Tutorials on Injection Mould Designing design using autodesk inventor

3/3/2014 Tutorials on Injection Mould Designing - GrabCAD

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Tutorials on Injection Mould Designing

Other sourbh basic educational mold mould mechanical engineering

By Sourbh on 29 Jul 05:30 27 answers 6051 views 16 comments

Basics Part and Working Features of Molding Assembly

Rest of Slides you were found out here in My Library:-"Tutorials on Injection Mould Designing"

Moulding Products:- "ALL-OUT Fuel Container, Injection blow moulding part"

"Container-Injection blow moulding part"

"Grabby Torch"

"Hexagonal Torch " Requested Design""

"Baby Girl Hair Clip"

"Something More than RC"

"Table Lamp"

"Table LAMP-II"



And also much more in my library..!!

27 answers

Sourbh 7 months ago

Than after this one.......

Learn much first than design it.

1. Step 1

5.

2. Step 2

6



3. Step 3

7.

4. Step 4

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5. Step 5

9

6. Step 6

10.



7. Step 7

11

8. Step 8

12.



Sourbh 7 months ago

than this

1. Step 1

13

2. Step 2



14

3. Step 3

15

4. Step 4

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5. Step 5

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6. Step 6

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7. Step 7

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8. Step 8

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9. Step 9

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10. Step 10

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11. Step 11

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12. Step 12

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13. Step 13

25

1.

Sourbh 2 months ago

day light means the min./max. opening of mould halves after filling of material ininjection mould for part ejection.



2. huuhoa 4 months ago

sorry i dont understand "day light" what is this mean

3.

Mehran Zaryoun 7 months ago

Perfect man, Thx

4. Sourbh 7 months ago

you're welcome dear Mehran

Sourbh 7 months ago

Go through this Presentation, you will Clear all your Doubts!!

Enjoy

1. Step 1

This one first...

1.



2. Step 2

2.

3. Step 3

3.



4. Step 4

4.

Sourbh 7 months ago

Dear Bobys Here is your Shrinkage Data Sheet

1. Step 1



All Data about Shrinkage Value of Different Plastic Materials..

thanks and Enjoy..!!

2. Step 2

2

1. BoByS 7 months ago



Amazing...just amazing!

2.

Sourbh 7 months ago

Thanks dear Bobys

Sourbh 7 months ago

Here is the working System and Different Zone's in Injection Molding Machine

1. Step 1

The Injection molding Machine

2. Step 2

Purging

Sourbh 7 months ago

Ya Of-course am in Way of Writing the book,



this Slides only the 0.1% of My Notes, which I prepared During My Academic Session. am did Lots of Research in Different types of Moulding Technique or Process. and also Designed and Manufactured it. Due to Low Internet Speed am Just Uploading the Less Amount of My works.

If You Have any type of Doubts and Question than Sourbh kumar is Ready to Give AnswerWith Suitable Examples.

Thanks

Sourbh 7 months ago

The next Part of this Tutorials is Here"Tutorials on Injection Mould Designing:- Design

Steps"

Prabhakar Purushothamman 6 months ago

Design of Three Plate Mold an Introduction

1. Step 1

Type of gate and type of ejection used in Three Plate Mould

2. Step 2



Three plate Mold Closed condition

3. Step 3

Three plate Mold Open condition

4. Step 4

THREE PLATE MOLD - Elements



5. Step 5

MOULD OPENS AT FIRST PARTING SURFACE

6. Step 6

Second Parting Surface Opens



7. Step 7

Stripper Ejection

8. Step 8

3 plate mould




Nice Contribution.

Thanks to share this.

Sourbh 6 months ago

Mould Steels

1. Step 1

1



Sourbh 6 months ago

Ok Today I will Tell you about Shrinkage, Completely

1. Step 1

Shrinkage and its Applications.

2. Step 2



Shrinkage

3. Step 3

Shrinkage of common plastics

4. Step 4

Application of Shrinkage, An Example



5. Step 5

Component drawing with shrinkage added

6. Step 6

core Insert



7. Step 7

Cavity Insert


Welcome dear..!!



2.

george avgerinakis 6 months ago

Thanx!

Sourbh 6 months ago

Today the topic is "FLOW SYSTEM"

No slide just Theory only, I will upload the slide soon.

Thanks and Enjoy..!!

