogeneous and dense grain structure with minimum
segregation and pin holes so as to assure a mold to satisfy with precise transcription
capability. 13Cr stainless steel for such purpose is normally made by vacuum process to suit
precision mirror polishing.
Benefits gained from this material must be low cost, short delivery and improved cycle time
due to high thermal conductivity.
Advantage of copper alloy is its high thermal conductivity, while disadvantage must be its
high cost. Therefore copper alloy is used for inserts to remove heat from hot spots.
Mold Design (Advance) Page 59
PITAC
Application to a whole cavity is limited to pressure casting and precision casting, which will
be explained afterward (Fig. 2-1-4-2.1).
In processing BeCu by EDM, be equipped with partial ventilation facility due to generation
of toxic gas. As polar consumption is high, processing BeCu by EDM is better be avoided.
BeCu has limitation for corrosion resistance, but it can be improved by electro less nickel-
plating on the surface as much as 0.01mm. In this way it will be also improved in abrasion
resistance.
Strength of carbide alloy mold is its high abrasion resistance, while weakness is its high
cost. Thus this material should be used just as inserts to the more extent than BeCu. In order
to cover its small transverse strength, which is a half of steel, it is recommended to apply
shrink fitting wherever applicable. Also be aware that its thermal expansion coefficient is
different from that of steel.
Therefore pay attention to fitting accuracy when it is used as an insert for high temperature
application.
Main Core
BeCu Insert
Main Core (for 4 corners)
Physical properties of steel such as tensile strength, hardness, elongation, etc. vary in
accordance with amount of carbon contents. To a greater extent, heat treatment will influence to
physical properties. We can say that good steel characteristics can be realized depending upon
how the steel is heat-treated. In these days, not only heat treatment but also surface hardening
process such as PVD is applied on mold to satisfy expected longer life of molds or requirements
from engineering plastic molding.
Length
Temperature (℃)
α Iron
δ Iron γ Iron
(Body-Centered Lattice) (Face-Centered Lattice)
Fig. 2-2-1-1-1.1 Iron Transformation and Atomic Structure
δ Iron+Molten Iron
Molten Iron
Austenite +
Molten Iron
Temperature (℃)
Austenite
① Heating
Heating rate: Heating should be done slowly except for surface quenching. The rate of
30 minuets per one inch for rising ambient to designated temperature is well accepted
standard. Simultaneous temperature rising from surface to the center is ideal.
Heating temperature: Tempering and annealing are carried out at lower than A1,
transformation temperature (727℃). Complete annealing and quenching are carried out
at A3 transformation temperature (or A1) + 50℃. In the case of alloy tool steel, often
used for mold, the temperature is 800 ~ 880℃ for SKS steel and 950 ~ 1050℃ for SKD
steel taking account of influence of alloy elements. Temperature is determined referring
to technical data from steel suppliers and JIS as well.
② Cooling
Cooling rate: Basic is to anneal slowly and quench fast. But low carbon steel requires
fast annealing and certain steel can be quenched under slow cooling rate. Particularly
influence of cooling rate varies substantially for alloy tool steel. Thus you should refer
specific transformation curve (TTT curve or S curve) given in hand book or catalog
supplied by steel suppliers for appropriate cooling rate.
Cooling range: Referring to Fig. 2-2-1-2.1, steel with poor quenching characteristic
shows nose of S curve in a short time, while steel with good quenching characteristic
shows the nose in the late stage. In quenching, cooling rate should be controlled in a way
that temperature up to Ms point (Martensite point) should stay out of the nose in
question. In short, cooling rate should be controlled to cool fast from heated point to Ms
point and to cool slowly after Ms point to assure homogeneous Martensite.
Nose of S-Curve
Nose of S-Curve
High carbon steel or high alloy steel, which is often used for mold, tends to leave austenite
structure in martensite structure. Important point to assure dimensional stability of mold is
how to minimize retained austenite content through appropriate heat-treating.
A few important considerations in quenching and tempering mold will be explained below.
When high temperature tempering is conducted on many kinds of alloy tool steel,
hardness can be improved at 500℃ due to improved conversion to martensite grain
structure (Fig. 2-2-1-3.1). Refer to catalogs and handbooks supplied by tool steel
manufactures for further details.
Hardness (HRC)
As Quenched
Tempering Temperature (℃)
Problem incurred from remaining austenite can be solved by high temperature tempering
for usual molds. If a mold is for high precision to be used at high temperature (100℃ or
higher) for long period of time, subzero treatment is recommended.
