SET C
1. Mold design chapter
1-1 Gate method
1-2 Guidelines for steel materials and mold life
1-3 Guidelines for steel material selection intended for plastic injection
materials
1-4 Comparison table of International Standards for steel materials of mold
1-5 Heat treatment method of steel materials
1-6 General data on steel materials used for mold making
1-7 Computation of deflection on moveable side
1-8 Computing necessary thickness of side walls of rectangular shaped
cavities(if bottom surface is integrated)
1-9 Computing necessary thickness of side walls of rectangular shaped
cavities(if the bottom surface is separated from the others)
1-10 Computing necessary thickness of side wall of cylindrical cavities
1-11 Mold temperature control method
1-12 Cross sectional shape design for “runners”
1-13 Guideline for designing tunnel gate
1-14 Head shape design for pinpoint gate
1-15 Runner lock structures for Pinpoint gate
1-16 Polishing, finishing of Plastic mold parts
1-17 Outline for food container mold
1-18 Outline for medical utensils mold
1-19 Outline for blow molding
2. Plastic injection materials chapter
2-1 predrying condition of plastic injection materials
2-2 tables showing material properties of plastic injection materials
2-3 trouble shooting for rejected works (bubbles)
2-4 trouble shooting for rejected works (sink mark)
2-5 trouble shooting for rejected works (flow mark)
2-6 trouble shooting for rejected works (burn)
2-7 trouble shooting for rejected works (silver streak)
2-8 trouble shooting for rejected works (defective brightness)
2-9 trouble shooting for rejected works (short shots)
2-10 injection materials and purpose of usage (polyamide)
2-11 injection materials and purpose of usage (polyacetal)
2-12 injection materials and purpose of usage (polycarbonate)
2-13 injection materials and purpose of usage (thermoplastic elastomer)
gate tip diameter
penetrating angle
angular aperture
gate land length
==Characteristics==
① gates are automatically cut
when mold open
② gate marks are small and not
obvious
③ gating are possible on both
movable and fixed side
④ pressure keeping is difficult
to apply due to fast gate sealing
==Characteristics==
① gate mark is same as that of
side gate
② after staying in the tab area
for a moment, melted resins
will enter into cavities. This
is the reason why flow marks
tend to generate at the area.
[Disc gate]
l= gate land length
h= gate depth
sprue
Disc gate
cavity
parting surface
core
==Characteristics==
①gate mark appears toroidally
at the inner surface of
molded items
② it is necessary to include
cutting out process of gate
③ cylindrical filling becomes
homogeneity
[Film gate]
b= gate length
l= gate land length
h= gate depth
sprue
cavity
runner
parting surface
core
==Characteristics==
① gate mark will remain on the
side surface of the product
② it is necessary to include
cutting process of film
shaped gate
③ it is suited to filling of
thin plate shaped products
[Side gate]
b= gate width
h= gate depth
l= gate length
side gate
cavity
Runner
Parting surface
core
==Characteristics==
① gate mark will remain on the
side surface of products
② it is necessary to include
gate cutting process
③ machine fabrication of
cavities at gate areas are
easy
④ filling of resins is
relatively easy
[Under gate]
under gate
cavity
runner
parting surface
core
b= gate width
h= gate depth
l= gate length
l1= inflow area
l2= gate land length
l3= runner overlapping length
==Characteristics==
①gate mark will remain at bottom
surface of products but not on
side surface
②it is necessary to include gate
cutting process
③gates are done by scrive
process on the core side
④it is relatively easy to fill
resins
[Direct gate]
∅D= gate diameter
θ= sprue removal pitch
sprue
cavity
parting surface
core
==Characteristics==
① large gate mark will remain
at the bottom surface of
product
② it is necessary to include
gate cutting process
③ it is relatively easy to
fill resins
[fan gate]
α= opening angle
l = gate land length
h = gate depth
runner
cavity
parting surface
core
==Characteristics==
① gate mark will remain
on the side surface of
products
② it is necessary to
include gate cutting
process, but cutting is
difficult
③ it is suited for thin
plate shaped items
[Pinpoint gate]
runner lock part
runner lock pin
runner plate
cavity
parting surface
core
∅d= gate diameter
l= gate land length
α= opening angle
SR= runner tip radius
θ= runner removing taper
h1= gate relief depth
h2= depth of the basin
SR = radius of basin
∅dr1= runner lock pin diameter
∅dr2= runner lock area diameter
h3= runner lock pin undercut length
h4= runner lock area depth
==Characteristics==
① one can locate gate at random area at flat surface of product
② gate mark appears small, and not obvious
③ tend to use multiple point gate
④ scrive process of gate area is relatively difficult
⑤ countermeasures for gate cutting remains must be establish
1-2 Steel materials and mold life guidelines
Guidelines of steel
materials and mold
life sample
appliances /
general items
automobile / OA
electronic parts /
mass production /
optical parts
marageing steel
Hardness(HRC)
prehaiden steel
mold life(expected shots) (×10,000 shots)
- non heat treated type
of steel
- prehaiden steel
- age hardening type of
steel
- quenching and tempered
type of steel
1-3 Guidelines for selecting steel materials depends on types of plastic injection
materials
Examples of
selecting steel
materials
depends on
types of plastic
injection
materials
JIS: Japan Industrial Standards
AISI: American Iron and Steel Institute
SAE: Society for Automotive Engineers
ASTM: American Society for Testing Material
BS: British Standards Institution
DIN: Deutche Industrie Normen
NF: Normes Francaises
Гost:
ISO: International Organization for Standardization
(Reference literature) JIS Handbooks
1-5 Heat treatment methods of steel materials
Heat treatment methods of mail steel materials
Types
of steel
Heat tempering method
Quenching method
Heat tempering
hardness (reference)
Standard quenching
Tempering
℃
Oil quenching
none
Air cooling
marquenching
air
cooling
Standard tempering
Standard quenching
air cooling
Air
cooling
preheat preheat
High temperature tempering
marquenching
cool down
preheat preheat
air cooling
Air
cooling
Tempering
℃
none
Tempering
℃
none
Air
cooling
Primary
preheat
Secondary
preheat
Cool down
Main
temperature
Air
cooling
1-6 General data on steel materials used for mold making
General data on steel materials used for mold making
Specific
ation
Material
quality
mild
steel
modulus of
longitudinal
elasticity
(Young's
modulus)
Cavity
mold plate
Backing plate
spacer block
Attachment plate
on movable side
B: width of mold plate (mm)
L: space inside spacer block (mm)
h: thickness of backing plate (mm)
l: length of part that receives internal pressure(p)of the cavity
b: width of part that receives internal pressure(p)of the cavity
p: internal pressure of cavity (Kgf/㎠)
E: modulus of longitudinal elasticity of materials (Young's modulus) (Kgf/㎠)
δmax : max deflection of backing plate (mm)
<Computation sample>
Question: How thick must be bottom part(h) for the following
movable side plate using carbon steel used in
mechanical structure(S55C)?