1. Step 1

Flow system: The design of a flow system to inject molten alloy in to a die cavitygreatly influences the success of a die. The failure of many dies can be traced to faultydesign of the flow system. By applying the basic principles of hydraulics a propermolten metal flow system can be developed.

The system aims at an efficient controlled delivery of through the flow system to thedie-casting with mixing of molten alloy and air. Machine suitability: Choice of suitable machine is important aspect of die designing. Two main

consideration determine suitability: Clamping force. Injection capability.

2. Step 2

Clamping force can be calculated by multiplying the projected area of the impressionincluding runners,gate overflow by the injection pressure.The result should be less thanthe clamping force of the machine. The injection capability or metal pumping capacity

of the machine must be determined from the pQ2 diagram. The flow system comprises of a series of passage of varying lengths and diameterswhich carry molten alloy at varying high velocities from the under side of the injectionplunger to the gate. The flow system should be properly designed and manufactured to minimize the

energy losses. The flow system should converge from gooseneck to gate, sharp corners should beavoided and the surface of the flow path should smooth and well finished.

3. Step 3



The sprue: The sprue has two basic functions: 1. To provide a smooth flow path between nozzle and runner.

. 2.To provide a means of rapidly solidifying molten metal alloy at the entrance of thedie after the cavity has filled and the flow has stopped.

3.Runner type sprues have been developed to achieve a smooth flow path withuniform cross section, minimum change of direction and smooth transmission fromnozzle to sprue and sprue to runner.

4. Step 4

The runner system from sprue to gate: Main runner:

The main runner join the sprue to the final tapered tangential runners feeding the gate.They should be as shot as possible and must have a constant cross sectional area.

Tapered tangential runners: Tapered tangential runners provide the final flow path from main runners to gate. Theyprovide an efficient flow path based on simple geometry and permit the use of the verythin gates (from 0.15-0.3mm).

5. Step 5

Runner cross section:

Circular sections give best flow efficiency and minimize thermal losses, but are theleast practical cross section from the tool makers view.

For tapered tangential runners modified square or trapezoidal shapes are used. Area

calculations are based on square sections and are converted into trapezoidal shapes.

Pairs of tapered tangential runners can be used to feed a long gate into a singlecavity.A thin delta shaped region between the paired runners is found.

6. Step 6

Shock Absorbers: The small ends of tapered tangential runners terminates in simple disk shaped shockabsorbers. The control the very high transient velocities which may occur at the small

ends of the runner. Shock absorbers also protect the die when the does not flowcompletely as in the case of a cold die during setup,when very high velocities can bereached. Fan Gate:



Correct design and dimensions of gates is essential to achieve high casting quality and

efficiency. The fan gate has been largely superceded by by the tapered tangentialrunner. To increase its efficiency the inlet should be larger than the gate.

7. Step 7

Gate Positioning General guidelines for gate positioning:

Center gating: Center gating offers the best feeding configuration. It permits the use ofshort direct feed system. It achieves an ideal flow path across the die cavity. Edge gating susing tapered tangential runners: The following are the recommendations : The longest uninterrupted length of casting available for casting should be choose but it

must satisfy the shortest and smoothest flow path across the cavity. The direction of metal flow in the cavity sho9uld be chosen such that at least one sideor corner be open during fill time to allow for venting.

8. Step 8

Gate area: The total gate area must always be smaller than nozzle exit area. But its should not beless than 40% of nozzle exit area.

Gate velocity: The velocity of molten alloy through the gate depends on : The energy of machine The pressure losses in the total flow system in the gate. The type of runner.

True velocity through gates fed by tapered tangential runners is higher than the figurearrived at using the formula: Velocity(v) = volume flow rate(Q) gate area(A)

9. Step 9

Air vents: The use of converging flow system with correctly designed runners ensures that air in

the feed system is pushed out a head of the molten alloy flow and expelled through thecavity trough the air vents. Depth greater than 0.075mm will lead to flashing problem. Overflows: No over flows need be cut prior to the first casting trial unless their use isspecified for ejection purpose. On trial if the castings exhibit poor finish or blister the

following conditions must be checked first: Machine operations and performance Feed system design and performance. This will establish both machine and die are operating at the design parameters.



10. Step 10

Thanks..!!!

Sourbh 6 months ago

Types of Injection moulding machine

1. Step 1

1

Zakir Qureshi 7 months ago

awesome job!!!

1.