Mass effect is a phenomenon in that cooling rate at the center of material cannot be as
fast as the surface so that the quenched hardness cannot be attained in the center of thick
material. Mass effect is associated with thickness of the material to be quenched and
quenching characteristic of the material. You need not too much concern about mass
effect on the mold for plastic molding because quenched hardness is not required in the
center the mold wall usually. However be minded in this respect if cavity and core are
odd shaped so that quenching of a material with poor quenching characteristic may
invite cracks or deformation due to mass effect.
Temperature (℃)
Time (Hr)
Housing
Door Basket
Furnace Bed
Insulation Material
(Ceramic Fiber)
Cooling Door
(Opened)
Temperature (℃)
Time (min)
Vacuum (Tore)
An object is heated in the atmosphere of nitride gas such as ammonia gas (NH3) to be diffusion-
permeated by carbon and nitrogen. Characteristics of this process can be summarized as follows:
① Any small surface of any kind such as internal surface of small hole can be hardened.
② Assuming proper tempering at higher temperature than nitride temperature is conducted,
deformation is small due to processing in rather low temperature (500℃ for alloy tool steel).
③ Does not influence surface roughness.
④ All steel except stainless steel can be treated, particularly effective for SCM steel, SKD-61 steel
and prehardened steel of precipitation hardened type.
⑤ There is no environmental problem as salt bath Nitriding.
⑥ White layer (or ε layer), hard and brittle composite, is formed on the surface. But this can be
minimized by controlling temperature and nitrogen concentration precisely.
In view of various characteristics above, a mold can be gas-nitride after finishing or before final
finishing. In the case of precision mold, gas Nitriding is conducted before final finish by leaving
finishing margin 0.01 ~ 0.02 mm. Nitride depths is at most 0.05 mm even for SKD-61. Therefore
amount of margin for finishing should be limited. Gas Nitriding is effective against galling and
seizing. Therefore you can apply this surface hardening not only for cavity and core but also for
sliding surface in the mold components.
Gas Nitriding is difficult to apply on stainless steel, as explained, because its surface is made of
stable oxidized steel. But ionized Nitriding to apply glow discharge under low-pressure gas can make
stainless steel nitride.
Ion plating is a kind of physical vapor deposition (PVD). This is a surface treatment method to ionize
vaporized coating elements such as carbide and nitride and to deposit them on the surface of an
object with negative voltage (Fig. 2-2-2-2.1).
PVD includes vacuum vapor deposition and spattering. But they are usually not applicable for
surface hardening.
① Deformation is extremely small because temperature under treatment is only 300 ~ 500℃. Be
minded tempering should be conducted at the higher temperature.
② Film thickness 1 ~ 4 µm is given evenly.
③ Super hard coating HV 2000 ~ 3000 can be attained by applying Tin and TiCN.
④ No influence to surface roughness.
In view of above characteristics, this method is applicable to cavity with flat shape and smooth
surface, core and core insert with simple shape. But you need to check carefully items ①, ⑦ and ⑧.
Referring to ⑤, ion plating is applicable to aluminum alloy and copper ally as well. But adhesive
strength is not so high because hardness of such material is not hard enough. Thus it is recommended
to limit this application to steel having hardness more than 50 HRC. Ion plating can be combined
with gas Nitriding for better surface hardening. In this case white layer should be removed by shot
pining in order to assure adhesive strength in ion plating.
The surface condition before ion plating processing should be metallurgically active. This can be
said to the surface when electro discharge machining is conducted. Ion bombardment processing is a
popular method in this respect by bombarding ionized argon gas on the object surface before ion
plating is processed.
Traditionally hard chrome plating and electro less nickel plating have been widely applied.
Treatment temperature for hard chrome plating is as low as 45 ~ 65℃. Hard chrome plating
is of low cost but with good abrasion resistance, mold separation and corrosion resistance. It
has been widely applied to mold, which is not complex in shape, or IC mold. Comparing
with PVD, plated film is thick, 0.01 ~ 0.03 mm, and in addition there will be a build up at
edges or corners. Thus you need to evaluate the usage carefully before application. Table
2.2.2.3.1 illustrates characteristics of hard chrome plating and electro less nickel-plating for
your reference.
Surface treatment by spattering, which is a dry type instead of a wet type in hard chrome
plating, is highlighted in these days. This has better adhesion and even film thickness, but
cannot be applied to small area such as internal surface of fine hole. With regard to coated
film, CVD, the same dry type as spattering, is far better in adhesive strength, but its
weakness lies in deformation to precision parts due to high temperature treatment.
