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1、,GE Plastics,Injection MoldTooling,e,GOODPART,Tooling Considerations,RESINSUPPLIER,END USER,MOLDER,MOLD MAKER,Tooling Considerations,TOOLING DEVELOPMENT,Tooling,Processing Problems,Black Specks Gloss Jetting Delamination Fingerprinting Plate-Out,Tooling Development,Weld Lines Burn Marks Dimensional
2、Control Streaking Sticking Brittleness,Processing Problems,Tooling Development,Processing Problems,Tooling Development,Inconsistent Cycle,THE WORST PROBLEM,Processing Problems,Tooling Development,-Anonymous,“TheCHEAPESTToolis The OneThatWORKS”,Tooling Development,Customs andPracticesof theMoldmaking
3、 Industry,Classificationsof InjectionMolds forThermoplasticMaterialsA Guide for the Purchaseror Manufacturer of Thermo-plastic Injection MoldsUp to 400 Tons and 400 tons and over.,S I,P,Tooling Development,Moldmakers DivisionThe Society of the Plastics Industry1275 K Street,N.W.,Suite 400Washington,
4、DC 20005(202)371-5200,Tooling Development,MOLD TYPES,Tooling,Types of Molds(Tools)(Dies),“A”Series“B”Series“T”Series“X”SeriesClass AClass BCollapsible CoreTwo PlateThree Plate,Acceleration KO“A”Side InjectionLifterCAMRunnerless-Internally Heated-Externally HeatedPrototypeMUDEtc.,Tooling Mold Types,T
5、ooling Mold Types,Two Plate DesignExploded View,Support Plate,Ejector Plate,Leader Pin,Return Pin,Tooling Mold Types,Two Plate Design,Tooling Mold Types,StandardTwo PlateMold,Sprue Bushing,“A”Plate,Clamping Plate,“B”Plate,Support Plate,Ejector Plate,Tooling Mold Types,Parting Line,Tooling Mold Types
6、,Two PlateMoldEjection,Tooling Mold Types,Two PlateMoldEjection,Ejected Part,Injection Molding Tooling,Injection Molding Tooling,Tooling Mold Types,Support Plate,Ejector,Retainer Plate,Ejector Plate,Ejector Housing,B Plate,X Plate,A Plate,Three Plate Design,Tooling Mold Types,Three Plate Design,Clos
7、ed,Tooling Mold Types,Main Leader Pin,Parting Line 1,Tooling Mold Types,Parting Line 1,Parting Line 2,Tooling Mold Types,Parting Line 1,Parting Line 2,Tooling Mold Types,Parting Line 1,Parting Line 2,PartingLine 3,Part,Runner,SPRUEBUSHINGS,Tooling Sprue Bushings,Heated Sprue-Helical Heaters-Gas Pipe
8、 Non-heated Sprue,SPRUE BUSHINGS,Tooling Sprue Bushings,COLD SPRUE BUSHING,Tooling Sprue Bushings,SPRUE BUSHING,Gas Pipe,Tooling Sprue Bushings,Hot Sprue Bushing,Tooling Sprue Bushings,RUNNERS,Tooling Runners,Material Flows Only Through Molten Portion of Runner,Outer Skin Chills on Contact with mold
9、 Surface,Runners Flow,Tooling Runners,Runners Design,Full Round MostEfficient,TrapezoidalGood,Half RoundNot Good,PL,Tooling Runners,R,D,R,D,RD W D1/83/161/83/161/43/161/45/161/45/167/165/163/81/23/8,Equivalent Round Runner,Design Alternative,Tooling Runners,Sprue Puller,REVERSETAPERBEST,Z PULLERGOOD
10、,GROOVETROUBLE-SOME,SUCKER PINNOTRECOMMENDED,Tooling Runners,RESTRICTIVE,PREFERRED,Tooling Runners,A small increase in radius dramatically increases the flow through the runner.,R=Radius,Q=Volumetric Flow Rate,Q=,8nL,Q Proportional to R2,n R P,2,Tooling Runners,Flow Direction,Cold SlugWell,Round Cro
