1. ADVANCE INJECTION MOULD DESIGN01
CORPORATE TRAINING AND PLANNING

2. CORPORATE TRAINING AND PLANNING
SPLIT MOULD 02
CORPORATE TRAINING AND PLANNING

3. CORPORATE TRAINING AND PLANNING
SPLIT MOULD
It is required for components incorporates a recess or projection right angle to the line of draw, to relieve the undercut before the moulding is removed.
A moulding which has a recess or projection is termed as undercut moulding.
The undercut may be external, internal, local part of the component.
Two or more parts of the cavity closed together in a chase bolster by using locking heels during injection. 03
CORPORATE TRAINING AND PLANNING

4. CORPORATE TRAINING AND PLANNING
Fig: 1.1
Fig: 1.2 04
CORPORATE TRAINING AND PLANNING

5. VISIBLE LINE ON MOULDING
Parting line: The line formed on the molding surface where the core and cavity closed together.
Joint Line: The line formed on the molding surface where the splits (side cores) are closed together. 05
CORPORATE TRAINING AND PLANNING

6. CORPORATE TRAINING AND PLANNING
SLIDING SPLITS
The splits are positioned in guides on a flat mould plate are actuated by mechanical or hydraulic system and those are held together by locking heels which project on the other mould half.
The splits are possible to mount on either the moving or fixed mould plate. 06
CORPORATE TRAINING AND PLANNING

7. CORPORATE TRAINING AND PLANNING
Fig: 1.3
Fig: 1.4 07
CORPORATE TRAINING AND PLANNING

8. GUIDING AND RETENTION OF SPLITS - SLIDING FIT
Fig: 1.5
Fig: 1.6 08
CORPORATE TRAINING AND PLANNING

9. CORPORATE TRAINING AND PLANNING
Fig: 1.8
Fig: 1.7 09
CORPORATE TRAINING AND PLANNING

10. CORPORATE TRAINING AND PLANNING
DESIGN CONSIDERATION
OF SPLIT MOULD
The side movement should ensure the split halves always come together in the same plane.
In split mould all the parts should have enough strength to withstand the force applied to the splits by the operating system.
It should allow smooth movements of splits. 10
CORPORATE TRAINING AND PLANNING

11. SPLIT DESIGN CONSTRAINTS
Amount of splits movement and delay period required.
Ease with which the molding can be removed.
Whether a short or long production run is required.
Whether the available machines are programmed for ancillary cylinder control.
Whether molding inserts are to be incorporated. 11
CORPORATE TRAINING AND PLANNING

12. CORPORATE TRAINING AND PLANNING
SPLIT MOULD
ACTUATION METHODS
Finger cam actuation method
Dog-leg cam actuation method
Cam track actuation method
Hydraulic actuation method
5. Angled-lift splits
6. Spring actuation system 12
CORPORATE TRAINING AND PLANNING

13. 1.FINGER CAM ACTUATION 13 Fig: 1.9 Fig: 1.10 Split in open condition
Sleeve ejector pin
Split in open condition
Split in closed condition
Fig: 1.9
Fig: 1.10 13
CORPORATE TRAINING AND PLANNING

14. FINGER CAM ACTUATION MOULD FOR CAP COMPONENT
CORPORATE TRAINING AND PLANNING

15. FINGER CAM MOULD FOR LEDHOLDER
CORPORATE TRAINING AND PLANNING

16. CORPORATE TRAINING AND PLANNING
FINGER CAM PIN
Hardened, circular steel pins, termed finger cams are
mounted at an angle in the fixed mould plate.
Length and angle of the finger cam determine the distance traversed by each split across the face of the mould plate. 14
CORPORATE TRAINING AND PLANNING

17. CORPORATE TRAINING AND PLANNING
FINGER CAM PIN
M = splits movement
 = Angle of finger cam, 10-25
L = working length of finger cam
C = clearance (0.75mm)
Fig: 1.11 15
CORPORATE TRAINING AND PLANNING

18. CORPORATE TRAINING AND PLANNING
CALCULATION
The finger cam movement can be computed by the Formula
M = (L sin ) – (C / cos )
If the required movement is known, the following formula used to determine the finger cam length.
L = (M / sin ) + (2C / sin 2)
Where, M = splits movements,
 = Angle of finger cam, 10-25
L = working length of finger cam
C = clearance (0.75mm)
Cam diameter is usually 13 mm. 16
CORPORATE TRAINING AND PLANNING

19. CORPORATE TRAINING AND PLANNING
2. DOG - LEG CAM ACTUATION
This actuation system is used where a more
splits delay time is required compare to finger cam actuation method. 17
CORPORATE TRAINING AND PLANNING

20. CORPORATE TRAINING AND PLANNING
DOG-LEG CAM
Fig: 1.12 18
CORPORATE TRAINING AND PLANNING

21. DOG-LEG CAM ACTUATED MOULD
Split in closed condition
Split in open condition
Fig: 1.14
Fig: 1.13 19
CORPORATE TRAINING AND PLANNING

22. CORPORATE TRAINING AND PLANNING
DOG LEG CAM ACTUATED
SPLIT MOULD
M = movement of each split,
La= angled length of cam,
Ls = straight length of cam,
 = Cam angle, C = clearance, D = delay,
e = length of straight portion of the hole. 20
CORPORATE TRAINING AND PLANNING
Fig: 1.15

23. CORPORATE TRAINING AND PLANNING
CALCULATION
Formula for calculating the opening movement, the length of cam, and the delay period
M = La tan  - C
La = (M + C)/ tan 
D = (Ls – e) + (C/tan )
Where M = movement of each split,
La= angled length of cam,
Ls = straight length of cam,
 = Cam angle, C = clearance,
D = delay,
e = length of straight portion of the hole. 21
CORPORATE TRAINING AND PLANNING