Based on Table1
A : E of S55C is E=210 ×10
kgf/㎠
Therefore
h=3√⎯5x500x30x1144
32x210x104x250x0.01
= 42.2 (mm)
Answer : at least 42.2mm is needed
In case one allows up to σmax=0.025
h=3√
5x500x30x1144
32x210x104x250x0.025
=31.1 (mm)
In this case, at least 31.1mm is needed
[Simplified computation when we assume l= L]
δmax = 5.p.b.L4
32.E.B.h3
(mm)
h =3√5.p.b.l4
32.E.B.δmax
(mm)
Table 1. List of value “E”
material
mild steel
prehaiden steel
(SCM440system)
extra super
duralumin
E (kgf/ cm2)
210x104
230x104
(75-105)x104
73x104
Table 2. rule of thumb for cavity internal pressure(p)
mold
condition
lower setting
of injection
pressure
higher setting
of injection
pressure
P (kgf/ cm2)
200 - 400
400 – 600
Table 3. rule of thumb for maximum permissible deflection considering
parting burrs
molding
materials
maximum
permissible
deflection σmax
(mm)
good flow
ability (such as
PA,PP etc.)
those which
with general
flow ability
products which
are not affected
by burr
generation
0.025
0.03 – 0.05
0.1 – 0.2
[Variation of maximum deflection by insertion of supporting blocks]
Position of supporting block
Maximum deflection σ
σ1 generates when position
is X= 0.421 × L/2
One portion at
the center for
supporting
block
※ δmax = maximum
deflection when there is no
supporting blocks
(Note) above computation may applied when supporting block is inserted with the
width equivalent to mold plate width B. On the other hand, above computation will
not applied once there is (are) insertion of supporting pins
Supporting
Supporting block
pin
Diagram 1 Case that above
computation applies
Diagram 2 Case that above
computation will NOT apply
Altered condition
Once one creates 1/2 of
inner support block space
once backing plate
thickness h become h1
Maximum deflection σ
Computing necessary thickness of side walls of rectangular shaped cavities (if
bottom surface is integrated)
p: cavity internal pressure (kgf/㎠)
l: cavity inner length (mm)
h: thickness of cavity side surface (mm)
a: sidewall height of cavity internal pressure (p) receiving area (mm)
E: modulus of longitudinal elasticity(Young's modulus) (kgf/㎠)
c: constant derived from l/a ratio
σmax: maximum deflection (mm)
<Computation sample>
Question: How much should be a minimum cavity side wall thickness
“h”for the following bottom surface integral hard steel mold?
380
381
From Table 1. E= 220 × 10⁴kgf/㎠
yh, l/a value is considered as modulus of longitudinal elasticity of
hard steel
382
l/a= 40/10 = 4
from the table it becomes
384 therefore
385
386
Answer : at least 2.95 is needed
at least approx.5mm is needed including over design thoughts
Computing necessary thickness of side walls of rectangular shaped cavities (if the
bottom surface is separated from the others)
Core
Cavity
Bottom bushing
p: cavity internal pressure (kgf/㎠)
l: cavity inner length (mm)
h: thickness of cavity side surface (mm)
a: sidewall height of cavity internal pressure (p) receiving area (mm)
b: cavity height (mm)
E: modulus of longitudinal elasticity(Young's modulus) (kgf/㎠)
σmax: maximum deflection (mm)
h = 3√12.p.l4.a
384.E.b.σmax
(note) this formula does NOT apply if it is bottom attached type of cavity
Table 1 Table for value “E”
Materials
mild steel
hard steel
prehaiden
steel
(SCM440system)
cast steel
extra super
duralumin
E (kgf/cm2)
210x104
220x104
230x104
(75-105)X104
73x104
<Computation sample>
Question: How much minimum thickness “h”do you have to provide on the side wall of
hard steel cavity which the bottom surfaces are divided as drawing?
A: if the maximum deflection of cavity side wall is σmax= 0.01mm, we will know
the modulus of longitudinal elasticity of hard steel is
E = 220 × 10⁴kgf/㎠ based on Table 1.
Therefore
at least 7.83mm is needed
hopefully 10mm is given including some allowance purpose
Computing necessary thickness of side wall of cylindrical cavities
<Computation sample>
Question: How much external radius of the following cylindrical
cavity shape made of SKD11 is needed?
Answer : SKD11 is hard steel materials, and therefore value of σ ℷ from
Table1.becomesσ₁= 1200 ∼ 1800 kgf/㎠. Just to give allowance on the
computation, we use smaller value to setσℷ= 1200 kgf/㎠.
430 therefore
Answer: At least 7.07mm is necessary. Giving some extra space, we will make it
10mm.
1-11 Mold temperature control method
Some of the engineering plastic and super engineering plastic generate
cavity temperature over 100 .
It is difficult to raise the cavity temperature by water temperature control,
once cavity surface temperature exceeds 90 .
Following methods are used generally for countermeasure.
1. Oil temperature control
Temperature is kept constant by oil exhaled from recycling pump passes
channels in mold and cavities, passes joint hose and circulate. Once
temperature will raise up to setting temperature, it is relatively easy to
sustain stable temperature.
But the weak point is, it takes time to startup temperature.
Also, there are other concerns like potential danger of burns, and difficulties
of post treatment.
2. Electric heater
Electric heater (cartridge heater) temperature control may be done with
temperature sensor (thermo-couple etc.) so that temperature will be kept
constant.
Since the heat capacity is big, startup temperature is fast.
Difficulty is that heater surroundings become high temperature, but low
temperature at isolated area from heater which means keeping heat
distribution constantly.
Heaters have product life, and therefore we must replace heater periodically.
For the heater attachment, it is important to provide right clearance at
attachment hole. Too big clearance will cause a situation like boiling without
water, and reduce heater life.