In this respect it should be worth attention that CVD in low temperature treatment or plasma
CVD is under development. Such new technology should provide you with a new insight for
a superior surface treatment.
Chapter - 3
Under-Cut
Handling
3- Undercut Handling
Undercut has nature in which ejection of a product in the direction of mold open/close cannot be
possible. As it affects mold cost and product cost as well, undercut should be avoided at the stage of
product evaluation. On the contrary, tendency is toward increased undercut to satisfy needs to
reduce number of parts and to simplify joints by utilizing resin elasticity.
Undercut mechanism as well as ejection mechanism is one of a few mechanical operations in the
injection mold. It is expected to make the mechanism reliable.
Here we will discuss various methods in handling undercut, and then typical methods, slide core
and inclined core, will be taken for details.
3-1 Classification
There should be various ways to classify undercut. Generally accepted way is to classify
undercut to two, namely whether the undercut locates outside of the product or inside, in other
words whether the undercut is to be handled from outside of the product or from inside.
Outside undercut
Undercut
Inside undercut
Through hole on the outside of a product may be classified to either way. It should be
appropriate to be classified to outside undercut because a handling from outside must be easier.
1) Outside undercut (Fig. 3-1.1)
Outside undercut is easier than inside undercut because enough space may be made
available. In the most cases, slide core mechanism, which will be explained later, is used for
the outside undercut handling. The weakness must be that parting line of slide core and
cavity comes on the outside of a product. This may influence appearance quality of the
product.
2) Inside undercut (Fig. 3-1.1)
Parting line is hidden in the inside of a product because undercut is located in the inside
(core side). But the design is difficult due to limited space. Various undercut handling
methods are proposed, in which inclined core (loose core) mechanism is widely accepted.
There are many handling methods are proposed depending upon shape and size of undercut.
Typical methods are as follows.
Slide core
Inclined core (loose core)
Dogleg cam
Undercut handling methods
Elastic core
Removable core
Enforcing
Power source of undercut handling is from mold open/close, ejection, outside force, manual, etc.
as showing in (Table 3.2.1).
◎: Suitable ○: Possible
1) Slide core
Slide core is the most widely used undercut handling mechanism. Normally it is applied for
outside undercut, but can be used for inside undercut depending upon the product
requirement. This mechanism is to release undercut by means of transfer of a core, which
forms undercut, in the parallel direction to the parting line. The name comes from sliding
transfer of the core.
Driving force for the sliding comes from either mold opening force, which is converted to
horizontal force through angular pin, and outsourced force such as hydraulic cylinder (Fig.
3-3.1).
Generally, angular pin or angular cam is mostly applied for a mechanism to utilize a mold
opening force. In this case slide core is located on the movable side and the slide stroke is
relatively small. If the slide stroke is big, mold design will be difficult due to restraints from
angular pin, length of the pin, mold thickness, etc.. In addition loss in molding cycle due to
big opening stroke will be invited. In this case you should consider application of outsourced
device to allow big sliding stroke. You may apply hydraulic cylinder, pneumatic cylinder,
actuator to convert motor rotation to linear force through rack and pinion gear, etc..
If a sliding core is installed on the fixed side, outsourced application makes the mechanism
simple and gives more flexibility for various product shapes with higher reliability. When
mold opens, product will separate from the fixed side mold (cavity) and transfer with the
movable side mold (core). Thus it is required to release undercut from the cavity before
mold opens.
When the driving force is sourced outside, you should design an electrical inter locking
device on the injection machine not to start mold opening or ejection process until slide core
comes to the designated position.
Angular Pin
Slide Core
Slide Core Coupling
Hydraulic / Pneumatic
Cylinder
Undercut Release
The undercut handling is done in such a way that the inclined core transfers to the direction
to release undercut incorporating to ejection stroke. Ejector plate installed on the inclined
core should slide smoothly on the ejector plate not to cause galling.
Traditional inclined core has a structure in which ejection point and guide area are located
too far a part. Then the ejection force works as a bending moment on the inclined core. Thus
traditional structure was considered as troublesome undercut handling mechanism (Fig. 3-
3.2).
But in these days, improved design is proposed, in which the bending moment on the
inclined core is eliminated by installing a slide guide rod diagonally on the receiving plate
and the movable side mounting plate. This improved type is available in the market (Fig. 3-
3.3).
