Parts plastic mold design and preparation process

Summary The present subject is mainly designed for the cover mold, plastic parts by
analysis and comparison process, the final design of an injection mold. The subject of the
process from the product structure, particularly the structure of the mold starting checking
the selection of the mold casting system, the structure of the molding portion of the mold,
the ejector system, cooling system, the injection molding machine and related parameters,
are detailed design, while and a simple preparation process of the mold. Indicating that
the entire design process through the die to achieve this plastic processing required. The
main task of the subject design is the design of the injection mold cover. Which is
designed to cover an injection mold to produce plastic products to automate increase
production. For a specific configuration of the lid, the mold is a double-point gate injection
mold parting surface. Since there are four small plastic inner bosses, the angle pin can not
be set, using structure activity solid inserts. The advantage that the simplified mechanism,
the shape of the mold reduced, greatly reducing the manufacturing cost of the mold. The
mold design shows through a die to achieve lid quality and processing requirements.

Categories mold cover mold

Abstract This topic mainly aimed at the mold design of plastic lid. Through the analysis
and comparison of the plastic product, the plastic mold was designed. This topic came
from the technology capability of product, the structure of the mold embarks, the pours
system, the injection molding system and the related parameter examination, the mold
took shape the partial structures, the against system, the cooling system all had the
detailed design, at the same time, the processing craft of the mold were simply
established. Through the entire process of the design indicated this mold can achieve the
processing craft which the plastic lid requested.

Key words plastic mold the plastic lid mold

1 Introduction
With the gradual improvement in China's current economic situation, in advocating cited
"the great rejuvenation of the Chinese nation" slogan, China's manufacturing industry has
become increasingly flourish; and mold technology has become an important symbol to
measure a country's level of manufacturing First, the mold industry can promote the
development of industrial production and improve the quality of, and access to great
economic benefits, which attracted great attention and appreciation of each country. In
Japan, the mold known as the "driving force into the affluent," the German crown as the
"emperor of the metal processing industry", is more direct in Romania: "Mold is Gold."
Visible mold industry an important position in the national economy. Our country mold
industry also attaches great importance, as early as March 1989 promulgated the
"Decision on current national industry policy points" in, put the development of mold
technology as the primary task of the machinery industry.
In recent years, the level of development and production of plastic mold very fast,
high efficiency, automation, large-scale, long life, precision molds the war in the mold
production in the proportion is growing. Plastic injection mold is first applied to the heating
cylinder of the injection molding machine, the plastic is melted with heat, at a screw or a
piston driven injection molding machine, the nozzle and the mold through the gating
system into the mold cavity, wherein the cured plastic forming.
The main task of this design is that the lid injection mold design. Which is designed to
cover an injection mold to produce plastic products to automate increase production.
Specific structure of the lid, through the design, so I designed two-point gate parting
surface of the mold have a deeper understanding. Meanwhile, in the design process, the
lot of information, manuals, standards, and journals, binding materials also knowledge of
the structure of the injection mold the composition (molded parts, injection system, the
guide portion, pushing mechanism, the exhaust system, the mold temperature Control
system) system has been understanding, broaden horizons, enrich knowledge for the
future independently mold design has accumulated some experience.

2 technical requirements and process analysis

2.1 Technical Requirements
2.1.1 Product design
Design shown in Figure 1, Figure 2 and Figure 3.

1 a plan view of FIG. 3D Product

2 a bottom view of 3D products

Figure 2D Figure 3 products

2.1.2 Technical requirements

The material is a plastic part PE (polyethylene) white, not dent the surface requirements.
It has three dimensions with a precision requirements this plastic parts: the part with a
plurality of precision sizes, namely:
68.2 + 0.75, 5.2 + 0.28, 0.52 + 66 are MT7 precision grade plastic, moderate level of
accuracy in mold design and manufacturing process to ensure that the strict accuracy of
these dimensions.
Size precision is no remaining free size, can be taken to check the accuracy of the
tolerance level MT10 values.

2.2 Analysis Process plastic parts

2.2.1 Process of the structure of plastic parts:

See a cover size, 71mm × 52mm external dimensions formed integrally Figure II and to
the corner of a rectangular body, but the interior of a rectangular chamber is 1.2mm high
with a width of four 1mm wide rectangular boss configuration, the cover are external
accessories , higher surface accuracy, dimensional accuracy is not required.
2.2.2 Analysis of plastic parts Process
(1) The larger the size of plastic parts and plastic parts requires high surface
precision level, no dents. Point gate runner double injection mold parting surface of the
cavity surface accuracy can be guaranteed.
(2) the plastic mass is small, plastic parts and more complex shapes. Processing and
heat treatment in order to reduce costs, the use of structural plastic parts activity inserts,
simplify the structure, reduce the cost of the mold.