MISUMI M-HTM3021 (Temperature controller for cartridge heater) can
control temperature by PID control method, therefore quite stable
temperature control than “ON-OFF type controller” is possible.
It is recommended to provide heat intercepting board in between platen and
mold attachment plate of injection machine. It is further recommended to
provide heat intercepting board surrounding mold plate.
[Table] Example of molding materials with high cavity surface
temperature
Name of plastic
In injection molding of PPS resins and liquid crystal polymer, one need to
maintain the cavity surface temperature above 100 . Therefore it is
necessary for one to control temperature thru oil or cartridge heater.
Commercially available “Cartridge heater” utilize [ON-OFF control] by power
ON and OFF to control temperature.
“ON-OFF Control” is simple structure to shift switch that the cost is cheap.
On the other hand, it has weakness like,
(ア)
cavity surface temperature gap is big
(イ)
instability
Instability cavity surface temperature will cause defects such as shrinkage
of dimension, unevenness of surface brightness on precision products.
To stabilize cavity surface temperature, we use “PID control”.
PID control is
P: Proportional
I: Integral
D: Derivative
PID control applies above to reduce lead time to stabilize temperature.
Heat intercepting board is very important parts considering that it stabilizes
temperature of injection mold, materialize energy conservation while
keeping the temperature.
Heat intercepting board has following usage
1. fixed to platen of injection mold machines and use
2. fixed to back of attachment plate of mold and use
Following are selection standard of Heat intercepting board.
1. Heat resistant temperature
Following are recommended working temperature as guidance
●
●
●
●
●
1-12 Cross sectional shape design of runner
Runner is channel to let molted resins to flow from sprue to product.
Selection of cross sectional shape of runner depends upon product size,
resin types, expected molding condition etc.
Following are basic standard for the selection of runner cross section shape.
[Diagram] shows main runner cross section shape
parting surface
movable side
angle
thin
fixed side
angle
inscribed circle
One may select runner from following 3 types
1) carve on movable side
2) carve on fixed side
3) carve on both movable and fixed side
Selection depends on shape restriction and mold parting position.
Symbols such as ◎: excellent , ○: proper, ×: inadequate
Important roll of runner is to let molten resin flow under minimal pressure
loss condition. Unnecessary large sized runner will increase scraps, worsen
material costs, prolonged molding cycle, and increase volume of disposing
waste.
Index to indicate runner efficiency is “inscribed circle diameter area” at
cross sectional shape. The bigger the space of inscribed circle, wider the
area that hot resins will flow, and therefore one can expect better flow of
molten resins.
So the ideal is the runner on round cross section shape. But cost wise this
becomes more expensive for mold cost because one must carve runner on
both movable and fixed side.
To comply on such nonconformity, further biting of trapezoidal shape or
semicircle cross section are utilize.
It is better to provide angles on the side of runner so that mold release
becomes better. On the other hand inner surface of runner must be polished
by rubber wet stone or rapping to avoid pressure loss.
1-13 Guideline of tunnel gate design
Tunnel gate (submarine gate) is widely used gate method where the
product and gate are automatically cut every time parting surface opens
and close.
It is necessary for one to know the basics such as shapes and dimension to
design tunnel gate. But for this time, we are introducing to you the basic
variation of molded products and gate, runner relation.
In the [Diagram], shows basic patterns of tunnel gate.
Put parting surface between, there are 4 patterns of gate-runner
combination on fixed side and moving side.
Fixed side tunnel gate
Fixed side runner
Movable side tunnel gate
Movable side runner
Fixed side tunnel gate
Movable side runner
Movable side tunnel gate
Fixed side runner
Movable side tunnel gate
Arrangement for hub
Fixed side runner
In case if tunnel gate is provided on the fixed side, cutting of product and
gate will be done while parting surface opens. Therefore, gate cutting
condition varies depending on mold opening speed.
On the other hand, in case if tunnel gate is provided on the fixed side,
cutting of product and gate will be done when runner ejector pin pushes
runner. This means, gate cutting condition depends on protruding speed of
runner ejector pins.
In case runner is provided on the fixed side, it is necessary to make
structure that the lock pins will pull runner toward movable side, because
there is a chance that runner itself may be left on fixed side.
In case runner is provided on the movable side, we must set ejector pin to
push out runner properly.
In special case, there are times that boss-shaped (sharpen up ejector pin)
tunnel gate is provided on the movable side, and fill resins from back
surface of top panel.
In actual practice, we must decide what type of gate and runner to use on
mold design based on product characteristics, and material properties.
If specification prohibits any trace of gate mark on side panel or top panel,
we rarely have to provide gate on back surface of products.
In such a case, “Curved tunnel gate” is rarely used.
Runner
Curved tunnel gate
Cavity
Ejector pin
Gate holding hub
Ejector pin
In the structure of curved tunnel gate, bulging gate shape extends from
parting surface to inner movable core. Therefore, gate opening locates at
top plate of core.
Ejector pins are provided on runner near the gate area, and boss is
provided at the top part of pin part to hold gate. Overall length of boss is
“H”. During the ejection, so as to undergo smooth gate cutting, it will hold
gate until product will be cutout from core completely.
Final shape of bulging part is usually corrected after several trial-and-error.
It is wise to set nested split type structure from very beginning, so that the
correction of mold become easy.
Gate passage is always affected by mold cooling time and pressure keeping
time. Try several variation as sample for prototype.
Whichever method one may choose, cutting condition at cutting area and
scum become common problem upon cutting product and gate.
Following factors may affect cutting condition
1. Gate tip shape design
2. gate size (cross-sectional shape)
3. distance from gate cutting part to runner lock part
4. acting condition of pressure keeping
5. orientation of high molecules at gate part
6. cutting timing of gate and products
Careful analysis must be made before entering into preparing mold for
precision mold and multi-cavity mold.
1-14 Pinpoint gate tip shape design
Following are potential problems on pinpoint gate structure.
1) Gate tip portion protrude and remain on the product surface, or pluck off
part of product
2) In comparison to high filling pressure and keeping pressure, filling cant
be done smoothly
Above are common problems and headaches of mold designer upon using
“Pinpoint gate”.
Following are technical trouble shooting.
[Diagram1.] Shows general pinpoint gate structure. Gate design without
any consideration usually looks like this.
On the other hand, [Diagram2.] shows contrive design to minimize above
problems.