If you adopt above reliable mechanism, you can extend the inclined core application to wide
range. You will have a benefit to minimize cavity pitch for multi cavity application with
outside undercut because it does not require a wide operation space that is needed if slide
core method is adopted.
3) Dogleg Cam
Dogleg cam is applied for a mold for multiple cavity in which the space is limited. In this
case undercut should be relatively small (Fig. 3-3.4).
If undercut area locates in the movable side, you may apply it on the both outside and inside.
But in practice inside undercut is more in cases. Core to form undercut is in the shape of a
dogleg. Similarly to the inclined core, the core will slide on the ejector plate in the releasing
direction from undercut area incorporating the movement of ejection stroke.
Accordingly, galling may be incurred if the core does not slide smoothly on the ejector plate
similar to the inclined core.
Another weakness may be that the core hole edge is subject to abrasion because the dogleg
cam hits on the hole edge every time when ejector plate returns to the original position.
PITAC
Inclined Core
(Loose Core)
Holder Bushing
(a) Inside undercut handling mechanism (b) Outside undercut handling mechanism
(a) Inside undercut handling mechanism
Fig. 3-3.3 New Inclined Core Mechanisms (from catalog of タカオ設計事務所)
Dogleg Cam
Operational trouble
will be incurred
unless this part moves
smoothly.
Advantage is that molding cycle can be made fast and reliable as there is no operation
mechanism like sliding. But you cannot apply it to a product with a big undercut because
undercut is handled only by the inclined core.
Collapsible core is often applied to a product, which has female threads inside like a bottle
cap. Spring core is used similarly to dogleg cam and inclined core (Fig. 3-3.6). As it is more
reliable than dogleg cam or the inclined core, consider the spring core first if situation is
allowed.
Screw
Collapsible
Spring Core Core
Sleeve
Center Pin
Accordingly the core cost can be low, but productivity should be low, too. This kind of core
is seldom used in Japan where labor expense is high. It is used only for a prototype mold
before production mold is produced.
Removable core is set at the undercut area in the mold like insert. Normally two removable
cores are prepared per one undercut so that one can be removed while another is under
molding processes.
Basically similar consideration to insert molding should be paid for the design of removable
core.
① To evaluate the method of the core removal at the time of mold design.
② To design the removal core that can be easily inserted in the mold with a foolproof
shaping.
③ To design the removable core to be positioned exactly in the mold. It should not be
dislocated by the mold clamping motion.
④ To layout an ejector pin for the removable core.
⑤ To use light metal with high thermal conductivity. Aluminum alloy is recommended.
3-3-6) Enforcing
This is to take the undercut out just by enforcing the product manually or by ejector
depending on the elasticity of the material. The quality of the product will be very much
influenced by the shape and the kind of material. Thus a thorough evaluation is essential at
the design stage (Fig. 3-3-6.1).
Following considerations are needed in the design when enforcing method is chosen.
① Undercut should be within a size so that distorted product could be elastically regained
to the designed shape.
② Edge of the undercut area should be designed to have smooth R corners.
③ If undercut is enforced by an ejector pin or a stripper plate, the structure should be made
so that the product can be elastically deformed.
④ Material should have enough elasticity to be distorted and to be regained to the designed
shape. Gene rally, crystalline non-reinforced resin such as PE, PP, PA, etc. is relatively
applicable for the enforcing.
Ejector Pin
Undercut
Area
Rough positioning between angular pins and sliding core is associated with difficulty to
keep relative position accurately in machining. This tells you that if 2 angular pins are
installed for a sliding core, one is in contact but another is not. This will give a moment
to sliding core, then result in galling on the sliding area.
Thus, one angular pin should be prepared for one slide core in the normal practice, but if
you need to install 2 angular pins for some reason, you need to machine relative
positions accurately (Fig. 3-4-1.1).
② To keep angle less than 25°
Angle of an angular pin is better be 10°~25°. In practice, 15° or 20° are often used. If the
angle is set beyond 25° in the case of large stroke, initial resistance due to mold
separation becomes too big to risk damage of the mold.(Fig. 3-4-1.2).
If you need a large stroke, you should consider outsourced actuator or installation of an
angular cam, which can change the angle in the ejection process.
The angle of a locking block should be 2° plus pin angle in principle.
In principle the main function of the spring is to push the sliding core against the stopper
in order to position the sliding core accurately, and the secondary function is to assist
separation of the product from the mold. The spring should not be too strong not to
induce unstable movement of the sliding core.