24. CORPORATE TRAINING AND PLANNING
3. CAM TRACK ACTUATION
This type of actuation system is used for components having under cut which requires more delay period
Due to external fitment of cam track the mold actuation system becomes simpler and mold cost is reduced.
The cam track is machined into a steel plate attached to the fixed mould half.
A boss fitted to both sides of the split runs in this cam track.
The movement of the splits accurately controlled by specific cam track design . 22
CORPORATE TRAINING AND PLANNING

25. CORPORATE TRAINING AND PLANNING
CAM TRACK PLATE
Fig: 1.17
Fig: 1.16 23
CORPORATE TRAINING AND PLANNING

26. SLIDING SPLIT MOLD (CAM TRACK PLATE ACTUATED)
Fig: 1.18 24
CORPORATE TRAINING AND PLANNING

27. ACTUATION MOLD IN CLOSED POSITION
ASSEMBLY OF CAM TRACK
ACTUATION MOLD IN CLOSED POSITION
Fig: 1.19 25
CORPORATE TRAINING AND PLANNING

28. CORPORATE TRAINING AND PLANNING
CAM TRACK
M = movement of each split,
La= angled length of cam track,
= cam track angle,
C = clearance,
D = delay,
R = radius of boss
Fig: 1.20 26
CORPORATE TRAINING AND PLANNING

29. CORPORATE TRAINING AND PLANNING
CALCULATION
M = La tan  - C
La = (M + C) / tan 
D = Ls + C/ tan  + r ( 1/tan  - 1/sin  )
M = movement of each split,
La= angled length of cam track,
 = cam track angle,
C = clearance,
D = delay,
R = radius of boss 27
CORPORATE TRAINING AND PLANNING

30. CORPORATE TRAINING AND PLANNING
4. HYDRAULIC ACTUATION
The splits are actuated by hydraulic system. It is independently opening movement of the mould. The splits can be operated automatically at any specific time by the operating program of the machine
ADVANTAGES
Cycle time less
Large delay movements and large split movements
can be achieved 28
CORPORATE TRAINING AND PLANNING

31. CORPORATE TRAINING AND PLANNING
DISADVANTAGES
The mould is more bulky as compared with the
other designs
Mould setting more difficult and the hydraulic system has to be connected each time the mould is set up. 29
CORPORATE TRAINING AND PLANNING

32. HYDRAULIC ACTUATION OF SPLITS
Fig: 1.21 30
CORPORATE TRAINING AND PLANNING

33. CORPORATE TRAINING AND PLANNING
ANGLED-LIFT SPLITS
In this method the splits are mounted in a chase-bolster, which forms part of the moving half of the mould.
The splits are moving outward with an angular motion which relieve the undercut portion of the molding and retraction of the split alignment is controlled by using spring actuation or cam track actuation 31
CORPORATE TRAINING AND PLANNING

34. CORPORATE TRAINING AND PLANNING
ANGLED LIFT
SPLITS DIAGRAM
Fig: 1.22
Fig: 1.23 32
CORPORATE TRAINING AND PLANNING

35. CORPORATE TRAINING AND PLANNING
TYPES OF ANGLED LIFT SYSTEMS
Angled guide dowel actuating system
Cam track actuating system
Spring actuation. 33
CORPORATE TRAINING AND PLANNING

36. DOWEL ACTUATING SYSTEM
ANGLED GUIDE
DOWEL ACTUATING SYSTEM
The Guide dowels are fitted at an angle to the underside of each split which passes through holes machined at an angle in the chase-bolster.
When the ejector system is actuated, the relative movement between the ejector plate and the chase-bolster causes the guide dowels to move forward at an angle corresponding to the splits which opens. 34
CORPORATE TRAINING AND PLANNING

37. ANGLED GUIDE DOWEL ACTUATION
Split in closed condition
Fig: 1.24 35
CORPORATE TRAINING AND PLANNING

38. 36  = Guide dowel angle. Fig: 1.25 Split in open condition
CORPORATE TRAINING AND PLANNING

39. CORPORATE TRAINING AND PLANNING
The convenient angle for the guide dowel is 10 it may be increased if large opening movement is required. The actual opening movement of each split calculated by the following formula.
M = E tan 
E = effective ejector plate movement,
 = Guide dowel angle. 37
CORPORATE TRAINING AND PLANNING

40. CORPORATE TRAINING AND PLANNING
CAM TRACK
ACTUATING SYSTEM
In this method the opening movement of the splits are controlled by a cam track. When the splits are actuated, studs fitted to each end of the split slide along this cam track.
Actuation of the splits is by means of pin ejector system. The splits are fitted into an open channel type chase-bolster, which have wear plates.
Studs, screwed into the splits, protrude into the cam track machined in the cam track plate which is attached to the bolster. 38
CORPORATE TRAINING AND PLANNING

41. CORPORATE TRAINING AND PLANNING
CAM TRACK ACTUATION
Fig: 1.26 39
CORPORATE TRAINING AND PLANNING

42. CORPORATE TRAINING AND PLANNING
CALCULATION
The opening movement of each split calculating by
M = E tan 
E = effective ejector plate movement,
 = Cam track angle, usually 15 40
CORPORATE TRAINING AND PLANNING

43. CORPORATE TRAINING AND PLANNING
SPRING ACTUATION
The opening movement of the split depends on the slot provided in the chase bolster and the spring effective expansion length.
This ejection method is suitable for shallow undercut components.
The ejector pin actuates the split, the spring exerts the a force to vertical direction, which maintains contact between the split and the angled wall of the chase-bolster and gives angled movement to the splits. Thus the splits get open. 41
CORPORATE TRAINING AND PLANNING