2. Gate
Opening angle
1. gate land
3. thickness relief
Length
4. Dimple
(basin)
Point 1 Gate land length L
If the gate land is unnecessary long length, it may remain as protrusion,
because gate will be cut in the middle portion.
From the study, we recommend that Gate length(L) size be 1∼2 times the
diameter of gate tip.
Point 2 Gate open angle A
One must provide tapering to open angle and create cone shape. As long as
it is cone shape, strong chance that contact point of minimal cross section
gate area and product shall be the cutting point.
Mold release becomes easy too. Value A is usually 15°∼30°. Bigger the
value, more assurance on cutting, but wearing out at the tip portion tends
to become faster.
Point 3 Slot
Once “Slots” are provided, they will encroach 1 step into the surface of
molded products. Because of this, protrusion will not exceed the surface
level of products even if it remains at cutting area.
One must first acquire “Approval” of product designer in prior to set slots on
the drawing.
Point 4. Dimple
Dimples are spherical shape concave provided at the opposite side of the
gate which has almost same wall thickness to product, so that molten resin
will flow stable when slots are created.
One must also first acquire “Approval” of product designer in prior to set
dimples on the drawing.
457
1-15 Runner lock structures for Pinpoint gate
Runner lock shapes in pinpoint gate structures have several patterns,
however usually applied pattern is indicated in Diagram 1.
Diagram 1.
Product
Gate
Runner
Fixed side mold plate +
Cavity
Narrow
Runner
Runner plate
Fixed side attachment plate
Runner lock pin
In the [Diagram1.], locate runner lock pin which has undercut shape at the
head area into the runner foundation. When fixed side of mold plate and
runner plate create a space, they will compulsively separate runner and
gate.
Runner lock pin will be engage by clearance fit to runner plate, and fixed to
fixed side attachment plate by plate and screw plug.
In this method, if one will work on thin product or resin with higher
pressure loss, channel within runner from the head portion of runner lock
pin becomes narrower. In this case, it is necessary for one to provide higher
filling pressure or pressure keeping as molding condition.
In this case, as indicated in [Diagram2.], one may set lock area one step
lower within runner plate. In this manner, one is necessary to create
coniform curving on top of runner plate. For this process, mold cost may
become higher, but be able to improve pressure losses during molding.
Place runner
locks one step
down
If incase one wish to reduce the molding cycle, create a pointed conifom
shape at tip of runner lock pin shown in [Diagram3.], which will also act
as slot like lock shape. In this way, excess materials at the runner
center will be reduced, therefore more efficient cooling is done, then
contribute to reduction of cycle.
But one must take care of coniform shape portion balance, because
poor balance at the area will cause fracture of cuneiform shape from the
base. One can also provide corner radius to improve strength.
One must select proper runner lock, by first determining expected roll of
runner lock in prior to design mold.
Encroach into inner side
also for the purpose for
relief thickness
1-16 Polishing finish of plastic mold parts
Cavity surface of plastic injection mold undergo mainly hand polish or
machine polishing after milling, EDM, wire cut process to smoothen the
surface.
Transcription surface for products be dull, and surface quality may
become poor if polishing condition is not good.
凹凸 surface may become potential undercut upon separating product
from cavity, and cause defective mold release.
Hard wetstone and abrasive grain are utilized for cavity polishing. You
may use rough mesh number (larger grain) to finer mesh number. Use
grinding fluid while making sure that clogging and galling will not take
place.
Polishing is not only done one direction but relative position and
circumferential direction so that polishing surface will be uniform.
Following are main polishing materials.
Natural polishing agent - silica group (agate, alcansas)
- Corundum group (emery, garnet)
- Diamond powder
Synthetic polishing agent - alumina (Al2O3)
- Silicon carbide (SiC)
- Boron carbide (BC)
- Synthetic diamond
Grain size of polishing materials ranges from #10∼#20000. Smaller the
value, rougher the mesh.
(Ex. Using #10∼#30 polishing results rough finish, but #1000∼#2000
polishing results finer finish)
In case one will use fine abrasive grain, we mix olive oil or vegetable oil
into maple, pine, willow, balsa like trees and polish.
1-17 Food container mold overview
Many plastics are used as food container. PET bottles, food cups,
wrappings are mostly plastics.
It is necessary to give extra care on food container quality, so that man
can enjoy foods not worrying hygienics, at the same time not to
damage lips and tongues by burrs.
Any pores or cracks on plastic will allow bacteria to infiltrate into foods
and spoil them. Such quality defects are not allowed too.
There are following major food containers
●
●
●
●
●
●
Necessity of function depends on food purposes such as thermostability
(for foods necessary to heat up), low thermal resistant(for food
necessary to freeze, refrigerate), gas barrier(for those foods that can
not be exposed to oxygen).
For food containers, sales of the foods will also depends on product
design(beautiful finish), which means 3 dimensional curved surface
shape and design become significant. Therefore, in product design and
mold design, one needs 3 dimensional solid data.
There are always chances of burrs to generate at parting surface,
therefore location of parting surface must be paid attention.
This is same for gate position and method.
Cavities, and cores must be fabricated by corrosion resistance steel
materials. It is better that one will not apply grease nor slide promoting
oil. This means non lubricating mold mechanism is recommended.
Electric injection machines are ideal, further ideal to work inside clean
rooms.
Its worth trying using valve gate and hot runners. If mass production is
expected, one can also use scrap press effects and high cycling.
1-18 Medical utensils mold overview
Many plastics are used in medical utensils. In many cases, injection
molding method is used for production.
This means many parts of medical utensils have been produced thru
mold making.
There are following major plastic medical utensils.
1.
2.
3.
4.
5.
6.
syringe (syringe body) : PP, PE
piston of syringe : PP
pipet chips : PP
catheter : PVC, PC
blood collecting test tubes : PC
dish for culturing : PS
For plastic medical utensils materials, only those which are allowed by
drug legislation and quality standard prescribed by Ministry Of Labor
and Health can be utilize. Those materials must withstand exposures of
UV lights and gamma rays used for sterilization, at the same time
passed the clinical test for blood coagulation reaction, allergies etc.
Basically, medical utensils are disposable. Therefore those materials
must be environmental friendly upon incineration.
It is recommended that mold materials shall be non rusting type. This is
the reason why many cases, medical utensil molds are made of
stainless, ion plating film, hard chrome plating so as to prevent
corrosion of core, cavity.