2.3. Process of plastic material

This lid is the use of PE (polyethylene) is injection molded. Check the relevant manuals
known
Polyethylene plastic is plastic industry, the largest output of varieties. Pressing force
employed in the polymerization can be divided into high, medium and low three.
Low pressure polyethylene is relatively hard, wear and corrosion resistance, good heat
resistance and insulation. Polyethylene odorless, milky white. Polyethylene certain
mechanical strength, but low compared to other plastics and its mechanical strength, poor
surface hardness. Polyethylene has a high degree of water resistance. Polyethylene by
heat, light, oxygen will produce aging and embrittlement. Temperature low-pressure
polyethylene 100 ℃ about. Polyethylene cold, -60 ℃ When still a good mechanical
properties, -70℃There is still some flexibility at the time.
Common thermoplastic molding characteristics
When polyethylene molding shrinkage in the direction perpendicular to the flow direction
quite different. Shrinkage direction of injection is greater than the yield in the vertical
direction, the deformation is easy to produce, and increased brittleness of the plastic
portion around the gate; large absolute value of the shrinkage of polyethylene, mold
shrinkage is large, easy to produce shrinkage can forcibly release soft easy to mold,
plastic parts have a shallow undercut when;; cooling rate must be sufficiently cooled, and
the cooling rate should be uniform.
2.4 molding process of

Check "mold design and manufacturing Cookbook" p.280 Table 2-31 conventional
plastic injection molding process parameters:
Preheating and drying temperature: 80-120℃Time: 1-2 hours; cylinder temperature:
160-180 rear section℃, Middle: 180-200℃, Anterior 200-220℃; Mold temperature:
80-90℃; Injection pressure: 700-1000 kgf / cm2 ㎡; molding time: 20-60 seconds injection
time, dwell time of 0-3 seconds, a cooling time of 20-90 seconds, 50-160 seconds total
cycle; screw speed: 48 rpm /Minute. Without post-processing.

3 to develop programs and molding operation principle

Determining the position of the parting surface 3.1

How to determine sub-surface factors to be considered more complex. Since the

parting plane in the mold by plastic molding impact position, various factors gating system
design, structure and technology of precision plastic parts, the shape and position of the
insert Release method of manufacturing a mold, the exhaust gas, the operating process
or the like Therefore a comprehensive analysis should be selected comparison parting
surface, the preferred embodiment from several reasonable solution. General should
follow the following principles when selecting sub-surface:
a) Ensuring that the plastic article can release
This is an important principle, because we set the purpose of sub-surface, it is to be able
to successfully emerge from the cavity products. According to this principle, it should be
preferred in the parting surface of the plastic article maximum contour line, preferably on a
plane, and the plane perpendicular to the mold opening direction. Typing entire profile was
reduced tendency should, should not affect the release of the concavo-convex shape, so
as not to affect the release.
b) reacting the shallowest depth of the cavity
Depth of the cavity size of the mold has the following three aspects affect the structure of
the mold and manufacturing:
1) currently processing a multi-cavity mold using EDM machining, the deeper the pocket
longer processing time, affecting the production cycle the mold, while increasing the cost
of production.
2) Effect of the depth of the mold cavity thickness of the mold. The deeper the cavity, the
thicker the movable, stationary mold. Processing the one hand more difficult; on the other
hand the maximum thickness of the various injection mold machine has a limit, so the
depth of the cavity should not be too large.
3) the deeper the depth of the cavity, at the same draft angle, the greater the upper and
lower ends of the same size the actual size difference, as shown in FIG 2. To control a
predetermined dimensional tolerances, it is necessary to reduce the draft angle, leading to
difficulties in the release of plastic parts. Therefore, when selecting the parting surface so
that the cavity depth as the shallowest.
c) allowing the plastic appearance, easy to clean
While the plastic mold with a very precise, but plastic parts demolding, will be in the
position of the parting surface of the burr left turn, we call burrs. Even cut off immediately
after the release of these burrs, but will still leave marks on the plastic parts, plastic parts
affect the appearance, it should avoid parting surface provided on the smooth surface of
the plastic parts, a position of the parting surface in FIG. 3, the plastic back piece cut off
edges, leaving traces in the plastic surface smooth; b position of the parting plane of FIG.
3 in a variation on the cross section, cut off the burr while still marks, but it seems obvious,
it should choose the latter.
d) to avoid side core

Injection molding, should be avoided as far as possible side core, because the core mold
side draw complicated structure, and directly affect the size of plastic parts, with accuracy,
time-consuming and is expensive, manufacturing costs increase significantly, it may not
have been in Wan to use in the case.