There are 2 ways for spring installation. One is to install it between sliding core and
main core. Another is to install it on the end of the sliding core by way of a stripper bolt.
The formar is popular because of its compact layout. In this case it is advised to prepare
a spring cover so that any foreign materials cannot be pinched by the spring (Fig. 3-4-
1.2).
Section A-A
Slide Core
Locking Block
Extrusion-cut
Surface
Stopper Block
The longer the guide is, the better the guiding stability will be. It must be ideal to have
the length 1.5 times of the slide core width. If it is not possible, maintain the length at
least more than the slide core width. If the length is less than the width, you will have a
back lashing movement similar to old drawers. Naturally this will cause galling. The
tendency toward a galling is evident if you try to handle multiple undercut areas by a
wide sliding core (Fig. 3-4-1.2). In this case prepare a narrow guide, which is a guide of
parallel key shape, on the bottom face of the sliding core and let the guide rails on the
side work in the direction toward brim thickness only.
In wear consideration, hardened metal or other kind of metal such as brass is used on the
sliding surface. This general principle should be applied to guide area of the sliding core.
Or one of sliding core and sliding guide should be made of hardened metal. Normally
sliding core of small and medium size mold is made of hardened metal, but mold bases
are not. They may be of pre-hardened steel as it is. In this case you are advised to attach
partially hardened wear plate on the sliding part of the mold base to improve wear
resistance. If partial load is not expected, wear plates made of brass or oil-less metal can
also be useful (Fig. 3-4.1.2).
As a spring of the ball plunger is not made strong, there is always a risk of dis-
Mold Design (Advance) Page 87
PITAC
positioning through vibration and moment inertia of the sliding core. This risk is
particularly evident when toggle-clamping mechanism with a quick motion is applied to
the injection machine.
The final positioning of the sliding core stroke in the direction of mold opening should
be set by a contact of the sliding core against a stopper block with a help of a spring
force (Fig. 3-4-1.1). Thus a ball plunger should be used as a supplemental means for
possible damage of the spring.
② To select the surface for positioning except touching surface in the mold clamping
direction
Positioning toward mold opening can be done by a stopper block. Do not position the
end of mold clamping against touching surface. Particularly if you use a small touching
surface as a stopper for positioning, the surface is likely to have marks or to be concaved
due to concentrated force on the surface.
Positioning toward mold clamping direction should be made against a large surface such
as core side, which does not affect product quality. The properly selected area should
function as a stopper to withstand touching of the sliding core together with a locking
block, and the touching face should be protected (Fig. 3-4-1.1).
3-4-4 Layouts
Slide core should be laid out horizontally in the direction of operation side to non-operation
side, and avoid a vertical layout (Fig. 3-4-4.1). If you need to select a vertical layout for a
product to require 4 directions sliding or for other reasons, safety consideration for the
sliding core not to fall by its weight should be made carefully.
A safety consideration may be to install a spring having 1.5~2.0 times strength of the sliding
core weight and in addition to install a ball plunger under the sliding core in case of the
spring failure.
Similar safety consideration had better be paid for any kind of layout of the sliding core.
Mold
Not preferable
sliding direction.
Preferable sliding
direction.
Bottom
It was explained that traditional inclined core has a weakness in mold failure and parting failure
because of a bending moment on the inclined core derived from too far a distance between
ejection point and guiding area.
It should be ideal to develop a new inclined core to eliminate such bending moment, but here we
will discuss some idea for modification or design points based on traditional design concept of
the inclined core.
Specifically, a quenched guiding plate can be installed on the support plate or the lower core
plate surface (the other side of PL surface). In this way two areas, core and support plate (or
core plate), will take care of guiding. This will contribute to improved operational stability
of the inclined core (Fig. 3-5.1).
You may apply non-lubricant type sliding plate available in the market. But modification by
having a quenched plate on the ejector plate and a cam follower or a needle bearing to
provide small friction resistance are more likely effective (Fig. 3-5.1).
Accordingly the product should not move angularly with the inclined core. Following points
may be useful to cope with this problem.
* If possible, to prepare a draft angle on the undercut area to reduce releasing resistance.
* To have an ejector pin to cut into the product as much as 0.1~0.3 mm.
* To make the height of the inclined core lower than the main core as much as 0.1~0.2mm.
Imagine an ejection stroke without undercut consideration and then set an minimum angle to
operate the undercut with the stroke.