44. CORPORATE TRAINING AND PLANNING
SPRING
ACTUATION METHOD
Fig: 1.27 42
CORPORATE TRAINING AND PLANNING

45. CORPORATE TRAINING AND PLANNING
SPRING ACTUATION SYSTEM
This actuation system is suitable for small straight and angled undercut components.
In this method the compression springs are used to force the splits apart and utilizes the angled faces of the chase bolster to close them. The opening of split movement should be limited so that they will allow to re-enter the chase bolster when the mould is closed.
The splits are mounted on the mould plate and retained by guide strips. Studs project from the base of the splits into a slot machined in the mould plate. The length of this slot therefore controls the opening movement of each split.
A compression spring is fitted between the studs in a link-shaped pocket situated in the lower mould plate. The splits are held closed by the chase bolster. 43
CORPORATE TRAINING AND PLANNING

46. CORPORATE TRAINING AND PLANNING
SPRING ACTUATION
Fig: 1.28 44
CORPORATE TRAINING AND PLANNING

47. CORPORATE TRAINING AND PLANNING
SEQUENCE OF OPERATION
The chase bolster holds the splits during the injection phase.
The compression springs exerts a force to split halves immediately when the mould starts to open.
The stud reaching the end of the slot in the mould plate stops the split movement.
Continued movement of the moving mould half operated the ejector system to release the molding . 45
CORPORATE TRAINING AND PLANNING

48. CORPORATE TRAINING AND PLANNING
CALCULATION
The formula for calculating the splits opening movement is
M = ½ H tan 
Where M = movement of each split, Approximately
H = height of locking heel
= angle of locking heel
Suitable angle for the locking heel is 20 to 25. 46
CORPORATE TRAINING AND PLANNING

49. CORPORATE TRAINING AND PLANNING
SIDE CORES
It is a local core mounted at an angle to the mould axis for forming a hole or recess inside the molding.
This side core prevents the in-line removal of the molding hence, side core must be withdrawn prior to ejection . 47
CORPORATE TRAINING AND PLANNING

50. CORPORATE TRAINING AND PLANNING
TYPES OF SIDE CORE
Internal Side Core Assembly
The dog-leg cam actuation method
The spring-loaded system
External Side Core Assembly
Side cores on the parting surface
Side cores below the parting surface
Angled withdrawal Curved side core 48
CORPORATE TRAINING AND PLANNING

51. CORPORATE TRAINING AND PLANNING
INTERNAL SIDE
CORE ASSEMBLY
In this method the side core is T-shaped is mounted in guides, which are securely attached to the moving mould plate.
The retaining plate to the carriage secures the side core element.The actuation of the carriage is by means of a finger cam/dog leg cam method
The carriage is locked in the forward position by the locking heel 49
CORPORATE TRAINING AND PLANNING

52. CORPORATE TRAINING AND PLANNING
DOG-LEG CAM
METHOD OF ACTUATION
Fig: 1.29 50
CORPORATE TRAINING AND PLANNING

53. CORPORATE TRAINING AND PLANNING
THE SPRING-LOADED SYSTEM
The spring-loaded system is an operating method confined to those moldings that have very shallow undercuts or projections. 51
CORPORATE TRAINING AND PLANNING

54. CORPORATE TRAINING AND PLANNING
Fig: 1.30 52
CORPORATE TRAINING AND PLANNING

55. CORPORATE TRAINING AND PLANNING
EXTERNAL SIDE
CORE ASSEMBLY
In this design, the side core is fixed to an extremely mounted carriage which is actuated by hydraulic or pneumatic means. 53
CORPORATE TRAINING AND PLANNING

56. CORPORATE TRAINING AND PLANNING
Fig: 1.31 54
CORPORATE TRAINING AND PLANNING

57. CORPORATE TRAINING AND PLANNING
CURVED SIDE CORE
The core is withdrawing from the mould along the arc of a circle.
It is suitable for components requires smooth curved internal hole
Example: telephone hand set and pipe fittings.
In this type of component the side core can be mounted on the parting surface of the mould. 55
CORPORATE TRAINING AND PLANNING

58. MOULDS FOR INTERNAL UNDERCUT COMPNENTS
05858

59. INTERNAL UNDERCUT
An internal undercut is the internal protrusion or recess
formed in the molding by using matching core or cavity.
It is prevents a moulding from being extracted from the core in line of draw.
059

60. EXAMPLES OF INTERNAL UNDERCUT COMPONENTS
Fig: 2.1
Fig: 2.2
060
CORPORATE TRAINING AND PLANNING

61. CORPORATE TRAINING AND PLANNING
FORM PIN
A component, which has a local undercut portion, can be successfully moulded in the conventional mould by incorporating the undercut form on a pin.
061
CORPORATE TRAINING AND PLANNING

62. UNDERCUT COMPONENTS WHICH NEED FORM PINS ACTUATION
Fig: 2.3
062
CORPORATE TRAINING AND PLANNING

63. TYPES OF FORM PIN EJECTION
Form Pin : Straight action
Form pin : angled action
063
CORPORATE TRAINING AND PLANNING

64. FORM PIN:STRAIGHT ACTION
This design is normally used for components, which incorporate an undercut on one internal wall only.
064
CORPORATE TRAINING AND PLANNING

65. CORPORATE TRAINING AND PLANNING
Fig: 2.4
Fig: 2.5
065
CORPORATE TRAINING AND PLANNING

66. FORM PIN: ANGLED ACTION
The basic feature of this design is that the working face of the form pin is caused to move inwards relative to the core during ejection, thereby relieving the undercut.
It can be used for components, which incorporate internal undercuts on one or more walls.
066
CORPORATE TRAINING AND PLANNING

67. CORPORATE TRAINING AND PLANNING
Fig: 2.6 67
CORPORATE TRAINING AND PLANNING

68. CORPORATE TRAINING AND PLANNING
CALCULATION
The amount of withdrawal is calculated by the following relationship:
M = E tan θ
Where, M = the withdrawing movement
E = ejection movement.
θ = fitting angle of the form pin. 68
CORPORATE TRAINING AND PLANNING