e) contacting the parting surface easily processed

Parting surface accuracy is an important part of the whole mold precision, flatness and
seeks movable parallel to the mating surfaces of the stationary die within tolerance.
Accordingly, the parting surface should be plane and perpendicular to the release
direction, so that the machining accuracy is guaranteed. The selection parting surface
beveled or curved, processing difficulty increases, and the accuracy can not be
guaranteed, easily lead to the phenomenon of flash burr.
g) that the side core as short as possible

Pulling shorter, the shorter the moving distance of the swash pump, on the one hand to
reduce dynamic, a thickness of the fixed mold, plastic parts to reduce the dimensional
errors; beneficial release hand, ensure precision plastic products.
h) in favor of exhaust

Of medium and small plastic parts due to smaller cavity, small amount of air, the exhaust
gas may be slit by the parting surface. Thus, when selecting an exhaust facilitate parting
surface. This principle, the parting surface should be located in the injection position and
finally to the molten plastic, the cavity is closed and does not
In summary, the injection mold parting surface choose many factors influence the total
release requirement is smooth, technical requirements to ensure that plastic parts, simple
structure and easy to manufacture mold. When you have selected a sub-surface scheme,
there may be some disadvantages, and then take other measures to make up for the
problems, to select close to the ideal parting surface.

3.2 molding listed programs

For the design of the lid injection mold, forming the following three options are available:
3.2.1 Option One
(1) parting surface: AA is a first parting surface; BB is a second parting surface, the
movable core and the movable model form the inner shape of the insert, forming the
external shape of the heart given model; parting surface position of Figure 3;
(2) arranged in the cavity: one uses a mold cavity, see Figure 3;
(3) the gating system: water intake from the center, shown in Figure 3;
(4) Exhaust: includes vent;
(5) adjusting the mold temperature: natural cooling;
(6) pulling mechanism: a core consisting of the main core and the insert metal, the core
automatic prolapse, insert events manually removed
(7) a release mechanism: the release of the push plate, the push surface BB.

3.2.2 Option II
(1) parting plane: As shown in FIG 3, AA is a first parting surface; BB second parting
surface;
(2) the cavity is arranged: using a two cavity mold; Figure 4
(3) the gating system: water intake from the side, Figure 4;
(4) Exhaust: includes vent;
(5) adjusting the mold temperature: natural cooling;
(8) pulling mechanism: the inner pumping mechanism Xinxie

3 a schematic view of the cover of FIG product

FIG schematic poured into cover product 4

Selected programs molding 3.3

Comparative forming two schemes, the final selection of a program. This is because:
Scheme II as thin-wall parts belonging to the cover, directly into the water from the inside
of the lid is easy to ensure a smooth surface, but due to the injection pressure acts directly
on the plastic parts, is easy to produce a large residual stress caused at the feed tilt plastic
parts deformation. Small batch and belongs to cover cost savings. Thus the use of a
program
Further, the second solution provided good pulling mechanism. A scheme may be
employed to automatically eject plastic parts, the movable insert and then remove the
condensate feed by hand, so that smooth release plastic parts, and the two solutions
while pulling mechanism more efficient, but more complex, difficult to implement
automatic core pulling, cost high.
In summary, the molding was finally determined for a program.

3.4 Analysis of structure of the mold (FIG. 5)

Figure 5
3.5 Mold operation principle and structural characteristics
3.5.1 action principle
The point gate injection mold double parting surface of the mold. Mold opening, the first
parting plane under the action of a spacer guide post, to remain frozen material pulled off
in the given template. By the second parting surface, since the push plate under the action
of the hydraulic ram in the mechanism and the core member and the plastic insert metal
on the movable die is pushed down, the slide insert metal member with a plastic outer
mold Release mechanism is pushed together and the movable insert special tools or
manually removed from the plastic member, (for the activities placed sequentially insert,
the push rod must be previously reset.) for setting them in the mold cavity injection
molding.

3.5.2 Structural features

Shaped portions: a movable die core 14, the movable insert 11 and the insert metal 12
formed plastic parts of the internal structure, the stationary platen cavity 6 is formed in the
outer structural plastic parts.
Pouring system: cold runner configuration, condensate material feed system for an off
certain opening stroke. When the injection molding machine is suspended, the need for a
cold runner slug cleared.
Releasing mechanism: As can be seen from the schematic view of the plastic inner
member 3 has four small bosses. It can not be disposed obliquely or inclined guide post of
the slider. So the use of active insert 11, prior to the clamping position and manually insert
the movable platen 6. Mold opening, the first type under the action of a spacer guide post
will automatically pull out and pull off the frozen material in the stationary platen 6; the
second type is the active insert is pushed together with the plastic parts Release means
an outer mold tool and then removed with a plastic material and removal of condensate,
and then inserts the activities into the mold cavity for the next injection molding.
Reset mechanism: In the mold clamping process, the return spring action, so as to drive
the reset lever 18 pushes the lever plate is fixed and the push plate 19 is reset.
Cooling system: This injection mold plastic parts due to a simpler structure, it is provided
two annular cooling water.
Guide means: a guide portion of this injection mold there are mainly two: one is movable,
guided between the guide sleeve 13 of the stationary mold 10, and second fixed guide
post 8 from the fixed mold between the seat and the movable platen.
The exhaust system: exhaust parting surface.