It is advised to limit the angle to maximum 15°. If it exceeds 15°, you are advised to
consider a design with no bending moment. This new type of core is subject to patent issue.
Thus you cannot manufacture it in house, but can purchase it in the market.
Mold Design (Advance) Page 90
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Draft Angle
Detail A
Receiving plate
Guide Plate
Wear plate
Chapter - 4
3-Plate Mold
4- 3 plate structure
When a gate is designed on the upper surface of the product like pin point gate, a runner
stripper plate is required for runner separation in addition to 2 plate mold. This is called 3
plate mold.
3 plate mold has one more plate on the 2 plate mold, but the structure and the operation is
quite different from the 2 plate mold. The big difference is in open/close of the plate. 3 plate
mold requires a big open/close stroke to open runner parting (PL2) for taking runner out in
addition to open/close of main parting line (PL1) for taking product out. Therefore the mold
cycle is slower than 2 plate molding. Another disadvantage in comparison with 2 plate mold
is the higher cost due to increased parts required for its complex structure. However 3 plate
mold is popular as it has advantage over 2 plate mold in molding comparatively large
products maintaining a good balance in the shape.
Factors to determine sequence of the opening are separation resistance of product and
runner, and operation resistance from runner stripper plate. In the normal mold, either main
PL surface or runner PL surface opens first and runner stripper plate opens next. Fig. 4.1
shows the relationship.
There is a mechanism to lock PL surface (PL1) and let the runner PL surface (PL2) open
first. This is applicable for a thin product of which releasing resistance is small on the core
side. This enables the product to stay on the core surface. (Fig. 4.2)
Basic structure of the movable side is the same. Thus various types of the mold explained for
2 plate mold are applicable to the case of 3 plate mold. In this way 3 plate mold can cope
with the requirement of various shapes of the products.
[Required Conditions]
(1) PL1 opens and then product stays on the
core side.
(F2 + F4) < F1
(2) Before PL3 opens, PL2 opens.
(F3 + F4) < (F6 + F7 + F8)
[Sufficient Conditions]
(1) Before PL2 opens, PL1 opens.
F2 < (F3 + F5)
(2) Before PL1 opens, PL2 opens.
F2 > (F3 + F5)
Fig. 4.1 Opening Sequence and Various Resistances for Three Plate Mold
Parting Lock
This double purpose structure provides more space for other components but be aware that
support pin collar cannot be used here. The support pin collar is a safety device to stop the
fixed mold plate from coming off from the support pin when a head of the stop bolt happens
to be broken. Therefore if the double purpose structure is adopted, you should either
consider other method for safety consideration or use stop bolts and puller bolts of higher
strength to ensure high reliability.
Be advised that the double purpose structure is inferior to the functionally shared structure in
terms of the positioning performance of the mold plate because there are possibility of pin
deflection and clearance problem with guide bushing as the support pin fixed on the fixed
side clamping plate has to guide the movable side mold plate. Considering all above,
Mold Design (Advance) Page 95
PITAC
following design criteria can be presented for designing guide and support pin structure of 3
plate mold.
① In the case of a mold with movable side guide pin structure, like stripper plate ejector,
the basic structure should be that support pin and guide pin/bushing are laid out
separately.
② In the case of a mold with a thick fixed side mold plate or with a large opening stroke in
PL2, select a basic structure to assure better performance for guiding mold plate because
support pin deflects and positioning performance should drop.
③ In the case of double purpose mold that requires accurate positioning of the movable and
fixed side mold plate, increase positioning accuracy of the cavity and the core by
applying a taper pin on the PL surface.
R plate R plate
Drawing
Fig. 4-1.1 Mold Guide Structure with Guide Pin and Support Pin
(from catalog of フタバ)
Type a in Fig. 4-2-1.1 is the most popular kind of stop bolt and it can be located in the same
location as puller bolt. Thus it is good in space utilization and in addition it saves machining
on various plates.
Other types are more or less the same shape as puller bolt, but a puller bolt is too long for
the stop bolt. It is rather recommended to find a stopper bolt among stripper bolts which
have better possibility to be used for a stop bolt and are available as standard press die parts.
Puller bolt has two types. One is male screw and another is female screw type. Female screw
type is widely used because it can be used as a pair with stop bolt. Even it is used
independently, female screw type has better reliability for repeated load application because
it can be fastened from runner stripper plate side (Fig. 4-2-2.1).
