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ISO 9001
006
Compression Mould
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Compression Molding
A two-piece mold provides a cavity in the shape of the desired molded
article.The mold is heated and an appropriate amount of molding
material is loaded into the lower half of the mold.The two parts of the
mold are brought together under pressure.
The compound, softened by heat, is thereby welded into a continuous
mass having the shape of the cavity.The mass then must be hardened,
so that it can be removed without distortion when the mold is opened.
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Compression Mould
A technique whereby molding compound is introduced into an open
mold and formed under heat and pressure.
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Flash-type molds
A type of mold designed to permit excess molding material to escape
during the final closing.
The material flowing across the land area has no other restriction to its
movement. This characterizes the name Flash Mold.
Flat and shallow parts should be molded in a flash-type mold.
The flash is always horizontal. If the mold is closed too slowly, a heavy
flash will result.If the mold is closed too quickly, the density of the
molded part will be low and the strength impaired.
Advantages
1.Lower mold cost
2.Good for small parts
3.Ease of loading inserts
4.Experimental molds may be made for prototype parts.
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Positive-type mold
The type of mold fully confines the molding material, and full mold
pressure is exerted at all times.There is sufficient clearance between the
cavity and plunger for the molding material to escape.The full pressure
is exerted on the molded part.
The travel of the force or plunger is limited only by the amount of
plastic molding powder placed in the die cavity.No external pressure
pads or stop blocks are used to limit the closed height of the mold.
The clearance space between the plunger and the cavity is called
vertical flash ring is 0.002 to 0.005 inch. per side.
It is used for molding high impact thermosetting plastic materials.
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Bulk Factor
The ratio of the volume of the loose plastic powder to the volume of
the molding is called bulk factor.
The inclusion of different fillers affect the bulk factor of the material.
The bulk factor for general purpose material and most mineral fillers
varies between 2 and 3.
In the case of light fabric filler the bulk factor will increases to between
8 and15 and use of a heavy fabric or string filler can increase the bulk
factor to between 12 and 24.
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Projected area
The projected area is the total area of the molding as seen when viewed in
the direction that it will be placed on the press in the plane normal to the
press opening.
The projected area can vary depending on the size of the component as
well as on the design of cavity or loading chamber and the compression
pressure also can vary based on the type of plastics materials.
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Compression pressure
The pressure needed to mould a particular article depends on the flow
characteristics of the material, the cavity depth and the projected area of
the piece part.
It is recommended that minimum molding pressure of 250kg/cm2 of
projected area be used.
But for calculation purpose the compression pressure for the particular
material is get from the material manufacturers or from the plastics hand
books or data books.
Clamping force
Clamping force(kgf) = Projected area of the molding(cm2) x
Compression pressure of the plastic material(kgf/cm2)
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Heating systems
The molds are generally heated electrically, but steam or hot water may
be used.Electrical heating is more up-to-date than steam or hot water
heating.The mold temperature can be controlled easily and over wide
range with electrical heating than with steam or hot water heating.
The maintenance of the switching and control devices in electrical
system is easy when compared with maintenance of complicated
equipments in steam heating.Less wasteful of time than for the steam or
hot water systems.
In electrical system the heating coil should be placed at equal distance
from the molding surface, as local overheating or under heating can
occur more easily than with steam or hot water systems.
There is no great difference in costs between the two systems, the
generally higher cost per calorie of the electric current being balanced by
the wastages found in steam systems.
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Types of heaters
Frames, tapes and cartridges are used as heaters.
Heat equipment & heater capacity
Heater tapes have diameter from 50 to 500mm and are available with
different widths.Their heating power amounts up to 3watt/cm2.
The cartridge diameters are 17 and19mm, and the cartridge length is
generally 100mm.The required number of cartridges may be calculated
from the current rate.The heating power must correspond to the weight
of the mold.
Medium sized and big molds are sometimes induction heated. Insulated
copper conductors of large cross-section are embedded in the mold.
Alternating current of 50Hertz at 20volt and several hundred ampere
cause eddy currents that heat up the mold.
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