Design 3.6, gating system

Pouring system can be divided into general casting systems and hot runner feed system
into two categories. The system controls the casting of plastic molding and filling process
of feeding two important stages of the quality of plastic great relationship. Gating system
means into the mold from the injection molding machine nozzle start, into the cavity until
the inlet flow passage that period.
A casting mold system common sprue, runner, gate, cold slug well of several parts.
3.6.1 sprue design
 Contacting the sprue nozzle made more hemispherical pits. Both should be closely
contacted to avoid overflow of a high pressure plastic, dimples spherical radius greater
than the radius of the nozzle ball 1-2mm; sprue small end large diameter should be about
0.5-1mm in diameter than the nozzle hole, often taking Ф4-8mm, depending on the article
size and feeding requirements of the decision. Larger diameter of the channels should be
more than the shunt large depth 1.5mm, its cone angle is not too large, and generally 2 ° ~
6 °.

3.6.2 gate design

Gate numerous forms, usually have edge gate, fan gate, gate seam, the ring gate,
gate spokes, point gate, submarine gate, gate ear, the sprue and the like. In view of the
specific configuration of the lid, the point selection gate.
For the design of the lid, because of its shape, although the rules, but more complex, are
small batch production. It is appropriate double parting surface point gate. Therefore, in
arranging a cavity, preferably in the form of a cavity of a mold to facilitate cost-saving
products, to simplify the mechanism. Size distribution and structure of the gating system
designed injection mold cover 6 as shown in FIG.

Figure 6 a schematic view point gate

By pouring point gate system, so that no cold slug well.

Select 4 injection molding machine and molded part designs

Select 4.1, the injection molding machine

The actual design in the plant design is different. The plant is already fixed in the injection
molding machine, mold designers typically are determined between a maximum yield of
the injection molding machine in the shop, that is to say the injection molding machine
plant selection is limited. In this design, we selected injection that is the principle of it is as
we expected product yield and the actual shape of the plastic parts to select any one of
the injection molding machine, the last school to meet the requirements of nuclear energy.
The same can also achieve the purpose of such training.
4.1.1 Calculation of the volume of the lid
The three-dimensional model of plastic parts, using three-dimensional software may
directly query the lid can be drawn Volume
V = 15043 mm3 cover
4.1.2 Quality of computing lid
Check "mold design and manufacturing Cookbook" P.276. Table 2-2 Main technical index
commonly known thermoplastic PE having a density of 0.91 ~ 0.96g / cm3, available mass
calculated lid
Lid M = 16.043 cm3 × 0.935g / cm3≈15g.
Injection volume V satisfies machine ≥V plastic parts /0.8
Where
Machine V - rated injection amount (cm2)
V plastic parts - plastic parts with a volume gating system and condensate material (cm2)
V plastic /0.8=15.043/0.8=18.8cm3

4.1.3 plastic injection machine parameters

Check "mold design and manufacturing Cookbook" P.103. Table 2-33 Model thermoplastic
injection and main technical specifications, and the total volume of the mass (2) can be
calculated primaries XS-ZS-22 machine. Plastic injection molding machine specification
parameters have the following Table 1
Screw (plug) Diameter (mm) 25,20

Nozzle sphere radius (mm) 12

An injection volume (cm3 or g) 30,20 hole diameter (mm) 2
Injection pressure (/ MPa) 75,115
Ejector ram has four sides, the top of the machine
Clamping force (/ kN) 250
Maximum injection area (cm2) 90
Mold Thickness (mm) 180 Maximum rod space (mm) 235
The minimum diameter of the positioning hole 60 (mm) Ф125 + 0.06

Table 1 The basic parameters of the plastic injection molding machine

4.1.4 selected from the standard mold

Based on the above analysis, and calculation of the position and size of the cavity size
may be determined structure and specifications of the formwork. Table look-up 7-1, 7-3
Selection:
A3-160160-18-Z2
Stationary platen thickness: A = 25mm
The thickness of the movable plate: B = 20mm
Fast pad thickness: C = 50mm
Mold thickness H = 40 + A + B + C = (56 + 25 + 20 + 50) mm = 151mm
Mold Dimensions 160mm × 160mm × 151mm

4.2, check the injection molding machine related parameters

4.2.1 injection pressure of check

Check "mold design and manufacturing Cookbook" P47 Table 3-1 Common
thermoplastics Injection Molding Parameters
Injection pressure 80MPa <115MPa (selected actual injection pressure of the injection
molding machine), desirable.

