MOLD DESIGN FUNDAMENTAL CALCULATION

Product BATTERY COVER

Code of Project MOT-009-NKD

1 Machine Clamping Force (Fc)

Formula : Fc = P x A / 0.8

A : Total Projection Area of product and runner (cm2) 140

P : Average Pressure inside cavity (kgf/cm2) 260 >>see Table 1
0.8 : Safety Ratio 0.8
Fc : Injection Machine Clamping Force (kgf) 50050 MINIMUM = 50 T

Table 1. Injection Pressure

Injection Pressure Pressure Inside Cav.
Name of Plastic Resin Resin Temp (°C)
(kgf/cm2) (kgf/cm2)
Poly Ethylene (PE) 180~130 600~1400 230~320
Poly Propylene (PP) 200~300 600~1400 220~320
Poly Styrene (PS) 180~315 700~1700 260~320
Poly Carbonate (PC) 280~320 800~1500 270~300
Acrylonitrile Butadine Styrene
200~280 700~1500 330~440
(ABS)
Poly Amide (PA) 230~300 800~1500 240~450

2 Injection Volume

Total Product Volume (cm3) 32

Ideal Injection Volume of Machine (cm3) 45.7

3 Gate Dimension
Table 2. Flow Coeficient
High Flow Middle Flow Low Flow
n=0.6 n=0.7 n=0.8
PS POM PA
PP PBT PVC
PE PA PMMA
AS
ABS

A. Side Gate Dimension

Formula : h=nxt
w = n x √A / 30

n : Flow coeficient 0.6 >>see Table 2

t : Product thickness (mm) 2.2
V : Product volume (mm3) 16047
A : V/t 7294.091
h : Height of gate (mm) 1.32
 w : Width of gate (mm) 1.708109

4 Mold Base Dimension

A. Pressure Plate Thickness (B)

Formula : 3 5 x P x L x M^4
B= √ 32 x E x L2 x Ymax1
P : Injection Pressure Inside Cavity (kgf/cm2) 280 >>see Table 1
L : Article Size (mm) 170
n : Number of Support Pillar Position 4
M : Distance between Spacer Blocks (mm) 264
E : Young Modulus of Elasticity (kgf/cm2) 2100000
Ymax1 : Deflection of Plate (mm) 0.01
L2 : Mold Move Length (mm) 250
B : Pressure Plate Thickness (mm) 22.24681

B. Wall Thickness (D)

Formula : 3 P x A x L^4
D1 = √ 32 x E x B2 x Ymax2
P : Injection Pressure Inside Cavity (kgf/cm2) 280 >>see Table 1
A : Wall Depth (mm) 15
L : Article Size (mm) 170
E : Young Modulus of Elasticity (kgf/cm2) 2100000
B2 : Mold Plate Thickness (mm) 60
Ymax2 : Deflection of Wall (mm) 0.05
D1 : Wall thickness (mm) 25.91303

Formula : C x P x A^4
D2 = √3 E x Ymax2
P : Injection Pressure Inside Cavity (kgf/cm2) 280 >>see Table 1
A : Wall Depth (mm) 15
L : Article Size (mm) 170
L/A : Depth Ratio 11.33333
C : Depth Coeficient 0.1 >>see Table 3
E : Young Modulus of Elasticity (kgf/cm2) 2100000
Ymax2 : Deflection of Wall (mm) 0.05
D2 : Wall Thickness (mm) 2.381102
 Table 3. Depth Coeficient
L/A C L/A C
1.0 0.044 1.7 0.096
1.1 0.053 1.8 0.102
1.2 0.062 1.9 0.106
1.3 0.070 2.0 0.111
1.4 0.078 3.0 0.134
1.5 0.084 4.0 0.140
1.6 0.090 5.0 0.142

5 Spring Force for Ejector Plate (Fs1)

Formula : Wxv
Fs1 =
n

h1 : Thickness of Ejector Plate 1 (mm) 25

h2 : Thickness of Ejector Plate 2 (mm) 30
w : Width of Ejector Plate (mm) 260
l : Length of Ejector Plate (mm) 450
W : Weight of Ejector Plate (kgf) 50.193
v : Safety factor 1.4
n : Number of Spring 4
s : Spring initial deflection 10
Fs1 : Minimum Spring Force (kgf) 17.56755
k : Minimum Spring Constant (kgf/mm) 1.756755

6 Spring Force for Slide Core (Fs2)

Formula : Wxv
Fs2 =
n

W : Weight of Slide Core (kgf) 2.842

v : Safety factor 2
n : Number of Spring 1
s1 : Spring Initial Deflection (mm) 5
Fs2 : Minimum Spring Force (kgf) 5.684
k : Minimum Spring Constant (kgf/mm) 1.1368

7 Finger Pin Diameter (Da)

Formula : k x s2 x cos β x L
Da = √3 (Tb/v) x π

k : Spring constant (kgf/mm) 1.1368

s2 : Spring final deflection (mm) 15
 β : Finger pin angle 15
L : Free length of finger pin (mm) 80
Tb : Bending stress of finger pin material (kgf/mm2) 120
v : Safety factor 4
Da : Finger pin diameter (mm) -2.224077

7 Core Pulling Distance

S = H x Tan α +2~3 H= 6.74

H = Lenght required for slider(mm) S= 13.1385

α = Dip Angle Pin

8 Length Angular pin

L = S/COS α -8.872064
MINIMUM = 50 TON
 Panjang (mm) Lebar (mm) Tebal (mm)
ADP-PLT-1 1000 600 45
SUP-PLT 1000 450 79.8
MLD-STA 1000 450 140
MLD-MOV 1000 450 170
SPC-BLC 1000 150 100
EJC-PLT-1 1000 246 30
EJC-PLT-2 1000 246 35
ADP-PLT-2 1000 600 45
Volume (mm³) Berat (kg) Berat (Ton)
27000000 210.6 0.2106
35910000 280.098 0.280098
63000000 491.4 0.4914
76500000 596.7 0.5967
15000000 117 0.117
7380000 57.564 0.057564
8610000 67.158 0.067158
27000000 210.6 0.2106
2.03112