69. CORPORATE TRAINING AND PLANNING
SPLIT CORE ACTUATION
This split core may be moved forward either in a straight plane or an angled plane. 69
CORPORATE TRAINING AND PLANNING

70. CORPORATE TRAINING AND PLANNING
SPLIT CORES-STRAIGHT
ACTION
This design is used for components, which incorporate an external undercut on one wall only.
The moulding can be removed at right angles to the mould axis. 70
CORPORATE TRAINING AND PLANNING

71. CORPORATE TRAINING AND PLANNING
Fig: 2.7 71
CORPORATE TRAINING AND PLANNING

72. SPLIT CORE ANGLED ACTION
In this design the split core is caused to move inwards during the ejection stroke, thereby withdrawing the restriction and allowing the moulding to be extracted in the line of draw.
The advantages of this method is that the withdrawing action automatic and the moulding does not have to be removed at right angles to the mould’s axis.
This design can therefore be used for components with undercuts on opposing faces in addition to being used for components with an undercut on one wall only. 72
CORPORATE TRAINING AND PLANNING

73. CORPORATE TRAINING AND PLANNING
Fig: 2.8 73
CORPORATE TRAINING AND PLANNING

74. STRIPPING INTERNAL UNDERCUT
Suitability:
 The shape of the undercut,
 The elasticity of the material, and
 Whether the external form permits expansion during ejection. 74
CORPORATE TRAINING AND PLANNING

75. CORPORATE TRAINING AND PLANNING
Fig: 2.9 75
CORPORATE TRAINING AND PLANNING

76. CORPORATE TRAINING AND PLANNING
CURVED SIDE CORE
Fig: 1.32 56
CORPORATE TRAINING AND PLANNING

77. MOULDS FOR THREAD COMPONENTS
CORPORATE TRAINING AND PLANNING

78. CORPORATE TRAINING AND PLANNING
MOULDS FOR
THREADED COMPONENTS
The threaded components are usually prepare for where the repeated disassembly or where the strength of assembly is required. The threads can be formed in by three methods:
Cored or drilled holes with either thread cutting or thread forming using self-tapping type screws.
Molded with local inserts.
Molded thread formed by using unscrewing threaded inserts.
CORPORATE TRAINING AND PLANNING

79. CORPORATE TRAINING AND PLANNING
TYPES OF THREADS
External thread.
Internal thread.
According to thread shape subdivided into continues and discontinuous thread.
CORPORATE TRAINING AND PLANNING

80. CORPORATE TRAINING AND PLANNING
Fig: 3.1
Fig: 3.2
CORPORATE TRAINING AND PLANNING

81. COMPONENTS INCORPORATING THREADS
Fig: 3.4
Fig: 3.3
CORPORATE TRAINING AND PLANNING

82. MOULDS FOR INTERNAL THREADED COMPONENTS
The internal thread is an internal undercut in that the thread forms a restriction, which prevents the straight draw removal of the moulding from the core. The types of mould design for withdrawing the moulding, as follows:
   Stripping (jumping-off) thread design
   Fixed threaded core design
   Loose threaded core design
   Collapsible core design
Unscrewing mould designs
CORPORATE TRAINING AND PLANNING

83. STRIPPING (JUMPING) INTERNAL THREADS
The moulding must be free to expand during ejection to permit the moulded undercut to ride over the restriction on the core.
2. The outside form of the component to be formed in a cavity, which is fully contained in one half of the mould.
3. The internally threaded component may be stripped (Jumped) from the core using the stripper plate design providing a roll thread and the plastic material has sufficient elasticity during the ejection phase.
4. This method is recommended for polyethylene (PE), polypropylene (PP) material.
CORPORATE TRAINING AND PLANNING

84. STRIPPING INTERNALLY THREADED COMPONENTS
Fig: 3.5
CORPORATE TRAINING AND PLANNING

85. FIXED THREADED CORE DESIGN
In this method, the thread form is incorporated on a non-rotating core fixed to the moving mould plate. An integer type cavity forms the external shape of the moulding.
In operation, when the mould is opened, the moulding remains on the core and is afterwards unscrewed by the operator by hand or using release devices.
CORPORATE TRAINING AND PLANNING

86. FIXED THREADED CORE DESIGN
Fig: 3.6
CORPORATE TRAINING AND PLANNING

87. CORPORATE TRAINING AND PLANNING
ADVAMTAGES
Mould cost is cheaper than the unscrewing mould design because of its require ejector mechanism
Maintenance cost is minimum as there are no moving parts within the mould.
DISADVANTAGES
This design particularly used for multi-impression moulds
where the individual moldings to be unscrewed manually.
Increases the moulding cycle time.
CORPORATE TRAINING AND PLANNING

88. CORPORATE TRAINING AND PLANNING
    LOOSE THREADED CORES
This method is suitable for a large component incorporates a local internally threaded hole or has several internally threaded holes in close proximity to each other.
Prevents automatic unscrewing thereby considerably reducing the cost of the mould.
Where a number of holes are closely spaced, automatic unscrewing becomes impracticable. Because it require space for gear arrangement in automatic unscrewing operation.
CORPORATE TRAINING AND PLANNING

89. CORPORATE TRAINING AND PLANNING
LOOSE THREADED CORES
Fig: 3.7
CORPORATE TRAINING AND PLANNING

90. CORPORATE TRAINING AND PLANNING
COLLAPSIBLE CORE
This design is suitable for components having internal thread and internal undercut.
The important advantage of this method over the
rotating threaded core designs is that it eliminates the need for complex unscrewing mechanism.
CORPORATE TRAINING AND PLANNING

