Mould and Die Design
Mould and Die Design
DESIGN
CHAPTER-1
INTRODUCTION
Feed System
Feed System
To provide a flow-way in the injection mould to connect the nozzle of
the injection machine to each impression.This flow-way is termed as
Feed System.
Normally the feed system comprises a Sprue, Runner and Gate, are
applied equally to the flow-way itself, and to the moulded material
which is removed from the flow-way in the process of extracting the
molding.
Sprue
The plastic material formed in the tapered passage which connects the
nozzle to the mould’s parting surface.
Sprue Bush
A hardened steel bush which incorporates the tapered sprue passageway.
When the mould opens it is essential that the sprue is pulled positively
from the sprue bush.With single impression moulds the sprue feeds
directly into the base of the component and sprue is pulled at the same
time as the molding is pulled from the cavity.
Runner
A channel, machined in one or both mould plates, to connect the sprue
with the entrance (gate) to the impression.
In two-plate mold the runner is positioned on the parting surface while
on more complex designs the runner may be positioned below the
parting surface.
The wall of the runner channel must be smooth to prevent any
restriction to flow.
Feed System
Runner Design
The designer should keep in mind the following points during
design of runner.
Shape and cross section of the runner
Size of the runner
Layout of the runner
Shape and Cross section:
Various shapes and cross sections are:
Circular
Semi- circular
Trapezoidal
Modified Trapezoidal
Hexagonal
Square
Runner Efficiency
Depends on:
Cross sectional area
Periphery of the runner
Depth of gate h = n . t
Where n = material constant ;
t = wall thickness of the moulding (mm)
Land length L = 0.5 – 1.5 mm
Types of gate
Edge gate
Tab gate
Sprue gate
Diaphragm gate
Ring gate
Fan gate
Submarine or Tunnel gate
Valve Gate
Edge Gate
Most common manual trim gate
Nominal thickness 50% to 75% nominal wall
Can be constant thickness or
tapered
Tab Gate
Gate goes into tab that goes to the part
Similar to edge gate
Used to lower shear stress in the part
Stress stays in the tab
Tab Gate
Sprue Gate
Sprue directly into part
Size at part dependant on sprue orifice size
Diaphragm Gate
Usedto gate into the inside diameter of round parts
Normally has thin land at part
Ring Gate
Like a diaphragm gate but is for the
outside of the part
Not recommended
Difficult to get even flow
Fan Gate
Wide edge gate
Balanced to achieve a flat flow front entering the part
Flash Gate
Similar to ring and fan gates
Designed to have flat flow front
entering part
Difficult to achieve
Not recommended
Submarine Gate
Tapered round gate that intersects the part below the parting
line
Very Common
Nominal orifice diameter 25% to 75% nominal wall
Parting Line
Cashew Gate
Curved tunnel gate
Difficult to machine
Possible maintenance problem
Pin Point Gate
Used in 3 plate molds
Very small orifice
Nominal orifice diameter 0.25 to
1.5 mm
Hot Drop
Delivers Flow
hot material to the channel
part directly
Gate geometry and size
dependant on type of hot
drop desired
Orifice size can be critical
so the nozzle will not drool
Gate geometry
varies widely
depending on drop
style and usage
Valve Gate
Similar to a hot drop but the gate orifice
is closed by a pin
Pin can be opened and
closed several times during
the cycle
Gate Balancing
The method of balanced gating, there are two ways of varying the
restrictions:
i) By varying the land length and
ii) By varying the cross-sectional area of the gate