11、ss Section(3/16“to 3/8“Dia.)Short LengthCold Slug Wells,Cold SlugWell,Tooling Runners,Unbalanced System,A,A,A,A,B,B,B,B,Tooling Runners,Artificially Balanced,1/8”,1/4”,3/8”,1/2”,1/2”Dia”,Tooling Runners,Balanced System,Tooling Runners,RUNNERLESS MOLDING,Tooling Runnerless Molding,Hot Runner Benefits
12、 Faster Cycles-15-20%Faster Eliminates Material Waste-No Sprues or Runners Improves Part Quality-Less Stress-Better Appearance,Tooling Runnerless Molding,RUNNERLESS MOLDING SYSTEMS:,INCOEKONAD-M-EPLASTHING Hot OneRAMA Cool OneHUSKYMOLDMASTERFASTHEATSPEAR EUROPE&ASIA,SPRUELESS,HOMEMADE,Compression Se
13、al,PlugMoldmakersChoice,Diameter FitSeal,Tooling Runnerless Molding,Cavity Plate=500,Manifold=5000,Thermal Expansion of Steel.00000633 Per Inch Per Degree,6 in.=.017 In.12 in.=.034 In.18 in.=.051 In.,Tooling Runnerless Molding,GATING,Tooling Gating,Direct Sprue GateEdge GateFan GateTunnel GateSingle
14、,MultipleTab GatesDisk GateRing Gate,Flash GateDiaphragm GateModified“S”GatePin GateJump GateValve Gate Etc.,Types of Gating,Tooling Gating,Direct Sprue Gate,Molded Part,Sprue,Tooling Gating,PART,RUNNER,GATE,LAND,Fan Gate,Tooling Gating,COLD SLUGWELL,RADIUS,Fan Gate,Tooling Gating,Edge Gate,Tooling
15、Gating,Single Tab Gate,Multiple Tab Gate,Gate,Tab,Sprue,6 in.Max,12 in.Max,Tab,Sprue,Gate,Gate,Tab,Tooling Gating,Multiple Tab Gate,Tooling Gating,Disk or Diaphragm Gate,Runner,Part,Runner,Sprue,Tooling Gating,Tooling Gating,Gate,Part,Runner Disk,Gate,Ring Gate,Runner,Parallel Runner,Gate,Flash Gate
16、,Parallel Runner,Tooling Gating,0.020 Land Length,0.050,900,Tooling Gating,Pin Point Gating,Molded Part,Sprue,Parting Line,Tunnel,Gate,Zero Land Length,Knock Out Pin,Grind Flat on Gate Side,Min.20,Fasten Pin Head To Prevent Turning,Tunnel Gate,Tooling Gating,Tunnel,Knock Out Pin,Tunnel Gate,Tooling
17、Gating,R,R,Gate,Cashew Gate,Tooling Gating,Knit Line,Gate Area,Tooling Gating,Knit Line and Gate Area,Injection Molding Tooling,Valve Gate Shut Off System,Bushings are Opened for Injection,Injection Molding Tooling,Valve Gate Shut Off System,A Fills,Bushing A Closes,Injection Molding Tooling,Valve G
18、ate Shut Off System,B Fills,Bushing B Closes,VENTING,Tooling Venting,Parting Line,.001-.0025Depth,Gate,Vent,.060 Min.,Note Step,.500,.050Min.,Tooling Venting,Clearance Around Knockout,.0025,Ejector Pin,Tooling Venting,TEMPERATURECONTROL,Tooling Temperature Control,The Most Efficient Cooling Systems
19、Are Those Which Operate Such That The Inlet and Outlet Coolant Temperatures Are Within 100 Of Each Other,Fluid Velocity Ft./Sec.,Turbulent Flow,Transition Area,Heat Transfer EfficiencyWater Coolant,0.5,1.0,1.5,2.0,Laminar,Flow,Tooling Temperature Control,120,125,125,135,135,145,130,140,140,130,150,1
20、45,O,O,O,O,O,O,O,O,O,O,O,O,IN,OUT,Tooling Temperature Control,Balanced Cooling Uniform CoolingMaximum Temperature Differential of 10 oF,Tooling Temperature Control,Injection Molding Tooling,Mold Cooling Series Bubbler,IN,OUT,POOR,Pin,Blade,Injection Molding Tooling,Mold Cooling Parallel Bubbler,IN,C
21、orrect,OUT,Pin,Tube,EJECTOR MECHANISMS,Tooling Ejector Mechanisms,Pin Diameter is as Large as PossiblePins Are as Numerous as PossiblePins Exert a Uniform Force on Molded Parts,Tooling Ejector Mechanisms,Factors Effecting Ejection Force,Sidewall DraftSidewall Contact AreaSidewall Polish/TexturingDeg
