Injection_mold_tooling通用公司.ppt

1、,GE Plastics,Injection Mold Tooling,e,GOOD PART,Tooling Considerations,RESIN SUPPLIER,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 Dimension

2、al 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 and Practices of the Mol

3、dmaking Industry,Classifications of Injection Molds for Thermoplastic Materials A Guide for the Purchaser or Manufacturer of Thermo- plastic Injection Molds Up to 400 Tons and 400 tons and over.,S I,P,Tooling Development,Moldmakers Division The Society of the Plastics Industry 1275 K Street, N.W., S

4、uite 400 Washington, DC 20005 (202) 371-5200,Tooling Development,MOLD TYPES,Tooling,Types of Molds (Tools) (Dies),“A” Series “B” Series “T” Series “X” Series Class A Class B Collapsible Core Two Plate Three Plate,Acceleration KO “A” Side Injection Lifter CAM Runnerless - Internally Heated - External

5、ly Heated Prototype MUD Etc.,Tooling Mold Types,Tooling Mold Types,Two Plate Design Exploded View,Support Plate,Ejector Plate,Leader Pin,Return Pin,Tooling Mold Types,Two Plate Design,Tooling Mold Types,Standard Two Plate Mold,Sprue Bushing,“A” Plate,Clamping Plate,“B” Plate,Support Plate,Ejector Pl

6、ate,Tooling Mold Types,Parting Line,Tooling Mold Types,Two Plate Mold Ejection,Tooling Mold Types,Two Plate Mold Ejection,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,Thr

7、ee Plate Design,Tooling Mold Types,Three Plate Design,Closed,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,Parting Line 3,Part,Runner,SPRUE BUSHINGS,

8、Tooling Sprue Bushings,Heated Sprue - Helical Heaters - Gas Pipe 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

9、 Molten Portion of Runner,Outer Skin Chills on Contact with mold Surface,Runners Flow,Tooling Runners,Runners Design,Full Round Most Efficient,Trapezoidal Good,Half Round Not Good,PL,Tooling Runners,R,D,R,D,RD W D 1/83/161/8 3/161/43/16 1/45/161/4 5/167/165/16 3/81/23/8,Equivalent Round Runner,Desig

10、n Alternative,Tooling Runners,Sprue Puller,REVERSE TAPER BEST,Z PULLER GOOD,GROOVE TROUBLE- SOME,SUCKER PIN NOT RECOMMENDED,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

11、,Q Proportional to R2,n R P,2,Tooling Runners,Flow Direction,Cold SlugWell,Round Cross Section (3/16 “ to 3/8 “ Dia.) Short Length Cold 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,Balan

12、ced System,Tooling Runners,RUNNERLESS MOLDING,Tooling Runnerless Molding,Hot Runner Benefits 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:,INCOEKONA D-M-EPL

13、ASTHING Hot OneRAMA Cool OneHUSKY MOLDMASTERFASTHEAT SPEAR EUROPE & ASIA,SPRUELESS,HOMEMADE,Compression Seal,Plug Moldmakers Choice,Diameter Fit Seal,Tooling Runnerless Molding,Cavity Plate = 500,Manifold = 5000,Thermal Expansion of Steel .00000633 Per Inch Per Degree,6 in. = .017 In. 12 in. = .034

14、In. 18 in. = .051 In.,Tooling Runnerless Molding,GATING,Tooling Gating,Direct Sprue Gate Edge Gate Fan Gate Tunnel Gate Single, Multiple Tab Gates Disk Gate Ring Gate,Flash Gate Diaphragm Gate Modified “S” Gate Pin Gate Jump Gate Valve Gate Etc.,Types of Gating,Tooling Gating,Direct Sprue Gate,Molde

15、d Part,Sprue,Tooling Gating,PART,RUNNER,GATE,LAND,Fan Gate,Tooling Gating,COLD SLUG WELL,RADIUS,Fan Gate,Tooling Gating,Edge Gate,Tooling 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 Diaph

16、ragm Gate,Runner,Part,Runner,Sprue,Tooling Gating,Tooling Gating,Gate,Part,Runner Disk,Gate,Ring Gate,Runner,Parallel Runner,Gate,Flash Gate,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 Ou