4.2.2 clamping force check

Clamping force means that when the high pressure melt filled the mold cavity, a large
force is generated in the cavity, so that trying to open up the mold parting surface, which is
equal to the plastic parts and runner system in the parting surface multiplied by the total
projected area of the plastic cavity pressure. Force acting on the surface less than the
rated clamping force injection molding machine F.
From (1) that the injection pressure of P0 = 75 ~ 115MPa (100 taken), the average
pressure of the actual mold cavity and the plastic melt flow path P = kP0 (k is the loss
factor, the range of 1/3 ~ 1/4 ), P0 = 0.3 × 100 = 30MPa projected area of plastic parts
FIG -2 probably be calculated from
A1 = 52.84 × 71.9 = 3796 mm2
Projected area of the gating system, pouring gate system as a point, so A2 ≈0
Therefore, the desired clamping force during injection lid
F = 3796 × 25 = 94.9KN <115KN;
Therefore, the clamping force is desirable.

4.2.3, the die mold and the injection molding machine to check the size of the relevant
portion
Injection molding machine mounting portion of various types of shape and dimensions
vary. Mold design should check main items are: nozzle size, positioning ring size, the
maximum mold thickness, the minimum thickness of the die and the die size of the
template plane mounting screw position size and the like. Now check the following:
a), nozzle diameter: sprue leading end diameter 3mm> nozzle hole diameter 2mm;
desirable
b), the positioning holes and the positioning ring size check: positioning ring diameter
100mm <125mm; desirable;
c), the maximum thickness and the minimum die thickness of die check: As can be seen in
FIG mold assembly:
A mold having a thickness of 151mm (60,180), desirable.
d), the planar size of the template and size of the mold mounting screw position check:
And the movable mold base plate dimensioned mold base plate are: 160mm ×
160mm, less than the size of the injection molding machine a value between four prism,
desirable.

4.2.4, and the opening stroke distance plastic check Release

Stroke injection molding machine mold is limited, the required articles taken out from the
mold must be less than the maximum distance from the injection molding machine mold.
From the mold can be divided in two categories check: First, the maximum injection
molding machine and the mold opening stroke irrespective thick; another is the maximum
opening stroke injection molding machine with a mold thickness related.
I checked should be checked in accordance with the first case, which is the basis for
checking
S H1 + H2 + a + (5 ~ 10) mm

among them,
Injection molding machine S-- maximum opening stroke, mm;
(XS-Zs-22 injection molding machine S = 160mm)
H1-- plastic release (Release distance) distance; mm
H2-- height plastic parts, including the gating system, mm
a - Remove frozen material required shortest distance mm

Referring to FIG lid injection mold assembly seen: H1 = 30mm, H2 = 11mm;

Obviously, S = 160> 30 + 11 + 33 + 10 = 84 mm, desirable.
This, the relevant process parameters have been checked by the injection molding
machine.

Design mold molding part 4.3

The cavity is formed directly on the plastic parts of the mold portion. All parts constituting
direct all parts of the mold cavity are referred to as molded parts, typically comprising: a
die, punch, forming stem, forming the ring, a variety of cavity inserts and the like.

FIG recess 7, a schematic view of the punch structure

4.3.1 the position of the parting surface and the cavity shape is determined:
Parting plane, simply put, is split mold extraction surface of the plastic parts.
Injection mold parting plane cover surface HH choice.
The structural characteristics of the cavity and core 4.3.2
Given the special structure of the lid, the lid molded part injection mold comprising: a
movable die core, fixed die core, the movable insert.
The reason for this choice is that: the outer cover, although the shape of the rules, but
more complex interior. Thus, using the activity should insert, the insert with four movable
therein to form a structure of four small bosses.
While the equivalent split mold core pulling. Four movable insert manually detached from
the parting surface.
This has the advantage that: (1) to avoid formation of complex structures to four small
bosses. Main core will remain in the movable mold side, just after the completion of
manually releasing the movable insert can be fitted.
Technical requirements: positioning between the insert and the core activities to be
guaranteed.
4.3.3 working dimension calculation molded part
Influence the dimensional accuracy of plastic parts is more complex factors, mainly the
following aspects
(1), part of the manufacturing tolerances;
(2), when the difference between the products and the production design and the
estimated actual shrinkage contraction ratio fluctuation;
(3), die wear during use. Impact of the above three areas expressed as follows:
1, a manufacturing error:△z = a • i = a (0.45 + 0.001D)
Wherein, D - the size of parts to be machined, molded dimensions may be considered to
be machined mold parts;
△ z - molded parts for manufacturing tolerance values; i - Tolerances;
a - coefficient accuracy, the most common mold manufacturing precision.
Molding shrinkage rate fluctuations 2
Wherein - plastic molding shrinkage; the LM - molding size; the LS - corresponding
dimension of plastic parts.
3 impact on the size of the cavity wear