22、ree of PackingMold TemperatureMold Release,Tooling Ejector Mechanisms,TEXTURING AND DRAFT ANGLE,Tooling Texture and Draft Angle,DRAFT ANGLE,DRAFT ANGLE,1/2o MIN,Tooling Texture and Draft Angle,Additional 1 Degree per Mil in Depth of Texture,Draft Angle for Textured Sidewall,Tooling Texture and Draft
23、 Angle,Quality of Texture Varies with Type of SteelIdentical Grades of Steel Can Etch Differently,Texturing Guidelines,Tooling Texture and Draft Angle,Enhances Styling and Aesthetics Reduces Rejects,Texturing Mold Finishes,Tooling Texture and Draft Angle,CORE PULLS,Tooling Core Pulls,Hydraulic Core
24、Pulls,Tooling Core Pulls,Tooling Core Pulls,Tooling Core Pulls,Tooling Core Pulls,PROTOTYPING,Tooling Prototyping,PrototypeTool MaterialsAluminum Beryllium AlloysMild SteelP20Steel,Thermal Conductivity(BTU/hr ft oF)956526219.4,2,Aluminum Thermal Conductivity Is 4.5 Times That of P20 Steel,Tooling Pr
25、ototyping,Parts Cool More Quickly in Aluminum ToolingParts Shrink Less in Aluminum Tooling,Shrink Is Different in Steel and Aluminum,Tooling Prototyping,Choose Prototype Tool Materials AfterConsideration of:,Dimensional Criteria of Part,Surface Finish Required,Wear Resistance,Tooling Prototyping,Par
26、t Design Dictates PerformancePerformance Dictates Material,Tooling Summary,Plastic Part Production,Material Dictates Tooling,Tooling Summary,Mold Design,GOODPART,Tooling Considerations,GE Plastics,EJECTOR MECHANISMS DESIGN,80 to 100 InSidewall ContactPIN DIAMETER1/8”1/4”3/8”,REQUIRESPIN BEARING SURF
27、ACE1 in21 in21 in2,1 In PinBearing SurfaceNUMBEROF PINS82209,2,2,Tooling Ejector Mechanisms,INTERNAL THREAD,SNAP LID,COMMON UNDERCUTS,Tooling Ejector Mechanisms,Detail on Side,External Thread,COMMON UNDERCUTS,Tooling Ejector Mechanisms,Latch or Hook,Bobbin or Spool,COMMON UNDERCUTS,Tooling Ejector M
28、echanisms,Blade atDeep Ribs,Rounds Pins,SleeveEjector,Boss,Eject,Mold PinStationary,Parts,Stripper Plate,Stationary Force,Knock OutBars,GOOD KNOCK OUTFOR ROUND PARTS,USED AROUNDPINS&BOSSES,Tooling Ejector Mechanisms,EFFECT OF THICKNESS ON SHRINKAGE,0.06,0.125,0.25,2,4,6,8,8,10,12,14,6,0,(VALOX 420),
29、A,B,B,A,-Direction of flow-Cross Flow Direction,Melt Temp,500 F(260 C)Mold Temp,150 F(66 C)Pressure 12,500 psiCycle Time 22 Sec,Thickness,Mils,Shrinkage,Mils/Inch,Shrinkage,Mils/Inch,O,O,O,O,A,B,GE Plastics,Some Other Options,e,104,TEMPERATURE CONTROLBASIC FOUNTAIN(BUBBLER),See ProcPict andSWProc fo
30、r otherOptions.,TEMPERATURE CONTROLBAFFLE EXTENSION FOR SLENDER CORE,GATING PIN GATE/THREE PLATE MOLD,RUNNER,PARTINGLINE,GATE,PARTINGLINE,.125-.250”,5,.100,.250”Flow,HOT SPRUE GATING,Heating Element Should Be fullyExtended to EnsureEven Heating,0,GatingLocation,Gate,Gate Location is stronglyinfluenced by the glass contentof the material.,End Gating is preferred in glass filled materials to minimize warpage.,RUNNERSBalanced Layout PreferredPrimary-Full Round or Trapezoidal.375-10”Long or Above.312-3”to 10”.250-3”or UnderSecondary-250 Minimum,GE Plastics,g,Injection MoldTooling,