17、t 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 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,Bus

18、hings are Opened for Injection,Injection Molding Tooling,Valve Gate Shut Off System,A Fills, Bushing A Closes,Injection Molding Tooling,Valve Gate Shut Off System,B Fills, Bushing B Closes,VENTING,Tooling Venting,Parting Line,.001-.0025 Depth,Gate,Vent,.060 Min.,Note Step,.500,.050Min.,Tooling Venti

19、ng,Clearance Around Knockout,.0025,Ejector Pin,Tooling Venting,TEMPERATURE CONTROL,Tooling Temperature Control,The Most Efficient Cooling Systems 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

20、 Area,Heat Transfer Efficiency Water Coolant,0.5,1.0,1.5,2.0,Laminar,Flow,Tooling Temperature Control,120,125,125,135,135,145,130,140,140,130,150,145,O,O,O,O,O,O,O,O,O,O,O,O,IN,OUT,Tooling Temperature Control,Balanced Cooling Uniform Cooling Maximum Temperature Differential of 10 oF,Tooling Temperat

21、ure Control,Injection Molding Tooling,Mold Cooling Series Bubbler,IN,OUT,POOR,Pin,Blade,Injection Molding Tooling,Mold Cooling Parallel Bubbler,IN,Correct,OUT,Pin,Tube,EJECTOR MECHANISMS,Tooling Ejector Mechanisms,Pin Diameter is as Large as Possible Pins Are as Numerous as Possible Pins Exert a Uni

22、form Force on Molded Parts,Tooling Ejector Mechanisms,Factors Effecting Ejection Force,Sidewall Draft Sidewall Contact Area Sidewall Polish/Texturing Degree of Packing Mold Temperature Mold Release,Tooling Ejector Mechanisms,TEXTURING AND DRAFT ANGLE,Tooling Texture and Draft Angle,DRAFT ANGLE,DRAFT

23、 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 Angle,Quality of Texture Varies with Type of Steel Identical Grades of Steel Can Etch Differently,Texturing Guidelines,Tooling Texture and Draft

24、 Angle,Enhances Styling and Aesthetics Reduces Rejects,Texturing Mold Finishes,Tooling Texture and Draft Angle,CORE PULLS,Tooling Core Pulls,Hydraulic Core Pulls,Tooling Core Pulls,Tooling Core Pulls,Tooling Core Pulls,Tooling Core Pulls,PROTOTYPING,Tooling Prototyping,Prototype Tool Materials Alumi

25、num Beryllium Alloys Mild Steel P20 Steel,Thermal Conductivity (BTU/hr ft oF) 95 65 26 21 9.4,2,Aluminum Thermal Conductivity Is 4.5 Times That of P20 Steel,Tooling Prototyping,Parts Cool More Quickly in Aluminum Tooling Parts Shrink Less in Aluminum Tooling,Shrink Is Different in Steel and Aluminum

26、,Tooling Prototyping,Choose Prototype Tool Materials After Consideration of :,Dimensional Criteria of Part,Surface Finish Required,Wear Resistance,Tooling Prototyping,Part Design Dictates Performance Performance Dictates Material,Tooling Summary,Plastic Part Production,Material Dictates Tooling,Tool

27、ing Summary,Mold Design,GOOD PART,Tooling Considerations,GE Plastics,EJECTOR MECHANISMS DESIGN,80 to 100 In Sidewall Contact PIN DIAMETER 1/8” 1/4” 3/8”,REQUIRES PIN BEARING SURFACE 1 in2 1 in2 1 in2,1 In Pin Bearing Surface NUMBER OF PINS 82 20 9,2,2,Tooling Ejector Mechanisms,INTERNAL THREAD,SNAP

28、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 Mechanisms,Blade at Deep Ribs,Rounds Pins,Sleeve Ejector,Boss,Eject,Mold Pin Stationary,Parts,Stripper Plate,Stationary Force,Knock Out Bars,GOOD KNOCK OUT FOR ROUND PARTS,USED AROUND PINS & BOSSES,Tooling Ejector Mechanisms,EFFECT OF THICKNESS ON SHRINKAGE,0.06,0.125,0.25,2,4,6,8,8,10,1