Valve gate molds are used in mass production items.
Needless to say that burrs for products are defects, therefore use
precision guide to locate movable side and fixed side, and also try to
apply contraption preventing the abnormal worn out of core pins of
centering location structure.
There must be delicate temperature setting for cavities and cores to
produce stable quality products. For this point, one must pay attention
to the structure of cooling circuit and heat pipes.
Cooling structure in core becomes very important for cylinder body of
syringe.
Removal of gases and resins on the mold surface is related to quality.
Gas vent settings and enforced ventilation structures are applied.
1-19 Blow molding mold overview
Blow molding method is usually applied to pet bottle containers for
juices (PET : polyethylene terephthalate resin) which blow methods are
used.
It is familiar in all over the world because it is used as shampoo
container, soy sauce and other seasoning container, detergent container
etc.
Polyethylene terephthalate, polypropylene, PVC, nylon, polycarbonate
may be used for blow molding method.
Exclusive blow machine is used for blow molding. In the mold, there is
only cavity on female mold, but no core on male mold.
Instead, there is a nozzle prepared to blow air. Balloon like performing
shape part called “Parison” blows, stick to cavity and transcribe shape.
Generally speaking, soft metal materials are used for cavities in blow
molding. These are aluminum alloy, bronze, and special steels.
Usually beautiful brightness surface is required to product, therefore
polishing of inner cavity surface must be done properly.
In beverage containers blowing, multi-cavity moldings are practice
generally which means contraption on cooling and temperature control
are important to comply high-cycle operation.
Also design of products that incorporated recycle is important, because
most of those blow items will be disposed after the consumption.
2-1
pre-drying condition of plastic molding materials
Usually, plastic molding materials comes in pellet form in the paper bag
upon their delivery.
Pellets absorbs moisture in the air, therefore hydrolysis may take place
on some resins in the process of molding if pellet still contains moisture,
or degrade physical properties of materials. There are also cases that
silver streak may appear on the surface of product, or short shots may
occur due to gases, and burns may be generated too.
Many cases, materials are first placed into box shape pre-drying device
before placing them into the hopper dryer.
It is recommended that proper drying temperature and time are take
into consideration. Moisture can not be eliminated completely even
placed for long period, if drying temperature is below the proper setting.
Quick consumption of materials after pre-drying is recommended. If
there will be any left over of materials in a daily production, you must
undergo pre-drying again before usage.
Pre-drying temperature of plastic molding materials
Name of materials
symbol
predrying temperature℃ drying time(H)
Liquid crystal polymer
LCP
110 – 150
4-8
Polyetherimide
PEI
120 – 150
2-7
polyamide imide
PAI
150 – 180
8 - 16
thermoplastic elastomer
TPE
120
3-4
polyether ether ketone
PEEK
150
8
polyphenylene sulfide
PPS
140 – 250
3-6
polyalylate
PAR
120 – 150
4-8
polysulfone
PSU
120 – 150
3-4
ABS resin
ABS
70 – 80
2-3
Acryl
PMMA
70 – 100
2-6
Polycarbonate
PC
120
4-6
Nylon 6
PA6
80
8 - 15
Nylon 66
PA66
80
8 - 15
Nylon 11
PA11
70 – 80
8 - 15
Nylon 46
PA46
80
8 - 10
Polyacetal
POM
110
2-3
PBT
PBT
120
4-5
Pellets of Plastic molding materials usually absorbs certain degrees of
moisture in the air. If there will be too much moisture absorption,
hydrolysis may take place (some resins cause chemical decomposition
by water) in the cylinder of injection machine during molten and
kneading process. Sometimes, silver streak, bubbles, defective
brightness, defective transcription may occur during injection.
To avoid above problems, we must first place the pellets in the drying
machines to remove water content.
Variation of flow of materials, degrading physical properties, defective
molding may happen if we do not give out predrying properly.
2 – 2 Tables showing material properties of plastic molding materials
Main plastic material physical properties list
Thermoplastic type of Plastic
Resin name
Grade
JIS testing
method
Mold
ability
High steel
ability
Heat resistance
Glass fiber
20 – 40%
Filling materials
Abbreviation
ABS
Drying temperature
70~80
70~80
70~80
Drying time
2
2
2
Injection mold cylinder
temperature
200~260
250~300
200~260
Injection mold temperature
50~80
50~80
50~80
Injection molding pressure
560~1760
560~1760
1050~2810
Compression mold
temperature
160~180
160~260
Compression mold pressure
0.7~506
0.7~5.6
Mold contraction rate
0.4~0.9
0.4~0.9
0.1~0.2
K6911.
K7112
D792
Specific gravity (density)
1.03~1.06
1.05~1.08
1.22~1.36
K6911.K7113
D638
Tensile strength
400~530
400~560
570~740
Elongation percentage
3.0~20.0
5.0~25.0
2.5~3.0
Compression strength
127~879
505~702
844~1550
Bending strength
773~914
703~1050
1120~1900
Impact strength (Izod)
10.9~33.7
10.9~35.4
5.4~13.1
Hard ness (Rockwell
R107~115
R100~115
M65~100
Heat resistance (continuos)
71~93
88~165
93~110
101~112
85~107
107~122
93~119
Mechanical
properties
Thermal
Characteristic
A.S.T.M.
Testing
method
ABS resin
Heat distortion (℃) a)bending
stress
K7206.