Sourbh 7 months ago

Thanks Zakir



Sourbh 6 months ago

When a basic mould consisting of two parts, is open there is only one space or daylightbetween the two mould halves. This is called a single-daylight mould. In a stripper platemould which consists of a fixed mould plate, the moving mould plate and the stripper platethere are two daylights when opened. This is called a double-daylight, stripper plate mould.

Another type of mould which also consists of three main parts a feed plate, a floating cavityplate and a moving mould plate, has two daylights and is termed as double-daylightunderfeed mould or three plate moulds. This design permits a particular feed techniqueknown as underfeeding.

A combination of stripper plate and underfeeding results in a triple-daylight mould.

BoByS 7 months ago

Can you tell us what is the scale factor for the cavities because of the shrinkage when thedetail cools (for different polymers)? I don't see this in the slides. :(

Thanks for this amazing tutorial!


Now the File is there download it, Shrinkage.pdf


ya ofcourse Dear I will Upload the next tutorials for Plastics were moulded through. And its combination of total Details Necessary for moulding..

3. BoByS 7 months ago

I can't wait! :)



Sourbh 5 months ago

Today the Topic is Runner's

1. Step 1

Cold Runner

In a cold runner mold, the runner is cooled and ejected with the part. Every cycle, apart and a runner are produced. The obvious disadvantage of this system is the waste

plastic generated. The runners are either disposed of, or reground and reprocessedwith the original material. This adds a step in the manufacturing process. Also, regrindwill increase variation in the injection molding process, and could decrease theplastic's mechanical properties.

Despite these disadvantages, there are many significant advantages to using a coldrunner mold. The mold design is very simple, and much cheaper than a hot runnersystem. The mold requires less maintenance and less skill to set up and operate. Colorchanges are also very easy, since all of the plastic in the mold is ejected with eachcycle.

2. Step 2

Hot Runner

In a hot runner mold, the runner is situated internally in the mold and kept atemperature above the melting point of the plastic. Runner scrap is reduced oreliminated. The major disadvantages of a hot runner is that it is much more expensivethan a cold runner, it requires costly maintenance, and requires more skill to operate.Color changes with hot runner molds can be difficult, since it is virtually impossible to

remove all of the plastic from an internal runner system. Hot runners have many advantages. They can completely eliminate runner scrap, sothere are no runners to sort from the parts, and no runners to throw away or regrindand remix into the original material. Hot runners are popular in high production parts,especially with a lot of cavities.

3. Step 3

Types of Cold Runner Molds

There are two major types of cold runner molds: two plate and three plate. A two plate cold runner mold is the simplest type of mold. It is called a two platemold because there is one parting plane, and the mold splits into two halves. Therunner system must be located on this parting plane; thus the part can only be gated onits perimeter.

4. Step 4



A three plate mold differs from a two plate in that it has two parting planes, and themold splits into three sections every time the part is ejected. Since the mold has twoparting planes, the runner system can be located on one, and the part on the other.Three plate molds are used because of their flexibility in gating location. A part can be

gated virtually anywhere along its surface.

5. Step 5

A two plate Cold Runner mould

6. Step 6

A Three Plate Cold Runner mould



Sourbh 5 months ago

Today Topic is Vacuum Forming, Let take a look on it.

1. Step 1

Vacuum Forming Process 1. The process involves heating a plastic sheet until soft. 2. The softened sheet is draped over a mould.

3. A vacuum sucks the sheet into / onto the mould. 4. The newly shaped sheet is taken off the mould.

2. Step 2

Typical PLASTICS used in the

vacuum forming process

PS Acrylonitrile Butadiene Styrene ABS

POLYSTYRENE POLYCARBONATE



PC POLYPROPYLENE

3. Step 3

Further PLASTICS used in the

vacuum forming process POLYVINYL CHLORIDE PVC PMMA Acrylic

PE POLYETHYLENE (woven sheet)

4. Step 4

a). Plastics are man made chemicals extracted mainly from petroleum. b). They are basically composed of hydrocarbons: groups of linked hydrogen andcarbon atoms. (Imagine them as a small train and carriage!)

c). Most plastics are made up of long chains of hydrocarbons. (Identical small trains joined together to form one very long train.)

What are Plastics ?

What are Plastics? continued

d). More than 50,000 molecules (long trains) may be joined in chains to producepolyethylene (or polythene). e). Very long straight or branched chains. are present in thermoplastics: eg. polyethylene and polystyrene. f). Thermoplastics always soften when heated and harden when cooled down.

g). This makes these plastics ideal for the vacuum forming process.