For the sake of calculation, where the release direction perpendicular to the surface does
not consider the amount of wear, a direction parallel to the surface before the release of
the wear. Mainly of the wear life of the mold is selected from the wear values increase with
increasing production; Also, consider the case for steel wear plastic; taking also into
account the case of heat resistance and resistance to mold the mold material, the cavity
surface is chrome nitride. Data introduced maximum wear amount of the plastic parts
preferably sized molds 1/6 total error (often taking 0.02 ~ 0.05mm), whereas for large
mold should take 1/6 or less. But in fact the polyolefin (such as PP), nylon, plastic, etc. is
small to mold wear, for small plastic parts, the molded parts to a certain extent the amount
of wear on the total error of the plastic parts, and for large plastic parts for little effect.
On the basis of the above theory, the following average shrinkage of molding size
calculated:
(1) Calculation of the radial dimension of the cavity:
Richard polyethylene (PP) shrinkage of Sq = (1.5 ~ 2.0)%, so that an average shrinkage
rate: Scp = 1.75%

Taking into account the actual requirements of the actual mold production conditions and
the workpiece, the molded part is taken IT7 tolerance level
level.
Cavity working part dimensions:
Cavity radial dimension: L + δ2m0 = [(1 + s) Ls-XΔ] + δ20
Cavity Depth dimensions: H + δ2m0 = [(1 + s) Hs-XΔ] + δ20
Core radial dimensions: l0m-δ2 = [(1 + s) Ls + XΔ] 0-δ2
Core height dimension: H0-δ2 = [(1 + s) hs + XΔ] 0-δ2

Where
Ls - maximum size of plastic parts substantially radial exterior dimensions (mm)
ls - type size minimum size substantially radially inner plastic parts (mm)
Hs - plastic exterior dimension substantially the height of the maximum size (mm)
hs - minimum dimension in the depth dimension substantially plastic type (mm)
X - correction factor of 0.5 to 0.75
△ - tolerance plastic parts
δz- mold manufacturing tolerances and generally (1/3 ~ 1/4)△

a), the main dimensions of the movable core calculation model

In order to calculate the reference unity, according to general practice, a predetermined
cavity (hole) as nominal minimum LM, the size of the LS cover, a mold for manufacturing
tolerances δZ =△/ 3,
Radial: LM = (LS + LS • Scp-3/4△),
= (36 + 36 × 2% -3 / 4 × 0.16)
= 36.6
Longitudinal direction: HM = (HS + HS • Scp-2/3△)
= (47 + 47 × 2% -2 / 3 × 0.16),
= 47.74,
Local dimensions in accordance with the remaining shrinkage scaled accordingly.
b), the main core is sized computing model
Radial: LM = (LS + LS • Scp-3/4△),
= (36 + 36 × 2% -3 / 4 × 0.16)
= 36.6
Longitudinal direction: HM = (HS + HS • Scp-2/3△)
= (23 + 23 × 2% -2 / 3 × 0.13),
= 23.17,
Local dimensions in accordance with the remaining shrinkage scaled accordingly.
c), the main dimensions of the active core calculation
Radial: HM = (HS + HS • Scp-2/3△)
= (44 + 44 × 2% -2 / 3 × 0.13),
= 23.17,
Longitudinal direction: LM = (LS + LS • Scp-3/4△),
= (36 + 36 × 2% -3 / 4 × 0.13)
= 36.63
Local dimensions in accordance with the remaining shrinkage scaled accordingly.

5 ejection mechanism design

Lid parting type employed in the form of a spacer guide post. Thus, while the parting
surface of the opening, the slug is also moved together with the fixed plate, the slug away
from the sprue bushing. In the role of a spacer guide post, to remain frozen material pulled
off in the given template. To the second parting surface, and finally push plate because the
push rod under the action of the hydraulic mechanism and the core member and the
plastic insert metal on the movable die is pushed down, to complete the whole process of
injection molding.

