Cover image for Injection Moulds for Beginners
Title:
Injection Moulds for Beginners
Personal Author:
Physical Description:
xviii, 308 pages : illustrations ; 25 cm
ISBN:
9781569906316
Abstract:
"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."

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30000010343386 TP1150 D36 2016 Open Access Book Book
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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

Forewordp. v
The Authorp. vii
Acknowledgementsp. ix
How to Use This Bookp. xvii
1 Introductionp. 1
2 Mould Typesp. 3
2.1 Simple Open/Close Mouldp. 3
2.1.1 Classic Structure of an Open/Close Mouldp. 6
2.1.2 Guiding Elementsp. 7
2.1.3 Backing Platep. 10
2.2 Moulds with Moving Elementsp. 11
2.2.1 Undercutp. 11
2.2.2 Slidep. 12
2.2.3 Slide Operationp. 13
2.2.4 Latch, Clip Lockp. 14
2.2.5 Inclined Ejectorp. 15
2.2.6 Forced Demouldingp. 17
2.2.7 Mould Sizep. 18
2.3 Mould for Threadsp. 19
2.3.1 External Threadsp. 20
2.3.2 Internal Threadsp. 22
2.3.3 Drive Types for De-spindlingp. 23
2.3.3.1 Hydraulic Unscrewing Unitp. 23
2.3.3.2 Gear Rackp. 24
2.3.3.3 High-Helix Lead Screwp. 25
2.3.3.4 Multi-cavity Mouldsp. 27
2.4 Multi-component Injection Mouldsp. 28
2.4.1 Material Pairingsp. 28
2.4.2 Mould Technologyp. 29
2.4.2.1 Shifting Technologyp. 29
2.4.2.2 Rotary Table Technologyp. 32
2.4.2.3 Sealing Slide Technologyp. 35
2.4.2.4 Further Technologiesp. 35
2.5 Stack Mouldp. 35
2.5.1 Material Combinationsp. 36
2.5.2 Hot Runnerp. 36
2.5.3 Opening and Closingp. 37
2.5.4 Toggle Leverp. 40
2.5.5 Ejectionp. 41
2.5.6 General Information on the Stack Mouldp. 41
2.6 Further Literaturep. 42
3 Preparationp. 43
3.1 CAD Systemp. 43
3.2 Data Transfer, Procedure, and Processingp. 44
3.2.1 Data Transferp. 45
3.2.2 Formatsp. 45
3.2.2.1 IGESp. 45
3.2.2.2 STEPp. 46
3.2.2.3 STLp. 46
3.2.3 Data Sizep. 48
3.2.4 Shrinkagep. 48
3.2.4.1 Material Selectionp. 48
3.2.4.2 Shrinkage (Physical Process)p. 49
3.2.4.3 Influencing Variablesp. 49
3.2.5 Calculation and Impactp. 51
3.2.5.1 Free Shrinkage, Constrained Shrinkagep. 53
3.2.5.2 Warpingp. 56
3.3 Specificationsp. 59
3.3.1 Location of the Component inside the Injection Mouldp. 59
3.3.1.1 Demoulding Directionp. 59
3.3.2 Number of Cavitiesp. 63
3.3.3 Arrangement of Cavitiesp. 66
3.4 Material Selection for Injection Mouldsp. 71
3.5 Mould Sizep. 74
3.6 Plate Thicknessp. 77
3.7 Demouldingp. 78
3.7.1 Basic Principle of Demouldingp. 78
3.7.2 Draft Anglesp. 78
3.7.2.1 Definitionp. 79
3.7.2.2 Effect on the Opening of the Mouldp. 80
3.7.2.3 Draft Angle in the Split Line Facep. 81
3.7.2.4 Demoulding Problems and Solutionsp. 83
3.8 Split Line Facep. 87
3.8.1 Plain Split Line Facep. 87
3.8.2 Contour-Forming Split Line Facep. 88
3.8.3 Jumping Split Line Facep. 88
3.8.4 Wear Plates in the Splitp. 90
3.8.5 Visible Split Linep. 91
3.9 Injectionp. 93
3.9.1 Injection and Feed Pointp. 93
3.9.2 Simulationp. 95
3.9.3 Sprue System, Sprue Typep. 101
3.9.3.1 Cold Runnerp. 101
3.9.3.2 Hot Runnerp. 102
3.9.4 Runnerp. 103
3.9.5 Sprue on the Partp. 105
3.9.6 Tunnel Gatep. 106
3.9.7 Film Gatep. 111
3.9.8 Diaphragm Gatep. 112
3.9.9 Hot Runner Single Nozzlep. 114
3.9.10 Hot Runner Distributorp. 116
3.9.11 Hot Runner Distribution System with Needle Valvep. 118
3.9.11.1 Integral Hingep. 122
3.9.12 Three-Plate Mouldp. 123
3.9.13 Tunnel Gate Insertsp. 126
3.10 Ventilationp. 127
3.10.1 General Information about Ventilationp. 127