91. CORPORATE TRAINING AND PLANNING
COLLAPSIBLE CORE
Fig: 3.8
CORPORATE TRAINING AND PLANNING

92. EJECTOR PLATE ASSEMBLY OPERATED USING COLLAPSIBLE CORE
Fig: 3.9
CORPORATE TRAINING AND PLANNING

93. CORPORATE TRAINING AND PLANNING
UNSCREWING MOULDS
High labour costs and other modern production requirements demand the maximum use of automatic operation.
In an unscrewing type mould either the cores or the cavities are rotated to automatically unscrew the moldings from the mould.
To provide the required rotary motion an unscrewing unit is fitted behind the moving mould plate in place of the conventional ejector unit
CORPORATE TRAINING AND PLANNING

94. CORPORATE TRAINING AND PLANNING
Manually powered fixed rotating core design
CORPORATE TRAINING AND PLANNING

95. CORPORATE TRAINING AND PLANNING
Manually powered fixed rotating core with gear transmission
CORPORATE TRAINING AND PLANNING

96. CORPORATE TRAINING AND PLANNING
POINTS CONSIDERED
In the axially fixed core design, the threaded core is merely rotated to remove the moulding.
In the extractor plate design, the extractor plate is actuated at the same time as the threaded core is rotated to remove the moulding.
In the withdrawing rotating core design, the threaded core is rotated by sun & planet gear mechanism and withdraws the moulding from the core plate.
CORPORATE TRAINING AND PLANNING

97. CORPORATE TRAINING AND PLANNING
IMPRESSION LAYOUTS
The pitch circle diameter .
2. The In-line layout.
CORPORATE TRAINING AND PLANNING

98. MACHINE POWERED IN-LINE UNSCREW SYSTEM
Fig: 3.12
CORPORATE TRAINING AND PLANNING

99. THE PITCH CIRCLE DIAMETER LAY-OUT
Fig: 3.13
CORPORATE TRAINING AND PLANNING

100. CORPORATE TRAINING AND PLANNING

101. CORPORATE TRAINING AND PLANNING
MULTIDAYLIGHT MOULD 01
CORPORATE TRAINING AND PLANNING

102. CORPORATE TRAINING AND PLANNING
MULTIDAYLIGHT MOULD
It is a complex mould having more than one-daylight when the mould is opened.
It consists of three main parts:
Fixed mould plate or feed plate,
Floating cavity plate or stripper plate,
Moving mould plate.
0102
CORPORATE TRAINING AND PLANNING

103. TYPES OF MULTI DAY LIGHT MOULDS
1. Double day light, stripper plate mould
2.  Double day light, under feed mould
3. Triple day light, underfeed and stripper
Plate mould.
0103
CORPORATE TRAINING AND PLANNING

104. DOUBLE DAYLIGHT, STRIPPER PLATE MOULD
Suitability : The circular box-type moulding, which have thin wall section.
Stripper plate:
The stripper plate is a rectangular plate, has aperture to sliding on the core for ejection.
It is mounted between the cavity plate and the core plate.
These types of ejection will not leave any depression on the molding.
0104
CORPORATE TRAINING AND PLANNING

105. CORPORATE TRAINING AND PLANNING
The moulding and feed system are removed in the first day light between the stripper plate and the fixed mould plate from the cavity plate.
Second daylight between the core plate and stripper plate for ejection.
0105
CORPORATE TRAINING AND PLANNING

106. STRIPPER PLATE EJECTION
Fig: 4.1
Fig: 4.2
Fig: 4.3
0106
CORPORATE TRAINING AND PLANNING

107. DOUBLE DAYLIGHT STRIPPER PLATE MOULD
Fig: 4.4
Fig: 4.5
Fig: 4.6
Fig: 4.7
Double Day Light With Underfeed Mould
0107
CORPORATE TRAINING AND PLANNING

108. DOUBLE DAY LIGHT WITH UNDER FEED MOULD
An Underfeed mould is one in which the feed system is arranged to feed into the underside of the component.
In this mould the extra plate is added behind the cavity plate to allow a runner system to be incorporated below the cavity or cavities.
It consists of three main parts
1. Feed plate.
2. Floating cavity plate.
3. Moving mould plate.
0108
CORPORATE TRAINING AND PLANNING

109. USE OF UNDERFEED TYPE OF MOULD
1. Multi-point feeding can be accomplished on single-impression moulds and on multi-impression mould.
2. Off-centre feeding can be achieved for both single and multi-impression moulds.
0109
CORPORATE TRAINING AND PLANNING

110. TRIPLE DAY LIGHT WITH UNDERFEED AND STRIPPER PLATE MOULD
A three-plate mold or triple daylight mould differs from a two plate in that it has two parting planes and the mold splits into three sections, every time the part is ejected.
Since the mold has two parting 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.
110
CORPORATE TRAINING AND PLANNING

111. TRIPLE-DATLIGHT, UNDERFEED-STRIPPER PLATE MOULD
Fig: 4.8
Fig: 4.9
111
CORPORATE TRAINING AND PLANNING

112. A THREE PLATE MOULD ASSEMBLY
Fig: 4.10
112
CORPORATE TRAINING AND PLANNING

113. CORPORATE TRAINING AND PLANNING
THREE PLATE MOULD
This mould is mostly prepared for multi impression circular cap components.
It is the combination of stripper plate and under-feed system.
113
CORPORATE TRAINING AND PLANNING

114. STRIPPER PLATE MOVEMENT
Fig: 4.11
Fig: 4.12
114
CORPORATE TRAINING AND PLANNING

115. CORPORATE TRAINING AND PLANNING
SECONDARY SPRUE BUSH
Multi daylight moulds are having two sprue bushes.
Primary sprue bush is mounted at fixed plate backside.
Secondary sprue bush is mounted in the floating cavity plate.
115
CORPORATE TRAINING AND PLANNING