5. Step 5

Advantages of the Vacuum Forming Process

Vacuum forming uses low pressures so only relatively low cost equipment /components are required.

Low pressures mean that moulds can be made of inexpensive materials and in a



short time.

Prototypes, small and medium quantity runs become economical.

6. Step 6

Disadvantages of

the Vacuum Forming Process More complicated machines and moulds are needed for automatic or continuousproduction of high volume items, eg. disposable cups and sandwich packs. The vacuum forming process starts with a flat plastic sheet and there may be a need

for a second process to trim the moulded end product. This means more expense toobtain additional equipment. NB. The trimmed waste, however, can be re-ground and recycled!

7. Step 7

The process requires heat, suction, and (thermo)plastic sheets.

Hot air is required to soften the plastic sheet and allow it to conform easily to the

shape of the mould.

Vacuum is then used to suck the plastic to the mould. Vacuum Forming is one of the

most common methods of producing low-high volumes of moulded useful forms that play a major role in our lives.

Sourbh 5 months ago

Requested by Ganesh, Lifter's and slider's

1. Step 1

Aha You asking Lifters and Slider in Terms of mould Design,

Dear Ganesh, First I wish to tell you that We not able to compare the lifter's andslider's because They are Different from each other, Area wherever its Employed..!!

I already Stated in my tutorials that A simple mould In which outer side of Component



having Undercut in Periphery, Needs the CAM Actuation that is Slider Mechanismworking there for Actuating the side and after Ejector's were Employed to Eject theComponents,

But at the same time Inner side also having the Undercut means we Employ the

Lifter's mechanism,

In Simple Language, Lifter's are the Clever modification of the normal Ejection systemthat Allows undercut feature in the core to be ejected from the mold. A Lifter's is anejector pin set into the core at an angle. Attached to the end of the ejector pin is ablock of steel that contains the undercutting feature. as the Ejector plate move forward

the ejector moves forward and slide way simultaneously, due to the angle on the lifterpin. this slide way motion motion eventually frees the hook(undercut) on the vent . The Lifter maintain the contact with the part during the Entire Ejection phase andactually assists the other ejectors in pushing the part off the core. for this reason, partsthat have a large number of lifters often need little or no regular ejection.

Finally the Conclusion is the Lifter's and sliders are two Different thing Employed forUndercut, One is for Internal Undercut (Core side) and second is for Outer Undercut(also called CAM actuated mechanism).

You able to Employ both of it in same Mould, or use any one of them with respect to

Easy Ejection of parts without rupture. Product Safety is Must.

Best Sourbh Kumar India



Sourbh 4 months ago

Here is the some example part for injection blow moulding

1. Step 1

fuel container`

2. Step 2

Jar



Kianoush 4 months ago

Very useful


Thanks dear Kianough, Please let me know if you need any answer related to anymoulding technique.

am ready to help you enerytime.

BoByS 7 months ago

I think that you need to write a book with your knowledge! Thanks for sharing this

information!

suresh.s 4 months ago

Sourbh Please share some knowledge about lifters & sliders ..............and how to find the



angle of lifter?

Sourbh 4 months ago

So Request is here for the Lifter's and slider's.

Today am gonna show you and to explain you that how is the Slider works and how wecalculate the angle of its with respect to our moulding part.

1. Step 1

Split:- The mould designer is frequently comforted with a component design that incorporate a recess or projection which prevents the simple removal of the mouldingfrom the Mould.

The component designer, while endeavoring to produce in line of draw componentdesigns, has often to include a recess or a projection to perform a particular functionor to satisfy on artistic requirement.

"A moulding which has recess or a projection is termed as undercut moulding" . The mould design for this type of component is inevitably more complex than for the in

line of draw component, as it necessitates the removal of that part of the impressionwhich forms the undercut prior to ejection.

2. Step 2

I will upload the remaining tutors soon..!!

Wait for it

huuhoa 4 months ago

thank you share


welcome dear



Sourbh 3 months ago

Requested by Sam

1. Step 1

Details 2D-Requested

Sourbh 15 days ago

The mold flow express Tutorials here.

1. Step 1

" https://grabcad.com/questions/mould-flow-training "

Sourbh 9 days ago

Mold calculator is in downloads:-

If you have any doubt than feel free to ask..!!



1. Step 1

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