3.10.2 Ventilation via Componentsp. 130
3.10.3 Geometric Design of Ventilationp. 132
3.11 Further Literaturep. 134
4 Componentsp. 135
4.1 Mould Inserts/Mould Coresp. 135
444 Mould Insertsp. 135
4.1.2 Mould Coresp. 140
4.2 Slidesp. 144
4.2.1 Application Areas of Slidesp. 144
4.2.2 Design of a Slidep. 146
4.2.2.1 Mould Contourp. 147
4.2.2.2 Split Line on Slidep. 148
4.2.2.3 Slide Body and Guidingp. 150
4.2.2.4 Operation of Slidesp. 152
4.2.2.5 Locking in the End Positionp. 157
4.2.2.6 Cooling in Slidep. 161
4.2.3 Further Slide Conceptsp. 162
4.2.3.1 Slide in Slidep. 163
4.2.3.2 "Backpack" Slidep. 165
4.3 Ejectorsp. 167
4.3.1 Types of Ejectorsp. 169
4.3.2 Ejectors as Auxiliary Toolsp. 174
4.3.3 Inclined Ejectorsp. 176
4.3.4 Stripper Platep. 178
4.3.5 Two-Stage Ejectorsp. 180
4.3.6 Collapsible Coresp. 182
4.3.7 Forced Demouldingp. 183
4.4 Cooling Systemp. 183
4.4.1 Cooling Type and Auxiliary Equipmentp. 186
4.4.1.1 Drilled Coolingp. 188
4.4.1.2 Redirection of Cooling Circuitsp. 190
4.4.1.3 Copper Coresp. 195
4.4.1.4 Heating Cartridgesp. 196
4.4.1.5 Connection of circuitsp. 197
4.4.2 Connection and Sealing of Cooling Holesp. 198
4.5 Components and Markingp. 200
4.6 Surfacep. 202
4.6.1 Rough Surfacep. 203
4.6.2 EDMp. 204
4.6.3 Grainingp. 206
4.6.4 Laser Texturingp. 207
4.6.5 Polishingp. 208
4.7 Systematic Design Approachp. 209
4.7.1 Strategyp. 209
4.7.2 Standard Partsp. 211
4.7.3 Manufactured Partsp. 213
4.8 Further Literaturep. 215
5 Assemblyp. 217
5.1 Systematic Assemblyp. 217
5.2 Spottingp. 222
5.3 Connection of Componentsp. 224
5.4 Check the Cooling for Leaksp. 227
5.5 Further Literaturep. 229
6 Further Knowledgep. 231
6.1 Process Chain in Mould Makingp. 231
6.2 Quality Assurancep. 233
6.3 Fits and Play in the Mould: What Must Fit?p. 235
6.4 Heat Treatmentp. 239
6.4.1 Annealingp. 240
6.4.2 Hardeningp. 241
6.4.3 Nitridingp. 243
6.5 Coatingsp. 245
6.6 Changes: What Is to Be Considered?p. 246
6.7 Further Literaturep. 248
7 The Finished Mouldp. 249
7.1 Mould Validationp. 249
7.1.1 Clamping and Connecting the Mediap. 249
7.1.2 Filling of the Mouldp. 252
7.1.2.1 Balancing Cavitiesp. 254
7.1.2.2 Optimising the Parametersp. 256
7.1.2.3 Influence on the Injection Processp. 257
7.1.3 Parameters during Injectionp. 257
7.1.4 Forces Acting in the Mould during the Injection Processp. 258
7.1.5 Initial Sample Inspection Reportp. 260
7.2 Labels on the Mouldp. 261
7.3 Further Literaturep. 262
8 Maintenance and Repairp. 263
8.1 Maintenance Schedulep. 263
8.2 Weldingp. 264
8.2.1 Tungsten Inert Gas Welding (TIG)p. 264
8.2.2 Laser Beam Weldingp. 265
8.3 Component Replacementp. 266
8.4 Further Literaturep. 267
9 Manufacturing Technologiesp. 269
9.1 Millingp. 269
9.1.1 3-Axis Millingp. 271
9.1.2 4- and 5-Axis Millingp. 273
9.1.2.1 4-Axis Millingp. 273
9.1.2.2 5-Axis Millingp. 274
9.1.2.3 3+2-Axls Millingp. 275
9.1.2.4 Simultaneous 5-Axis Millingp. 276
9.1.3 CAM Programmingp. 278
9.2 EDMp. 282
9.2.1 Sinker EDMp. 283
9.2.2 Wire EDMp. 285
9.3 Grinding/Profile Grindingp. 286
9.4 Drilling/Deep Hole Drillingp. 287
9.5 Turningp. 289
9.6 New Technologiesp. 290
9.6.1 LaserCUSTNGĀ®/Laser Sinteringp. 290
9.6.2 Vacuum Solderingp. 291
9.7 Polishingp. 293
9.8 Further Literaturep. 293
10 Practical Guidelinesp. 295
10.1 Design Check Listp. 297
10.2 Design Colour Chartp. 298
10.3 Sequential Function Chartp. 299
10.4 Maintenance Schedulep. 300
10.5 Formulas and Calculationsp. 301
Indexp. 303