116. CORPORATE TRAINING AND PLANNING
SECONDARY SPRUE BUSH
Fig: 4.13
116
CORPORATE TRAINING AND PLANNING

117. CORPORATE TRAINING AND PLANNING
It is the simplest form of feed system.
It is not practicable for all types of components. The shape of the component affects the design of the floating cavity plate, which in turn determines the type of feed system can be adopted and it requires the extra operation for removal of runner from the moulding.
117
CORPORATE TRAINING AND PLANNING

118. REVERSE TAPER SECONDARY SPRUE
REVERSE TAPER SPRUE
Fig: 4.14
118
CORPORATE TRAINING AND PLANNING

119. CORPORATE TRAINING AND PLANNING
REVERSE TAPER
SECONDARY SPRUE
Standard type of pin point gate is used.
The main use of this sprue is to release the component
with automatic de-gating in three-plate mould.
Drawback of this method: the feed system is not free to fall when the mould is opened because the secondary sprues are retained within the floating cavity plate.
The feed system is removed by hand if the basic underfeed mould design is used.
119
CORPORATE TRAINING AND PLANNING

120. UNDERCUT RUNNER SYSTEM SECTION VIEW
Fig: 4.15
Fig: 4.16
120
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121. CORPORATE TRAINING AND PLANNING
Fig: 4.17
121
CORPORATE TRAINING AND PLANNING

122. CORPORATE TRAINING AND PLANNING
DESIGN CONSIDERATION
 The float period must be sufficient to permit the floating cavity plate to clear the reverse-tapered sprues before the puller pulls the sprue.
Considerable runner deflection is necessary to ensure that the secondary sprues are not pulled back into their holes when the puller is actuated.
To ensure that the puller is pushed back to its moulding position when the mould is closed, the diameter of the puller must exceed the width of the runner.
122
CORPORATE TRAINING AND PLANNING

123. CORPORATE TRAINING AND PLANNING
RUNNER STRIPPER PLATE
The fixed secondary puller is fitted directly below each secondary sprue.
To release the feed system from this fixed secondary puller a runner stripper plate is introduced between the feed plate and the floating cavity plate.
123
CORPORATE TRAINING AND PLANNING

124. UNDERFEED MOULD SECTION VIEW01
Fig: 4.18
124
CORPORATE TRAINING AND PLANNING

125. CORPORATE TRAINING AND PLANNING
UNDERFEED MOULD
Fig: 4.19
Fig: 4.20
Fig: 4.21
Fig: 4.22
125
CORPORATE TRAINING AND PLANNING

126. CORPORATE TRAINING AND PLANNING
STACK MOULD
When two injection moulds are operated in tendem in the same molding machine it is called stack mould.
Used for molding shallow, small parts in large quantities like tape cassettes.
The cavities are located in two planes corresponding to two parting lines and are filled.
The clamping force required is 15% higher than a standard mould.
126
CORPORATE TRAINING AND PLANNING

127. CORPORATE TRAINING AND PLANNING
It is a simplest mould design, from a runner point of view is a single-cavity, single-face mold arranged in back to back configuration of same impression or different impressions.
The machine nozzle injects plastic directly into the mould cavity. The single-face mould can also be extended to a multi-cavity layout.
The machine nozzle injects the melt into a runner system that feeds each individual cavity.
It is suitable of which has the thin-wall injection molding with hot runner designs.
127
CORPORATE TRAINING AND PLANNING

128. CORPORATE TRAINING AND PLANNING
STACK MOULD IN IMM
Fig: 4.23
128
CORPORATE TRAINING AND PLANNING

129. CORPORATE TRAINING AND PLANNING
Fig: 4.24
129
CORPORATE TRAINING AND PLANNING

130. CORPORATE TRAINING AND PLANNING
TYPES OF STACK MOULD
FOUR-FACE (FOUR-LEVEL) STACK MOLDS
2.   THREE-FACE (THREE-LEVEL) STACK MOLDS
130
CORPORATE TRAINING AND PLANNING

131. 1.FOUR-LEVEL STACK MOULDS
Four-level stack molds quadruple output over single-face molds, and are suited to very high production volumes of shallow parts.
Quick Change molds switch from one product to another in less than an hour in both single-face and two face stack mold applications.
Two-cavity slack molds allow molding of large parts in a back-to-back configuration, thus doubling the machine capacity.
131
CORPORATE TRAINING AND PLANNING

132. CORPORATE TRAINING AND PLANNING
The four-face stack mold is two stack molds placed back to back and it increases the mold shut height.  
It operates in the same molding machine as a conventional slack mold.
Cycle limes identical to those of a conventional mold.
Shot-to-shot changeover time of less than one hour required for both mechanically and air ejected parts in the stack mold.
Machine shut height remains the same from one product to the next.
132
CORPORATE TRAINING AND PLANNING

133. 2.THREE-LEVEL STACK MOULDS
Three-level stack molds permit molding of deep-draw or tall pans to maximize the productivity of machine shut height.
It is the development of a proprietary melt transfer system to pass the plastic across the mold parting line.
The system avoids drooling on mold opening due to the self-decompression of the central hot-runner system.
133
CORPORATE TRAINING AND PLANNING

134. CORPORATE TRAINING AND PLANNING
The three-level stack mold uses triple valueless melt transfer system (VMTS) crossover nozzles to provide equal pressure and flow characteristics to the plastic melt to each cavity.
This stack mold configuration fills in when a two-level mold cannot produce enough pans and a four-level mold is too large for the machine.
Three-level stacks is used to mold both shallow draw (for example, packaging lids) and deep draw pans (such as tall containers).
They can be combined with quick-change systems to give added flexibility to high-production tooling.
134
CORPORATE TRAINING AND PLANNING