5.1 Design of the spacer guide post means

5.1.1 a calculation
To guarantee both remove the plastic mold pieces can remove the slug in the flow path for
a dual injection mold parting plane, a need to increase the separation distance between
the stationary platen and the intermediate plate in the mold opening distance. The size
should be a guarantee can be easily taken out frozen material within the flow path. Slug
length is d = 15 + 14 + 4 = 33mm
. In response to this, a≥33mm

5.1.2 Selection guide post spacer

Guide post spacer length s = 15 + 25 + 20 = 60mm

Spacer guide post headroom k = 60-4-5-10 = 41mm≥33mm

The first requirement is satisfied parting surface.
5.1.3 The Allen screws within the parameters of the maximum tensile force from the guide
post EXAMINATION
Charles "Die practical technology integrated design manual" P.421. Table 2-31 shows the
corresponding maximum tension
M4 is selected socket screw can.
5.1.4 determining spacer guide column diameter:
Check "mold design and manufacturing Cookbook" P.422. Table 2-35, it was found Bevel
column diameter d = 20mm.

5.2. Core design

Part of the inner surface of molded plastic parts, said male mold or core, which are: a
main core, the small core, the movable insert, screw threaded ring core and the like. For
simple construction of the container, housing, cover, plastic cover or the like, the part
forming the inner surface of its body portion is called a main core or punch, and the other
aperture forming core or cores is known as a small rod shaped .
The structure of the lid, which is composed of a main core and core insert four active
components.
5.2.1 Design of the main core
According to the structure of the main core can be divided into two kinds of integral and
modular.
A modular core, complex structures can be simplified processing core, to reduce heat
distortion, inexpensive mold maintenance, saving valuable tool steel. In order to ensure
secure assembly accuracy of the core and the combined size, the required size of the
insert, the higher geometric tolerance level, combined mechanism must be strong, the
machining process of the insert is better. Therefore, a reasonable choice of modular
structure is very important.
Chosen according to structural formula blind hole lid mechanism. Blind bore-like
structure shown in Figure 8

FIG 8 blind hole core composition formula

In order to facilitate the introduction of insert metal and plastic parts, the following main
design around the core at an angle of 3. --5. Slope, with the gap in order to ensure that it is
conducive to install positioning activities inserts.

5.2.2 activities designed inserts

Since the inner lid consists of a rectangular cavity, but has a width of four 1mm wide
1.2mm high rectangular boss configuration. Requiring the use of four active inserts, only
two pairs of slide insert: insert metal inserts 1 and 2 activities. Taking into account the
activities of the insert during installation, the movable insert in the mold should have a
reliable positioning of the mating face and the seating surface of it, it should generally be
designed to 3. -5. Slope. To ensure that with the gap.

9 slide insert 11

FIG insert 12 10 Activity

Design 5.3 ejector mechanism

Specific shapes and structures from the point of view of the lid, the size small, and
therefore, can be launched using 4.
According to the structure of the article, to determine a common set four rods on four
active dome insert.
Since the inside of the plastic member has four small bosses, it can not be disposed
obliquely or inclined guide post of the slider, activity using the solid insert, before the mold
insert positioned manually movable template. To insert cheaper to install, launch
mechanism should be introduced so that the first reset, do so, on four plunger return
spring installation of four. Therefore, as shown in FIG. 11
FIG 11 a schematic view of the push rod fixed to plate

Ordinary round jack according to GB / T4169.1-1984 selection, both meet the

requirements.
7-13 look-up table, model selection φ10mm × 59mm round jack 2; φ6mm × 59mm model
selection round jack 2.
5.4, the design of the cooling system
Since the article is about 1.1mm average wall thickness, the larger the size of the article,
determining the water pore diameter of 6mm.
Because many factors position of the cooling waterways, structure, surface condition, flow
rate, water and other mold materials affect heat transfer to the mold cooling water difficult
to calculate accurately. Actual production, cold water is usually determined according to
the structure of the mold, to meet the requirements by adjusting the temperature, the
water velocity.
Since the movable mold by the core member and the fixing plate and the composition, by
structural constraints, a cooling water passage disposed below 12

FIG 12 a schematic view of the water passage

Forming part of the process 5.5

5.5.1 movable die core machining process (FIG. 13)

Step No. Name Content step
Saw cutting the material 1
2 forging forging hexagonal 38mm × 26mm × 28mm
3 annealing heat treatment, hardness of not greater than 229HRC
4
Milling the milling, the size of the lower plane to 22.4mm; to reference plane A, milled to a
size of the four sides 33mm, 24mm; milling the vertical direction angle of the inclined
surface 4 of the four, left margin grinding 0.1mm ~ 0.2mm
5 heat treatment and quenching, HRC52 ~ 58
Grinding polished 5 A, B face to size
Forming the four sides and four bevel grinding to size
7 hard chromium plating Surface treatment
Polishing the surface of the clamp 8 Ra0.4um

FIG 13 a schematic view of the core type

5.5.2 die machining process (Fig. 14)

