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Summary
Summary
This applications-oriented book describes the construction of an injection mould from the ground up. Included are explanations of the individual types of tools, components, and technical terms; design procedures; techniques, tips, and tricks in the construction of an injection mould; and pros and cons of various solutions.
Based on a plastic part (""bowl with lid"") specially developed for this book, easily understandable text and many illustrative pictures and drawings provide the necessary knowledge for practical implementation. Step by step, the plastic part is modified and enhanced. The technologies and designs that are additionally needed for an injection mould are described by engineering drawings. Maintenance and repair, and essential manufacturing techniques are also discussed.
With the purchase of this book, you also receive a free personal access code to download the eBook.
Author Notes
Rainer Dangel is a qualified mouldmaker and has been active in mouldmaking for over 35 years, during almost 25 of which he constructed moulds on a freelance basis. During this time, he acquired extensive knowledge in this technically very demanding area. He is managing director of his own company, Dangel Formentechnik.
Table of Contents
Foreword | p. v |
The Author | p. vii |
Acknowledgements | p. ix |
How to Use This Book | p. xvii |
1 Introduction | p. 1 |
2 Mould Types | p. 3 |
2.1 Simple Open/Close Mould | p. 3 |
2.1.1 Classic Structure of an Open/Close Mould | p. 6 |
2.1.2 Guiding Elements | p. 7 |
2.1.3 Backing Plate | p. 10 |
2.2 Moulds with Moving Elements | p. 11 |
2.2.1 Undercut | p. 11 |
2.2.2 Slide | p. 12 |
2.2.3 Slide Operation | p. 13 |
2.2.4 Latch, Clip Lock | p. 14 |
2.2.5 Inclined Ejector | p. 15 |
2.2.6 Forced Demoulding | p. 17 |
2.2.7 Mould Size | p. 18 |
2.3 Mould for Threads | p. 19 |
2.3.1 External Threads | p. 20 |
2.3.2 Internal Threads | p. 22 |
2.3.3 Drive Types for De-spindling | p. 23 |
2.3.3.1 Hydraulic Unscrewing Unit | p. 23 |
2.3.3.2 Gear Rack | p. 24 |
2.3.3.3 High-Helix Lead Screw | p. 25 |
2.3.3.4 Multi-cavity Moulds | p. 27 |
2.4 Multi-component Injection Moulds | p. 28 |
2.4.1 Material Pairings | p. 28 |
2.4.2 Mould Technology | p. 29 |
2.4.2.1 Shifting Technology | p. 29 |
2.4.2.2 Rotary Table Technology | p. 32 |
2.4.2.3 Sealing Slide Technology | p. 35 |
2.4.2.4 Further Technologies | p. 35 |
2.5 Stack Mould | p. 35 |
2.5.1 Material Combinations | p. 36 |
2.5.2 Hot Runner | p. 36 |
2.5.3 Opening and Closing | p. 37 |
2.5.4 Toggle Lever | p. 40 |
2.5.5 Ejection | p. 41 |
2.5.6 General Information on the Stack Mould | p. 41 |
2.6 Further Literature | p. 42 |
3 Preparation | p. 43 |
3.1 CAD System | p. 43 |
3.2 Data Transfer, Procedure, and Processing | p. 44 |
3.2.1 Data Transfer | p. 45 |
3.2.2 Formats | p. 45 |
3.2.2.1 IGES | p. 45 |
3.2.2.2 STEP | p. 46 |