135. CORPORATE TRAINING AND PLANNING
HOT RUNNER MOULD 01
CORPORATE TRAINING AND PLANNING

136. TYPES OF INJECTION MOULD
COLD RUNNER
2. HOT RUNNER
A runner is the channel in the mold that conveys the molten plastic material from the barrel of the injection-molding machine to the part. 02
CORPORATE TRAINING AND PLANNING

137. CORPORATE TRAINING AND PLANNING
COLD RUNNER MOULD
The runner is cooled and ejected with the part.
Every cycle, a part and a runner are produced.
There are two major types of cold runner molds: Two plate and Three-plate mould. 03
CORPORATE TRAINING AND PLANNING

138. ADVANTAGES OF COLD RUNNER MOULD
Mold requires less maintenance.
The mold design is very simple and much
cheaper than a hot runner system.
Less skill to set up and operate.
Color changes are also very easy, since all of
the plastic in the mold is ejected with each cycle. 04
CORPORATE TRAINING AND PLANNING

139. DISADVANTAGES OF COLD RUNNER MOULD
The waste plastic is generated.
The runners are either disposed of or reground and reprocessed with the original material.
This adds a step in the manufacturing process.
Regrinding increases variation in the injection molding process, and decreases the plastic's mechanical properties. 05
CORPORATE TRAINING AND PLANNING

140. CORPORATE TRAINING AND PLANNING
HOT RUNNER MOULD
The hot runner mould contains a heated runner manifold block, insulated from the rest of the mould keeps the runner permanently melt.
The hot runner mould replaces the conventional sprue bushing with a hot sprue bushing or a heated nozzle.
The polymer material directed to the mould cavities without heat loss and pressure loss.
Large moulding like automotive dash board, bumpers, computer housing, multi colour moulding etc. are produced in this process. 06
CORPORATE TRAINING AND PLANNING

141. CORPORATE TRAINING AND PLANNING
HOT RUNNER MOULD
In a three-plate cold runner mold the runner system must be reground and the material is reused.
It is possible to eliminate the runner system entirely by keeping it fluid.
The material is kept plasticized by the hot runner manifold, which is heated with heating element (like electric cartridges).
The block is usually thermostatically controlled.
Heater bands, which are individually controlled, can be mounted round the nozzle.
The plastic is kept fluid and the injection pressure is transmitted through the hot runner manifold. 07
CORPORATE TRAINING AND PLANNING

142. Assembly of hot runner mould08
Assembly of hot runner mould
Fig: 5.1
CORPORATE TRAINING AND PLANNING

143. Hot runner mould section view09
Hot runner mould section view
Fig: 5.2
CORPORATE TRAINING AND PLANNING

144. TYPES OF HOT RUNNER MOULD
A hot runner system is divided into two parts
The manifold
The drops .
The manifold has channels that convey the plastic on a single plane, parallel to the parting line, to a point above the cavity.
The drops, situated perpendicular to the manifold, convey the plastic from the manifold to the part. 10
CORPORATE TRAINING AND PLANNING

145. HOT RUNNER WITH EXTERNALLY HEATED MANIFOLD AND DROPS11
Fig: 5.3
CORPORATE TRAINING AND PLANNING

146. TYPES OF HOT RUNNER SYSTEM
Internally drops and manifolds.
Externally heated drops and manifolds. 12
CORPORATE TRAINING AND PLANNING

147. EXTERNALLY HEATED HOT RUNNER
Externally heated hot runner channels have the lowest pressure drop of any runner system (because there is no heater obstructing flow and all the plastic is in molten state).
They are better for colour changes none of the plastic in the runner system freezes.
There are no places for material to hang up and degrade, so externally heated systems are good for thermally sensitive materials. 13
CORPORATE TRAINING AND PLANNING

148. INTERNALLY HEATED RUNNER SYSTEM
Internally heated runner systems require higher molding pressures, and color changes are very difficult.
There are many places for material to hang up and degrade, so thermally sensitive materials should not be used.
Internally heated drops offer better gate tip control. It separate runner heat from the mold because an insulating frozen layer is formed against the steel wall on the inside of the flow channel. 14
CORPORATE TRAINING AND PLANNING

149. INTERNALLY HEATED CORE ROD SECONDARY NOZZLE
Fig: 5.4 15
CORPORATE TRAINING AND PLANNING

150. DESIGN CONSIDERATION FOR HOT RUNNER MOULD
Insert plug close off manifold bores should be smooth.
Runner diameters should impart shear stress not more than 1 percent of the resin’s tensile strength.
The pressure drop from sprue bushing to tip should not be more than 25 percent of the maximum plastic fill pressure, with the resulting temperature increase remaining as close to the desired melt as possible.
A runner volume of 25 percent of the part volume, and a shear rate of about 1000 sec-1, are good
Sufficient heating elements should be incorporated so that the hot-runner unit heats quickly to the required moulding temperature from cold. 16
CORPORATE TRAINING AND PLANNING

151. CORPORATE TRAINING AND PLANNING.
  Sufficient heat energy must be supplied to the hot-runner unit it replaces conduction, convection and radiation heat losses.
  To ensure that the temperature of the melt in the flow-way is maintained without either hot or cold regions, careful location of the heating elements is essential.
   Considerable production time may be lost if a heater fails. Thought must be given therefore to choice of heating element; its location and the facilities for. removing it. 17
CORPORATE TRAINING AND PLANNING

152. CORPORATE TRAINING AND PLANNING
The layout of the wiring system should be neat and easily traceable.
  Heating element wires, which are subject to, heat or abrasion attack should be protected.
Use manufacturer’s recommended clearances when fitting heating elements of the cartridge type.
Flat-type heating elements and induction heating elements should be completely enclosed within the unit for maximum efficiency. 18
CORPORATE TRAINING AND PLANNING