K7207
b) bending stress
99~108
Thermoplastic type of plastic
Etylene-vinyl
acetate
AS Resin
Polyamide (Nylon)
General
Nylon 6
Glass
fiber 20 –
30%
SAN
Nylon 66
Glass fiber
30%
EVA
Nylon 11.12
Glass fiber
30%
-
PA6
PA66
PA11.12
85
85
80
80
80
80
70~80
2~4
2~4
8~15
8~15
8~15
8~15
8~15
200~260
200~260
120~230
240~290
240~290
260~300
260~300
190~270
50~80
50~80
20~60
40~120
40~120
40~120
40~120
20~100
710~2320
1050~2810
562~1410
150~200
90~150
70.3~703
0.04~1.76
0.2~0.7
0.1~0.2
0.7~1.2
0.5~1.5
0.4~0.6
0.8~1.5
0.5
0.3~1.5
1.07~1.10
1.20~1.46
0.92~0.95
1.12~1.4
1.35~1.42
1.13~1.15
1.38
1.03~1.08
600~840
600~1440
95~200
700~850
1650
770~850
1850
530~550
1.5~3.7
1.1~3.8
500~900
200~300
3~6
150~300
3
300~500
984~1200
1550
914
1340
1050
2070
984~1340
1550~1830
1270~2320
429~1200
471~1260
Non
destructive
3.3~5.4
16
4.3~5.4
12
10~30
D17~45
R119
M101
R120
M100
R106~109
82~121
93~149
82~121
82~121
82~149
M80~90
M100~E60
60~96
93~104
88~104
88~110
33.7
88.1
210
74.8
77
54.2
101~115
77~80
203
239
208
236~239
167
Thermoplastic type of Plastic
Methacrylate
resin (acryl)
Polyacetal
General
-
General
Glass fiber
20%
PMMA
General
High
impact
Thermos
ability
Glass
Fiber 40%
-
POM
PP
PS
HIPS
PS
70~100
110
110
2~6
2
2
190~290
180~230
180~230
200~300
200~300
170~280
190~280
199~280
40~90
60~120
60~120
20~90
20~90
20~60
10~80
20~80
703~1410
703~1410
703~1410
703~1410
703~1410
703~2110
703~2110
703~2110
149~218
171~288
171~288
129~204
121~204
129~204
141~703
0.35~0.70
0.35~0.70
70.3~703
70.3~703
70.3~703
0.1~0.4
2~2.5
0.4
1.0~2.5
0.2~0.8
0.4~0.7
0.4~5.7
0.2~0.6
1.07~1.20
1.41~1.42
1.61
0.90~0.91
1.22~1.23
1.03~1.05
1.03~1.06
1.05~1.09
470~770
580~800
1250~1300
210~400
560~1000
350~840
200~350
350~530
2~10
25~75
3
100~800
2~4
3~4
13~50
2~60
844~1270
1270
1200
260~562
387~492
809~1120
281~633
914~1340
991
1970
352~492
492~773
562~984
211~844
1.6~2.7
5.4~13
10
2.2~110
7.6~11
1.4~2.2
3.3~20
M85~105
M78~94
M79
R50~111
R102~75
M60~75
M10~80
59.8~93
90
104
88~115
121~138
65.3~76.5
59.3~79.2
73.7~99
124
110
45.9~59.8
59.8~93
104
90
79.2~107
170
158
103~130
117~161
82~110
82~104
2.2~19
M70
90
Thermoplastic type of Plastic
Polycarbonate
Low
density
General
Glass fiber
less than
10%
Polyethylene
Moderate
density
polybutylene
terephthalate
High
density
Glass Fiber
10 – 40%
PC
Glass fiber
20 – 30%
LDPE
MDPE
HDPE
PBT
120
120
120
120
120
>4
>4
>4
4
4
270~380
270~380
270~380
150~270
200~300
200~300
230~280
230~280
80~120
80~120
80~120
20~60
10~60
10~60
40~80
40~80
700~1410
700~1410
1050~2810
562~2110
562~2110
703~1410
562~1800
562~1800
249~326
135~176
149~190
149~232
0.7
7.03~56.2
7.03~56.2
0.35~0.56
0.5~0.7
0.2~0.5
0.1~0.2
1.5~5.0
1.5~5.0
2.0~6.0
1.5~2.0
0.2~0.8
1.19~1.20
1.27~1.28
1.24~1.52
0.91~0.925
0.926~0.940
0.941~0.965
1.31~1.38
1.52
550~700
630~675
840~1760
42~161
84~246
218~387
550~540
110~1340
100~130
5~10
0.9~5.0
90~800
50~600
20~130
50~300
2~4
844
984
914~1480
190~253
605~1020
1270~1650
949
1050
1200~2250
844~1170
1830
75~100
5.5
11
Non
destructive
2.7~87
2.7~110
4.4~5.4
7.0~8.7
R115~125
M75~85
M88~95
D41~50
D50~60
D60~70
M68~78
M90
121
135
135
82~100
48.7~121
121
49.8~121
115~176
129~140
142
143~149
40.3~48.7
40.3~48.7
43.1~54.2
49.8~85
220
132~143
146
149~154
48.7~73.7
48.7~73.7
59.8~88
115~193
225
337~492
Thermoplastic type of plastic
Polystyrene
Polyvinyl chloride
Flexible
rigid
Glass fiber
20 -30%
-
-
PS
SPVC
HPVC
Fluororesin
Polyphenylene chloride
Crystal liquid polymer
Glass fiber
40 %
FEP
Glass
fiber 40%
PPS
LCP
120~140
120~140
140~160
140~160
3~5
3~5
4
4
170~280
160~190
170~210
370~430
315~330
315~360
250~310
250~310
20~80
10~20
10~60
95~230
130~150
130~150
70~110
70~110
1050~2810
562~1760
703~2810
352~1410
300~1000
300~1000
150~500
150~500
140~176
140~204
315~399
35.2~141
52.7~141
70.3~140
0.1~0.3
1~5
0.1~0.5
2~3
0.6~0.8
0.2~0.4
0.1~0.8
0.1~0.55
1.20~1.33
1.16~1.35
1.30~1.58
2.15~2.17
1.3
1.60~1.67
1.35
1.7
633~1050
100~240
400~500
180~210
630
1500~1550
1060~1335
900
1~2
200~450
40~80
250~330
1~2
0.9~4
1.3~4.5
1.8
949~1270
63~120
562~914
155
1.4~2.2
2.2~100
703~1120
Largely
change
Non
destructive
<2.7
5~8
13~21
8.7
M70~95
A50~100
D68~85
D60~80
R123
R123
R60~63
R79
82~93
54.2~79.2
204
90~104
59.8~76.5
97~110
57.0~82
135
250~265
332~335
319
738~1410
69.8
2-3 Countermeasure on defective molding
“Bubble” “Void” are phenomenon where air bubbles are generated within
molded products. These bubbles or voids will be considered rejected on a
product such as lens, prism because appearance and optical characteristic
be disturb by such defect. It will also reduce strength and become cause of
destruction of machine once those defective items are used as machine
parts.
There are 2(two) major cause of bubbles.
One cause is that, air was mixed into molten plastic. This is called bubbles.
Other one is caused in the process of shrinkage of molded articles known as
“Void”. In the void, insufficient pressure keeping was applied to thick wall
area, and this caused abnormal shrinkage just like this happened in the
process of generation of “Sink mark”.