3.2.2.3 STL | p. 46 |
3.2.3 Data Size | p. 48 |
3.2.4 Shrinkage | p. 48 |
3.2.4.1 Material Selection | p. 48 |
3.2.4.2 Shrinkage (Physical Process) | p. 49 |
3.2.4.3 Influencing Variables | p. 49 |
3.2.5 Calculation and Impact | p. 51 |
3.2.5.1 Free Shrinkage, Constrained Shrinkage | p. 53 |
3.2.5.2 Warping | p. 56 |
3.3 Specifications | p. 59 |
3.3.1 Location of the Component inside the Injection Mould | p. 59 |
3.3.1.1 Demoulding Direction | p. 59 |
3.3.2 Number of Cavities | p. 63 |
3.3.3 Arrangement of Cavities | p. 66 |
3.4 Material Selection for Injection Moulds | p. 71 |
3.5 Mould Size | p. 74 |
3.6 Plate Thickness | p. 77 |
3.7 Demoulding | p. 78 |
3.7.1 Basic Principle of Demoulding | p. 78 |
3.7.2 Draft Angles | p. 78 |
3.7.2.1 Definition | p. 79 |
3.7.2.2 Effect on the Opening of the Mould | p. 80 |
3.7.2.3 Draft Angle in the Split Line Face | p. 81 |
3.7.2.4 Demoulding Problems and Solutions | p. 83 |
3.8 Split Line Face | p. 87 |
3.8.1 Plain Split Line Face | p. 87 |
3.8.2 Contour-Forming Split Line Face | p. 88 |
3.8.3 Jumping Split Line Face | p. 88 |
3.8.4 Wear Plates in the Split | p. 90 |
3.8.5 Visible Split Line | p. 91 |
3.9 Injection | p. 93 |
3.9.1 Injection and Feed Point | p. 93 |
3.9.2 Simulation | p. 95 |
3.9.3 Sprue System, Sprue Type | p. 101 |
3.9.3.1 Cold Runner | p. 101 |
3.9.3.2 Hot Runner | p. 102 |
3.9.4 Runner | p. 103 |
3.9.5 Sprue on the Part | p. 105 |
3.9.6 Tunnel Gate | p. 106 |
3.9.7 Film Gate | p. 111 |
3.9.8 Diaphragm Gate | p. 112 |
3.9.9 Hot Runner Single Nozzle | p. 114 |
3.9.10 Hot Runner Distributor | p. 116 |
3.9.11 Hot Runner Distribution System with Needle Valve | p. 118 |
3.9.11.1 Integral Hinge | p. 122 |
3.9.12 Three-Plate Mould | p. 123 |
3.9.13 Tunnel Gate Inserts | p. 126 |
3.10 Ventilation | p. 127 |
3.10.1 General Information about Ventilation | p. 127 |
3.10.2 Ventilation via Components | p. 130 |
3.10.3 Geometric Design of Ventilation | p. 132 |
3.11 Further Literature | p. 134 |
4 Components | p. 135 |
4.1 Mould Inserts/Mould Cores | p. 135 |
444 Mould Inserts | p. 135 |
4.1.2 Mould Cores | p. 140 |
4.2 Slides | p. 144 |
4.2.1 Application Areas of Slides | p. 144 |
4.2.2 Design of a Slide | p. 146 |
4.2.2.1 Mould Contour | p. 147 |
4.2.2.2 Split Line on Slide | p. 148 |
4.2.2.3 Slide Body and Guiding | p. 150 |
4.2.2.4 Operation of Slides | p. 152 |
4.2.2.5 Locking in the End Position | p. 157 |
4.2.2.6 Cooling in Slide | p. 161 |
4.2.3 Further Slide Concepts | p. 162 |
4.2.3.1 Slide in Slide | p. 163 |
4.2.3.2 "Backpack" Slide | p. 165 |
4.3 Ejectors | p. 167 |
4.3.1 Types of Ejectors | p. 169 |
4.3.2 Ejectors as Auxiliary Tools | p. 174 |
4.3.3 Inclined Ejectors | p. 176 |
4.3.4 Stripper Plate | p. 178 |
4.3.5 Two-Stage Ejectors | p. 180 |
4.3.6 Collapsible Cores | p. 182 |
4.3.7 Forced Demoulding | p. 183 |
4.4 Cooling System | p. 183 |
4.4.1 Cooling Type and Auxiliary Equipment | p. 186 |