Fixed Side
Mounting Plate
Puller Bolt
Characteristics
• High Space Efficiency • Good molding • Good molding • Good molding
• Poor in molding workability. workability. workability.
workability and • Poor reliability in • High reliability in • High reliability in
maintainability. strength of screw area. strength of screw area. strength of screw area.
• Good maintainability. • Poor maintainability. • Good maintainability.
• High cost.
Female Type
Male Type
Female Type
Like above example, tension link gives more flexibility in layouting parts for mold opening
control, but close attention should be paid not to interfere with couplers mounted on the
plate side face for temperature control. Also attention should be paid on the workability of
product take-out, particularly of manual take-out, because tension link is installed on the
side face of the mold plate. Thus the layout of the tension link should be carefully made in
consideration of take-out method of product and runner as well.
4-2-4 Chain
Tension link and puller bolt are normally installed in the range of mold thickness, but once
in a while there is a case in that the range of mold thickness is not wide enough for their
installation when the extent of the opening is large relative to the mold thickness. In this case
chain can be effectively applied (Fig. 4-2-4.1).
As it is flexible, the chain can be used for most of the cases. When the mold is closed, the
chain can be folded and stored within the mold plate thickness. However a chain may hang
down when the mold is closed and may interfare with couplers for temperature control
device. Thus a chain should be only used for special cases as in the case explained above.
Drawing
• One end is fixed by a bolt. Thus • Can be used for a big opening.
operation is assured. • Rather high noise.
• Possible to make mold open / close • Cannot make mold open / close fast
Characteristic fast.
• Less noise.
• Not suited for a big opening.
Chain
For example, in the case of shallow product, which has not, much difference in the releasing
resistance of fixed side and movable side, the product tends to remain on the fixed side due
to gate cutting resistance. In such case it is effective if PL1 is locked by a parting lock by
eliminating a chance of the product to remain on the fixed side. In a ward, the parting lock
stabilizes releasing balance of the fixed and movable side.
Types
Creation of operational resistance can be made by mechanical system, friction, magnetic
force, etc.. Parting locks associated with various methods are classified as follows.
Mechanical lock
Parting locks Spring lock
Plastic lock
Magnet lock
As you see, this kind of mechanical locking device can eliminate mold parts, such as a
tension link to control mold opening of PL1. The most important thing is the proper
timing of the locking release. Parting line opens in the sequence of PL2→PL3→PL1.
Release bar of the mechanical locking device should be adjusted to release the latch
somehow earlier than the opening extent set by stop bolt or puller bolt.
If the release if too early, it will result in insufficient opening of PL3 (PL between fixed
side clamping plate and runner stripper plate). If the release is too late, it will result in
the damage of stop bolt or puller bolt. Mechanical locking device can be said the most
reliable parting locking device though it is costly.
Mold Design (Advance) Page 101
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Traditionally the plate spring has been commonly used but adjustment of the spring force
could not be made. In these days a roller to enable both locking and adjustment by a dish
spring with a screw is made available in the market. This type is available in the market
and the reliability has much improved.
Spring locking device cannot control a stroke of the mold opening but is easier to be
handled comparing to mechanical locking device. In the durability aspect, it is much
better than plastic locking device to follow.
The center of the extruded part of the plastic cylinder is made by a tapered bolt. Thus the
outside diameter of the extruded part can be changed by screwing in the tapered bolt.
Thus the friction force can be adjusted. (Fig. 4-3-1.3)
This parting lock device is less costly and easy for installation but due to the stress
relaxation of plastic material tapered bolt it tends to be loosened comparing to other
options. Thus evaluate how to stop loosening of the bolt and be ready for spares for the
replacement whenever needed.
This device has no better reliability comparing to mechanical locking device and no
adjustment mechanism comparing to spring locking device and plastic locking device.
But it can contribute to an efficient molding cycle because no mold clamping force is
wasted, and you need not slow down the speed of mold closing. In addition the device
can be made to standard parts because it can be easily installed and removed to and from
the mold plate.