Following can be possible countermeasures for above problems.
Countermeasures for bubbles
1. Countermeasures related to mold
1. There are no air vent or lack of numbers of air vent
2. There is no cold slag well, or it may be too small
2. Countermeasures related to injection molding condition
1. too fast screw rotational speed
2. too high cylinder temperature
3. too fast injection speed
3. Countermeasures on product design
1. insufficient predrying of mold materials
Countermeasures on void
1. Countermeasures on molds
1.
2.
3.
4.
There is no air vent, or lacking
There is no cold slag well, or it is too small
too small sprue, runner
too small gate
2. Countermeasure related to injection mold condition
1. Too high cavity surface temperature
2. Too low pressure keeping
3. lack of pressure keeping time
3. Countermeasure on product design
1. insufficient predrying of molding materials
2. too thick molded product wall thickness
2-4
Countermeasures on defective molding (sink mark)
“Sink mark” is a phenomenon which generate slight concave due to
shrinkage of product surface.
It may become defective quality in case product used for surface
appearance.
There are following methods to control sink mark.
1. Countermeasures related to mold
1.
2.
3.
4.
5.
6.
Set the cavity surface temperature slight lower
Make gate size bigger
Make runner size larger
Use larger sprue
Review cooling channels of mold to improve cooling efficiency
Improve the structure where difficult cooling area to become easier
to cool. (Ex. Baffle plate structure, cooling pipe structure, heat pipe,
non-ferrous bushing)
7. Increase the number of gate
8. Relocate gate position to thick wall area
2. Countermeasures related to injection mold condition
1.
2.
3.
4.
5.
6.
7.
8.
Set pressure keeping time longer
Set pressure keeping to higher setting
Set the injection speed faster
Set nozzle temperature lower
increase indiscrete value
Increase cushion volume
Change the injection mold machine
Exchange the “backflow prevention ring” of injection unit
3. Countermeasure on product design
1. remove the thick wall area of products
(Ex. Material relief shape, alter into another parts)
2. apply amorphous resins
2-5
Countermeasure for defective molding (flow mark)
“Flow mark” is a phenomenon where melted resin flowing marks remains
on the surface of products. This may become a cause of reject depends
upon degree of such mark appearance. Products such as electric appliances
or cosmetic product casing are particular about such appearance.
Flow mark is generated in the process that molted resins contact metal
surface in the mold will encounter different degree of cooling at the tip of
resins.
Following methods are considered to improve the flow mark.
1. Countermeasures related to molds
1.
2.
3.
4.
set the cavity surface temperature lower
expand the size of the gate
enlarge the size of the runner
secure enough cold slag well
2. Countermeasures related to injection molding condition
1.
2.
3.
4.
5.
6.
set the injection pressure higher
set the injection speed faster
secure enough measurement to increase the cushion volume
set the pressure keeping time longer
set the resin temperature higher
enlarge the nozzle tip diameter larger
3. Countermeasures related to molded article design
1. set the variation of wall thickness of molded articles smaller
2-6 Countermeasures on defective molding (Burn)
“Burn” is a phenomenon where black burning materials are generated on
the surface of molding articles. Air which remained in the cavity while
compressed will generate heat, and this heat burns the plastics when
molten plastics are filled into cavity.
Burn can be appearance defect, causing missing parts, and decreasing
material properties.
Following are considered countermeasures on burns.
1. Countermeasures related to mold
1.
2.
3.
4.
provide the air vent
prepare deeper air vent and secure enough vent passage
dismount mold and wash give out maintenance to air vent
use insertion mold structure or bushing structure so that air will escape
from parting surfaces
5. Use vacuum aspirator device
6. change the gate position
2. Countermeasures related to injection molding condition
1.
2.
3.
4.
set the injection speed slower
set the cylinder temperature lower
make smaller measurement
avoid staying of resins in the cylinder
3. Countermeasures related to molded article design
1. try to apply design that avoids thinner wall areas of molded articles
2. change the wall thickness of molded articles, and flow of plastics
3. alter the design that allows air to stay
2-7 Countermeasures on defective molding (Silver streaks)
Silver streak (silver film) is a phenomenon where shinny stripe marks are
generated on the surface of molded articles. This may become potential
rejects as an exterior parts for electric appliances, automobile, bicycle for its
defective appearance quality.
Silver streaks occur because the air and volatile gas in the molding
materials come out on the surface of products.
Following are potential countermeasures on silverstreaks.
1. Countermeasures related to mold
1. improve the functions of air vent
2. enlarge the gate size
3. enlarge the cold slag well
2. Countermeasures related to injection molding condition
1. confirm the preheating condition(temperature, drying time) of
molding materials and apply proper drying.
2. set the injection speed slower to slower filling
3. set the cylinder temperature lower
4. reduce the screw rotation speed
5. avoid staying in the cylinder
3. Countermeasures related to molded article wall thickness
1. prepare as much as possible the uniform wall thickness
2-8 Countermeasures on defective molding (defective brightness)
Ideal surface of molded articles must be the transcribed surface appearance
of cavities, but there are times that surface of molded articles exhibit
obscured or uneven brightness surfaces.
This may become major defect cause on the product exterior surface which
the appearance quality is considered significant.
Following are potential countermeasures on defective brightness.
1. Countermeasures related to mold
1.
2.
3.
4.
5.
6.
there might be NO air vent or lack of air vent
small gate
small and narrow sprue and runner
cavity plating is NOT good condition
cavity surface polishing is NOT good condition
deposits are attached to the surface of cavity
2. Countermeasures related to injection mold condition
1.
2.
3.
4.
5.
6.
lack of measurement
too short cushion surface
too low pressure keeping
too short pressure keeping time
low cavity surface temperature
insufficient predrying of molding materials
2-9 Countermeasures on defective molding (Short shots)
Short shot is a phenomenon where incomplete filling takes place at the part
of molded articles.
There are 2(two) potential cause of short shots.
First cause is, cooling down and solidifies of tip of materials while molten
resins flow.
Second cause takes place in the process of flowing. Because air traps are
generated depends on the flowing condition.
To take countermeasures on short shots, one must first find out the cause
of problems from the above cause.
■ Short shots caused by flow tip solidification
1. Countermeasures related to mold
1.
2.
3.
4.
5.
6.
7.