Step No. Name Content step

Saw cutting the material 1
2 forging forging hexagonal 164mm × 164mm × 30mm
3 annealing heat treatment, hardness of not greater than 229HRC
Six to 4 planing planing size 161mm × 161mm × 27mm
5 parallelepiped grinding mill size to 160.4mm × 160.4mm × 26mm; and to ensure that A,
B side, on a plane perpendicular sides of the 0.02mm / 100mm
6 CNC milling (1) A, B plane and is milled cavity, and milling φ30mm aperture;
(2) milling and feed inlet runner to a size
7 Kenko sprue runner clamp Ra (0.2 ~ 0.4) um
8 heat treatment and quenching, HRC54 ~ 58
9 grinding mill to a size below 25.42 ± 0.03mm cavity surface finish. Note that guarantee /
100mm in each vertical plane, the vertical error 0.02mm
In 10 Milling A, B plane and is, 4 × 16mm aperture to a desired milling; milling φ18mm
hole, leaving polishing amount 0.015mm
Clamp 11 8M8mm prepared hole drilling, tapping and to the requirements, various types
of grinding surfaces of the cavity design requirements Ra0.1mm
Grinding gate and runner of design requirements.

14 a schematic view of the die in FIG.

5.5.3 Events machining process insert 11 (FIG. 15)

Step No. Name Content step

1 at the feed into the blank: 30mm × 40mm × 30mm blank
2 plane milling surface six milling into 15mm × 31.9mm × 22.5mm;
Milling bevel angle to the vertical direction to a size of 4 degrees;
Milling 6mm × 1.2mm × 1mm.
3 heat treatment and quenching, HRC54 ~ 58
4 and lower surfaces of the grinding mill to a size of 22.3 ± 0.060.02 mm
5 hard chromium plating Surface treatment
6 clamp the polishing surface Ra0.4um

15 a schematic view of the insert 11 as shown in FIG Activity

5.5.4, active insert 12 machining process (Fig. 16)

Step No. Name Content step

Cutting the blank 1 into: 35mm × 62mm × 30mm blank
2 plane milling surface six milling into 20mm × 52.8mm × 22.5mm;
Milling bevel angle to the vertical direction to a size of 4 degrees;
Milling 6mm × 1.2mm × 1mm.
3 heat treatment and quenching, HRC54 ~ 58
4 and lower surfaces of the grinding mill to a size of 22.3 ± 0.060.02 mm
5 hard chromium plating Surface treatment
6 clamp the polishing surface Ra0.4um

16 12 a schematic view of the insert shown in FIG Activity

Installation, commissioning and maintenance of the mold 5.6

5.6.1 mold mounting

(1), clean template and a mold mounting plane positioning holes dirt, burrs on the
surface;
(2), it is not due to dimensions of the mold, so the use of the entire installation process.
The first pad on the machine below the well plate two guide rails, between the frame into
the mold from the side, into the stationary die positioning holes, and being put, slow
closing template, the pressing mold and the pressing mold clamping platen or fixed
screws, a movable die and preliminarily fixed, and the slow mold opening and closing, the
movable mold alignment, should ensure a smooth opening and closing the mold, flexible,
non-jamming, then fixing the movable die;
(3) adjusting clamping mechanism, to ensure that there is sufficient distance and mold
clamping force, the mold is closed properly;
(4), slow opening until the back stop template until a template, adjusting ejector means, to
ensure the ejection distance. Closing movement of the mold was observed ejection
mechanism, the operation is Ping Heng, flexibility and coordination.
(5), installed the mold, barrel and nozzle temperature to be raised to a predetermined
temperature from 20º ~ 30º, a correction to the relative position of the nozzle and the
sprue bush where the contact arc, a paper sheet available on the nozzle and the gate
between the sets of observed both contact patch, checking anastomosis shall make a
snug fit, the corrected tightening screw injection molding seat, the fastening positioning.

5.5.2 Debugging

When the test mode, may often appear on the plastic parts ills, this must cause analysis,
troubleshooting. Cause of times, a lot of waste, sometimes single, but often the cause is
multifaceted comprehensive. Required in accordance with molding conditions, molding
apparatus, mold structure and manufacturing precision, shape and structure of plastic
parts individually analyzed to identify factors the main contradiction therein, and then
adjusting the molding process parameters to take, trimming die or the like to be addressed.

6. Conclusions
The main task of this design is that the lid injection mold design. Which is designed to
cover an injection mold to produce plastic products to automate increase production.
Advantage of the present design with a simplified mechanism, reducing the manufacturing
cost of the mold. Specific structure of the lid, through the design, so I designed two-point
gate parting surface of the mold have a deeper understanding.

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