153. CORPORATE TRAINING AND PLANNING
The hot-runner unit must be insulated from the rest of the mould structure.
For many materials, close control of the temperature of the melt is vital. Hence Careful consideration to be made for the location of thermocouples.
To minimize degradation, color-changing and material-changing problems the melt flow-way must be as streamlined as possible, without sharp corners, ledges or other stagnation points which tend to hold back the polymer melt for extended periods. 19
CORPORATE TRAINING AND PLANNING

154. APPLICATIONS OF HOT RUNNER MOULD
It allows for the pin gating of mouldings on multi-impression types of mould
It allows for multi-point gating on single-impression and multi-impression mould
It allows for side or film gating of large mouldings.
It permits the semi-runnerless design to be adopted, where small groups of impressions are fed from secondary sprues. 20
CORPORATE TRAINING AND PLANNING

155. CORPORATE TRAINING AND PLANNING
THE MANIFOLD BLOCK
Rectangular Manifold Block
Circular manifold block 21
CORPORATE TRAINING AND PLANNING

156. CORPORATE TRAINING AND PLANNING
Fig:5.5
Fig:5.6 22
CORPORATE TRAINING AND PLANNING

157. RECTANGULAR MANIFOLD BLOCK
Fig:5.7
Fig:5.8
Fig:5.8
Fig:5.9 23
CORPORATE TRAINING AND PLANNING

158. CORPORATE TRAINING AND PLANNING
THE MELT-FLOW-WAY
Fig: 5.10 24
CORPORATE TRAINING AND PLANNING

159. CORPORATE TRAINING AND PLANNING
RUNNER PLUG
It is made from stainless steel for plugs in the flow path of hot runner system to direct the plasticized materials. It has larger thermal expansion than the manifold material. As the manifold is heated to operating temperature, the stainless plugs will expand at a greater rate making the possibility of leakage impossible. 25
CORPORATE TRAINING AND PLANNING

160. CORPORATE TRAINING AND PLANNING
TYPES OF NOZZLES
Extended nozzle
2. Barb nozzle
3. Antechamber nozzle 26
CORPORATE TRAINING AND PLANNING

161. CORPORATE TRAINING AND PLANNING
1.EXTENDED NOZZLE
On the extended nozzle a resistance type band heater is provided which is controlled by means of thermocouple.
To minimize the transfer of heat from the heated nozzle to the mould, a circumferential clearance of at least 7mm must be provided between the two parts.
The main advantage of this nozzle is to minimize the length of the sprue gate as short as possible. 27
CORPORATE TRAINING AND PLANNING

162. CORPORATE TRAINING AND PLANNING
Fig:5.11
EXTENDED NOZZLE 28
CORPORATE TRAINING AND PLANNING

163. CORPORATE TRAINING AND PLANNING
2.BARB NOZZLE
This type of nozzle is used to minimize the blemish on the component at the gate point.
The plastic material flows through to the nozzle, sprue and gate. After solidification, the sprue is pulled from the sprue bush by the barb of the nozzle. 29
Fig:5.12
CORPORATE TRAINING AND PLANNING

164. CORPORATE TRAINING AND PLANNING
3.ANTECHAMBER NOZZLE
It is termed as hot well design, a small mass of plastic material is retained in the antechamber which insulates the central core of plastic material.
The plastic material remains fluid to allow it to pass intermittently through the antechamber into the impression.
This type of nozzle is used for moulding thin-walled components. 30
CORPORATE TRAINING AND PLANNING

165. CORPORATE TRAINING AND PLANNING
INSERT
ANTECHAMBER 31
CORPORATE TRAINING AND PLANNING
Fig:5.13

166. INSULATED RUNNER MOULD
In this type of mould the melt flows from standard or extended nozzle into a large diameter runner via the reverse taper sprue and gate.
The outer layer of the melt solidifies against the cold runner wall which forms an insulating shell, while the centre core of the material retain in the molten state.
The outer layer of runner acts as an insulating media and avoids heat loss from the polymer melt to the mould. 32
CORPORATE TRAINING AND PLANNING

167. CORPORATE TRAINING AND PLANNING
Fig:5.14 33
CORPORATE TRAINING AND PLANNING

168. CORPORATE TRAINING AND PLANNING
EXPANSION PROBLEMS
The hot-runner unit mould is that metals expand when heated.
The manifold block increases in all three dimensions when the temperature is increased.
The distance between the centers of the secondary nozzles increases with respect to the ‘fixed’ distance between the centers of the impressions machined in the cavity plate.
When designing the hot-runner mould, allowance must be made for this expansion to ensure that the centerlines are in line during production 34
CORPORATE TRAINING AND PLANNING

169. CORPORATE TRAINING AND PLANNING
EXPANSION PROBLEMS
Fig:5.15 35
CORPORATE TRAINING AND PLANNING

170. CORPORATE TRAINING AND PLANNING
NOZZLE LENGTH
200
250
300
48 mm
68 mm
0.13
0.20
0.17
0.21
0.30
The equation for calculating expansion is as follows:
e = L X  X  T
Where e = expansion (mm or in)
L = length dimension (mm or in)
 = Coefficient of thermal expansion (mm/mm C or in / inC)
 T = increase in temperature ( C) 36
CORPORATE TRAINING AND PLANNING

171. DESIGN OF HOT RUNNER MOULD FOR CAP
CORPORATE TRAINING AND PLANNING

172. HOT RUNNER MOULD FOR CAP SEAL
CORPORATE TRAINING AND PLANNING

173. THREE PLATE HOT RUNNER MOULD FOR CAP
CORPORATE TRAINING AND PLANNING

174. THREE PLATE HOT RUNNER MOULD FOR LEAD FRAME
CORPORATE TRAINING AND PLANNING

175. UNSCREWING HOT RUNNER MOULD FOR CAP COMPONENT
CORPORATE TRAINING AND PLANNING