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This three day, total 24 hours, seminar offers a thorough review of the Fundamental Mold Design requirements, and
concentrates on the design elements that are necessary to produce a sound operational
injection mold.
This course is intended for,
and will benefit all professionals involved in the injection molding and tool
manufacturing process, such as tool designers, liaison engineers, toolmakers
and mold maintenance personnel, set-up personnel, tool room
and molding room management
personnel. It is also designed as a continuation for those individuals who have
previously attended seminar #I, Injection Molding Technology.
Practical technology and underlying mold engineering
principles will be lectured during this presentation.
At this seminar you
will....Increase understanding of the
major considerations required when evaluating injection molding machine specifications and
how to relate this technical data to mold design and material processed.
Be introduced to the fundamental components which compose the
injection mold.
Understand the nomenclature.
Evaluate the basic mold lay-out and learn how to scrutinize the
design concept.
Take a subject of unique complexity and reduce it to a subject
almost of simplicity
Receive a source of technical information tempered with a
considerable amount of practical hands-on experience.
Learn to design for competitiveness through proven concepts for
mold manufacturing technology.
Comprehend the segments on techniques, allowing one to communicate
efficiently with the mold maker, and developing a practical outlook which benefits the
project's end result.
Broaden your skills on the
selection of tool steels and other materials used in the moldmaking industry.
Receive a comprehensive
custom-developed instruction manual, provided only to participants of this seminar, which
will serve as a valuable source in the future.
Seminar Outline
I
Mold Engineering principles
- Mold filling.
- Gate location(s), Polymer orientation and effects on shrinkage,
core deflection weld lines and vent locations.
- Parting line location.
- Cooling requirements; effect on crystal structure, physical and
dimensional characteristics.
- Effect of molding conditions and wall thickness on mold shrinkage.
II Review of the injection molding
machine specifications
- Rated clamping force, opening force, platen size, distance between
tie-bars.
- Mold height (min-max), or daylight (min-max), mold opening stroke,
ejector stroke and ejector force, K.O. bar location(s).
- Rated injection capacity, injection velocity (max), injection rate
and injection pressure, plasticizing capacity.
- Nozzle stroke, nozzle contact force and nozzle penetration past
stationary platen.
III Some basic calculations
- Determination of shot weight and clamping force requirement.
- Estimating cooling and cycle time.
- Estimating ejection force requirement, relating to the type of
ejection selected.
- Cavity side walls and estimated amount of deflection.
IV Introduction to Injection Mold
Design
- Terminology used in the moldmaking industry
- Two plate molds
- Three plate molds
- Stack molds
- Interchangeable mold frames
- Specialty molds: Unscrewing mold, Prototype mold base, MUD frames,
Combination mold, Roundmate®
V Runner lay out, type
of gates and mold venting
- Sprue bushings and sprue puller designs.
- Runner lay out, runner configuration and recommended runner sizes.
Balancing runner systems.
- Gate types: standard gate, fan gate, direct sprue, ring gate, film
or flash gate, tab gate pinpoint gate, submarine or tunnel gate, curved tunnel gate,
chisel gate.
- Venting: perimeter venting, ring venting, venting with lamina
assembly, ejector pin venting, etc. Recommended vent depth versus molding material.
VI Mold components
- Cavity and core inserts, core pin application(s) and method of
cavity and core locating. Through pocket, blind pocket, channel pocket, etc.
- Support pillars and riser blocks.
- Leader pin and leader pins bushings, parting line interlocks.
- Ejector pins, stop pins, ejector pin assembly. Ejector blades and
sleeves. Guided ejector mechanism.
- Stripper plate and stripper rings, delayed stripper ejection. Ring
and bar ejector system.
- Air ejector systems and vacuum breaks. Programmed ejection.
VII Mold Cooling
- Basic water cooling theory. Velocity of cooling
media. Reynolds, Prandtl and Nusselt numbers. Heat coefficient
transfer. Thermal conductivity and specific heat of the cooling media and how to influence
the quantity of heat to be extracted from the mold.
- Methods of
applying cooling to the mold:
Waterline lay out and cooling passage
designs: baffles, cascades,
inserts, etc. Seals and O ring installation. Thermal conductivity of
materials used in the mold making industry.
Heat pipes (latent heat of evaporation).
Vacuum cooling
VIII Materials
used in mold making Structure of steel. Tool steel
alloys. Principle function of alloying elements in tool steel. Heat treatment (annealing,
stress relief, hardening, case hardening). Nonferrous materials used in the mold making
industry. Tool surface enhancements commonly used in the Plastic Processing Industry.
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