4.4.1.1 Drilled Cooling | p. 188 |
4.4.1.2 Redirection of Cooling Circuits | p. 190 |
4.4.1.3 Copper Cores | p. 195 |
4.4.1.4 Heating Cartridges | p. 196 |
4.4.1.5 Connection of circuits | p. 197 |
4.4.2 Connection and Sealing of Cooling Holes | p. 198 |
4.5 Components and Marking | p. 200 |
4.6 Surface | p. 202 |
4.6.1 Rough Surface | p. 203 |
4.6.2 EDM | p. 204 |
4.6.3 Graining | p. 206 |
4.6.4 Laser Texturing | p. 207 |
4.6.5 Polishing | p. 208 |
4.7 Systematic Design Approach | p. 209 |
4.7.1 Strategy | p. 209 |
4.7.2 Standard Parts | p. 211 |
4.7.3 Manufactured Parts | p. 213 |
4.8 Further Literature | p. 215 |
5 Assembly | p. 217 |
5.1 Systematic Assembly | p. 217 |
5.2 Spotting | p. 222 |
5.3 Connection of Components | p. 224 |
5.4 Check the Cooling for Leaks | p. 227 |
5.5 Further Literature | p. 229 |
6 Further Knowledge | p. 231 |
6.1 Process Chain in Mould Making | p. 231 |
6.2 Quality Assurance | p. 233 |
6.3 Fits and Play in the Mould: What Must Fit? | p. 235 |
6.4 Heat Treatment | p. 239 |
6.4.1 Annealing | p. 240 |
6.4.2 Hardening | p. 241 |
6.4.3 Nitriding | p. 243 |
6.5 Coatings | p. 245 |
6.6 Changes: What Is to Be Considered? | p. 246 |
6.7 Further Literature | p. 248 |
7 The Finished Mould | p. 249 |
7.1 Mould Validation | p. 249 |
7.1.1 Clamping and Connecting the Media | p. 249 |
7.1.2 Filling of the Mould | p. 252 |
7.1.2.1 Balancing Cavities | p. 254 |
7.1.2.2 Optimising the Parameters | p. 256 |
7.1.2.3 Influence on the Injection Process | p. 257 |
7.1.3 Parameters during Injection | p. 257 |
7.1.4 Forces Acting in the Mould during the Injection Process | p. 258 |
7.1.5 Initial Sample Inspection Report | p. 260 |
7.2 Labels on the Mould | p. 261 |
7.3 Further Literature | p. 262 |
8 Maintenance and Repair | p. 263 |
8.1 Maintenance Schedule | p. 263 |
8.2 Welding | p. 264 |
8.2.1 Tungsten Inert Gas Welding (TIG) | p. 264 |
8.2.2 Laser Beam Welding | p. 265 |
8.3 Component Replacement | p. 266 |
8.4 Further Literature | p. 267 |
9 Manufacturing Technologies | p. 269 |
9.1 Milling | p. 269 |
9.1.1 3-Axis Milling | p. 271 |
9.1.2 4- and 5-Axis Milling | p. 273 |
9.1.2.1 4-Axis Milling | p. 273 |
9.1.2.2 5-Axis Milling | p. 274 |
9.1.2.3 3+2-Axls Milling | p. 275 |
9.1.2.4 Simultaneous 5-Axis Milling | p. 276 |
9.1.3 CAM Programming | p. 278 |
9.2 EDM | p. 282 |
9.2.1 Sinker EDM | p. 283 |
9.2.2 Wire EDM | p. 285 |
9.3 Grinding/Profile Grinding | p. 286 |
9.4 Drilling/Deep Hole Drilling | p. 287 |
9.5 Turning | p. 289 |
9.6 New Technologies | p. 290 |
9.6.1 LaserCUSTNGĀ®/Laser Sintering | p. 290 |
9.6.2 Vacuum Soldering | p. 291 |
9.7 Polishing | p. 293 |
9.8 Further Literature | p. 293 |
10 Practical Guidelines | p. 295 |
10.1 Design Check List | p. 297 |
10.2 Design Colour Chart | p. 298 |
10.3 Sequential Function Chart | p. 299 |
10.4 Maintenance Schedule | p. 300 |
10.5 Formulas and Calculations | p. 301 |
Index | p. 303 |