Expand further the gate size
Expand further the runner size
use the larger sized sprue
too small cold slag well
provide heat insulating plate at bottom surface of mold plate
increase the number of gate
alter the location of gate
2. Countermeasures related to injection mold condition
1. set the resin temperature higher
2. set the cavity surface temperature higher
3. increase the filling pressure
4. set the pressure keeping higher
5. set the pressure keeping time longer
6. increase the measurement value
7. increase the number of cushon
8. change the injection machines
9. exchange the backflow prevention rings of injection unit
10.exchange the injection nozzle tip diameter of injection machine larger
3. Countermeasures related to molded article design
1. increase wall thickness of molded articles
2. provide ribs at the area where there is poor flowing
■ Short shot due to air trap
1. Countermeasures related to mold
1.
2.
3.
4.
provide an efficient air vent at air trap generating areas
change the gate position
change the runner balance
review and improve the structure into heatup possible structure where
there is poor flow
5. change the structure to insertion or bushing structure where there is
poor flow
2. Countermeasures related to injection mold condition
1.
2.
3.
4.
5.
change the injection speed, to change the flowing patterns
relayout the position of screw speed pressure exchange position
set the injection speed slower
set the cavity surface temperature higher
set the mold clamping pressure slight lower
3. Countermeasures related to mold article design
1. review and apply uneven wall thickness of molded articles
2. increase the wall thickness of molded articles
2-10
Molding materials and its usage (polyamide)
Polyamide is also known as “Nylon(trademark)”. There are PA6,PA66,PA46,
and aromatic polyamides.
Characteristics of polyamide are that it is outstanding in friction abrasion
character. Because of this characteristics, materials will not cause much
noise, stable sliding. Its also has superior resistant character to organic
solvents and oils.
On the other hand, it has great water permeability and hygroscopic property.
This means, one can expect dimensional change of products,
There will be an improvement of heat resistant and strength by filling glass
fibers.
Following are main usage:
■ Automobile parts
● throttle cam
● intake control valve
● door mirror bracket
● electric oil sensor
● intake manifold
● throttle body housing
● shifting lever set
● engine cover
■ electric / electronics parts
● FPC connector
● Coil bobbins
● Relay
● Switch parts
■ electric appliances / residential related
● surfing board
● electric shaver moving parts
● residential window handle levers
● electric tool housing
■ others
● fastener
● chair legs
2-11 Molding material and its usage (polyacetal)
POM resins (Polyacetal, polyoxymethylene) are superb in mechanical
specification like breaking strength, and worn out resistance property so
they are known as engineering plastics.
In POM, there are “homopolymer” and “copolymer”.
There are differences in strength, thermal resistance, molding condition
between homopolymer and copolymer.
Biggest feature of “POM Resins” are self-lubrication. It is valued functions
when its applied as gear, bearing like parts where there are always facing
frictions.
Crystallinity is high, therefore is shows good result in strength and thermal
resistance.
In injection molding, one must take care not this materials to stay long
period in the cylinder, because they will undergo thermal decomposition.
Followings are main usage.
■ Automobile parts
● fuel gauge
● fuel chamber
● door mirror warm gear
● mirror stay
● fuel pump
● radiator drain cock
■ Electric / Electronics parts
● CD pickup unit
● Switch stem
● DVD drive unit / pulley. Cum
● Magnetic memory device roller
■ precision parts
● watch gears
● bearing
■ others
● shower bib
● fastener
● gas meter parts
● flushing toilet parts
2-12 Molding material and its usage (polycarbonate)
Polycarbonate is a transparent strong thermal resistant material applied in
diverse areas.
Recently alloy type of usage of polycarbonate by mixing it with ABS resins
and used for industrial purposes.
It is amorphous and exhibit good light transmittance therefore applied as
lens and cover materials. It also exhibits outstanding strength especially
shock resistance among other plastics.
However it will be corroded by organic solvents. This is the reason why one
must pay great attention, if ever grease group of chemicals and solvents
are applied on the material.
In injection molding, this material exhibits poor liquidity. Therefore filling
pressure must be set higher. One shall also necessary to increase the
temperature up to approx 80 .
Following are usage of the materials.
■ Automobile parts
● meter panel
● head lamp lens
● door handle
● sun roof
● instrumental panels
● wheel cover
■ Electric / Electronics
● cellular phone case
● memory sticks
● CD disc
● DVD disc
● Digital camera case
● Printer chassis
● PC casing
■ optical components
● camera lens
● aspheric surface lens
● prism
● light conductor
● protection goggle
● dome shape roofing
● window glasses
2-13 Molding material and its usage (Thermoplastic elastomer)
Thermo plastic elastomer (TPE) is a synthetic resin which has rubber like
properties.
Automobile tire is one good example of rubber, but those rubbers are
solidify thru chemical reaction and therefore generally speaking it is not
possible to fabricate by injection process.
On the other hand, TPE can fabricate thru injection molding. It is
thermoplastic and therefore one can fabricate without burrs under relatively
fast cycle time.
In many cases now, this material is applied to products such as sticker parts,
sports items, toys, writing materials. 1.43M tons(2001) has been consumed
in the world.
TPE shows rubber like flexible hypertrophic properties because it contains
soft segments and hard segments.
There are following types of TPE available, and being used accordingly.
(1) SBC (styrenic TPE)
Sole, automobile parts, food container, writing material grip, sports
items
(2) TPVC (vinyl chloride TPE)
Electric wire coating, automobile parts, electric appliance
(3) TPO (olefine TPE)
Automobile parts, construction/civil work parts, electric appliance
(4) TPE (Polyurethane TPE)
Watch band, sole, automobile parts. etc
(5) TPEE (polyester TPE)
Automobile parts, electric appliance, industrial materials. etc.
(6) nitryl TPE
(7) TPAE (polyamide TPE)
(8) Fluoro-chemical TPE
(9) Silicone TPE
<reference/citation list>
1) c Michio Komatsu : “Molds for beginners. Introduction to plastic injection
mold, molding technology.” Mold technology
April 2004, special issues, [Daily industrial journals]2004
2) c Michio Komatsu : “Plastic injection molding design manual, pin gate
structure” mold technology. March 1998 special issue, Daily industrial
journals 1998
3) c Michio Komatsu : “Plastic injection design manual” Daily industrial
journals (1996)
4) “Plastic mold standard parts 2005.6 ∼2007.4”MISUMI Inc. (2005)
5) Technology course, MISUMI online, MISUMI Inc, www.mol.ne.jp