Mold Design (Advance) Page 103
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Plastic Lock
Bushing
Dowell Pin
Tapered Screw
Material SS400
Magnet MLK 40-100 Alnico Magnets (Max. temp. 80℃) Magnet Lock
Magnet Lock Steel Block
MLK 80-200 Rare Earth (Max. temp. 200℃)
Square Magnet
Steel Block
Application
Material SS400
Fig. 4-3-2.1 Runner Lock Pin and its Tip Shape (fromミスミcatalog)
Runner
Lock Pin
Big Big
Gate
a. Poor Resin Flow b. Poor Gate Cut-off c., d. Good Resin Flow and
(improper) (improper) Good Gate Cut-off
(proper)
Fig. 4-3-2.2 Proper / Improper Design for Resin Flow and Gate Cut-off
Screwed Plug
Collar
Bushing
Fig. 4-3-2.3 Proper / Improper Structure for Galling of Runner Lock Pin
The similar function can be attained by installing a spring between the runner stripper plate
and the fixed side mold plate being guided by a puller bolt. Generally this mechanism is
used more frequently but this does not have a function to support opening of PL3. (Fig. 4-3-
3.1)
The runner ejector is sold in the market as a set including runner ejector pin, spring and
housing. This can be easily installed if the specification meets the requirement (Fig. 4-3-
4.1).
When it is applied, the runner ejector should not use a pin smaller than runner width. A part
of the pin should be in contact with PL2 surface of the fixed side mold plate, otherwise the
pin will be inside of the groove of the runner and may be in touch with the surface of the
draft angle or the bottom of the runner. In either case, function of ejector cannot be worked.
(Fig. 4-3-4.2)
Mold Design (Advance) Page 108
PITAC
Push Pin
Fig. 4-3-3.1 Supplemental Device for PL Opening by Push Pin and Spring
①Housing ②Pin
①Housing ②Pin
Material Material
Hardness Hardness
Pin
Housing
Spring
Runner
A case of malfunction because pin is Pin does not perform as an ejector
in contact with runner. (Pin is to be because it goes into resin.
returned by resin pressure)
(a) Proper (b) Improper
Advantage is that runner layout is flexible, thus this gate can be applied to small
products and to big products as well. Disadvantage is that this gate does not suit to a
resin of poor flowability such as acryl resin because the gate is small and nor to a resin to
include fiberglass, which erodes the gate quickly.
Automated cut-off in the pinpoint gate works like a pulling action generated by the mold
opening force. Therefore the cut length varies. To cope with this problem gate area
sometimes is designed to be 0.3~0.5mm in concave shape. To compensate decreased
thickness of the product, it is advised to make the core side the same amount in convex
shape if possible (Fig. 4-4.1).
Gate Shape
Defective molding may be derived from improper setting of the injection parameters or material
conditions.
Corrective action or improved procedure should be in practice by finding out the cause of the
defective molding.
Typical phenomena of the defective molding, possible causes and actions for improvement shall be
explained as follows:
A short shot is a condition in which resin cannot be fully filled into the mold. This will cause
poor appearance and poor function of the product.
Flashes are thin filmy resin adhered to edges of the product. Flashes may cause difficulty in
assembly of the molded parts and may be hurting when handled.
Sink mark is a concavity on the product surface. It causes poor appearance and poor function of
the molded product.
5-4 Void
One is caused by water or air mixed into the material and another is caused by vacuum cavity
created when material is contracted. Void results in weak strength of the product or poor
appearance if the products need to be transparent.
Flow mark is a wavelike mark of the resin flow left on the surface of the product. Appearance
and surface quality should be affected.
Weld line is a line mark on the surface of the product appeared around merging area of the resin
flow. Appearance and strength of the product should be affected.
5-7 Burn
Burn is a phenomenon in that resin burns when air is heated upon compression around final
filling area and air pocket area. Burn should affect appearance and quality of the product.
5-8 Jetting
Jetting is a snaking mark appeared on the product surface, this tends to appear when the gate is
too small.
Poor luster is a phenomenon in that luster on the product surface is not enough or inconsistent. It
affects appearance of the product.
Foreign matters such as dusts, dirt, bugs, etc. may be included in the material. Appearance and
material strength may be affected.
Poor releasing of the mold is a phenomenon in that the product sticks to the cavity. There are
three patterns for this problem. One is that the product sticks to the cavity when the mold is
opened. The second is that the product sticks to the core when product is to be ejected. The third
is that the product sticks to the slide core. When poor releasing happens, naturally continuous
production is interrupted and product surface may be damaged.
Dimension defect is a phenomenon is that the product dimensions fall outside of specified
tolerances.
<References>
1) “Reading of Plastic Molding”, written by Y. Sakurauchi, published by (株) 工業調査会
2) “Easy Injection Molding”, written by K. Takano, published by (株) 工業調査会
3) Molding Standard Parts Face 1999-2001, published by (株)ミスミ
Fig. 5.3 Relationship between Injection Pressure and Pressure in the Cavity