MOLDS & DIES

MOLDS
 CORE AND CAVITY
• The assembly of plates having an impression into which
plastic melt is injected and cooled to form a component

• The impression is formed by two members:

i) The CAVITY which is the female portion of the

mould, gives the molding its external form
ii) The CORE which is the male portion of the mould,
forms the internal shape of the molding

IMPRESSION
• It is the part of the mould which gives shape of the
molding. The space between core and cavity when the
mould is closed is called impression.
 Mold Operation

MOLD CLOSING

MOLD OPENING
CORE - CAVITY - COMPONENT

Component
(Component )

SPRUE
CORE

CAVITY
 Nerves of CORE AND CAVITY
SPRUE
RUNNER AND GATE SYSTEM:
Sub Runner

Material may be directly injected into the

impression through the sprue bush

For moulds containing with multi-impression

it may pass from sprue bush hole through a
RUNNER and GATE system before entering
impression. Gate is a channel or orifice
connecting runner to impression.
 Body of MOLD

FIXED HALF & MOVING HALF

• Various mould parts fall naturally into two

sections or Half.

• Half attached to the stationary platen of

machine is termed “fixed half”.

• Other half of the mould attached to the

moving platen of the machine is known as
moving half.
 FIXED HALF & MOVING HALF

• Generally core is situated in moving half because,

the molding, as it cools will shrink on to the core
and remain with it as mould opens.

• this will occur irrespective of whether the core is in

the fixed half and moving half.

• Basically due to the shrinkage of moulding on to

the core , some form of ejection mechanism is
required to eject the part.

• Motivation for ejector system is easily provided if

core is in moving half.
 MOULD LOCATION
Accompanied by Positioning

i) Locating ring

ii) Sprue bush

iii) Nozzles
 LOCATING RING

• Register ring or locating ring is a circular member fitted on to the front

face of the mould. Its purpose is to locate mould in its correct position on
the injection molding machine.

• When mould is mounted on machine ,the front mounted register rings fits
into circular hole which is accurately machined in injection platen (Fixed
Half) on cylindrical–nozzle axis.

• This ensures small aperture in nozzle is in direct alignment with sprue

bush hole.

• Sprue-bush is the connecting member between machine nozzle and the

mould face, this alignment of nozzle aperture and sprue bush hole
permits uninterrupted flow of material from cylinder through nozzle and
sprue hole into mould runner system. locating rings forms direct
connection of between sprue-bush and machine nozzle.
LOCATING RING
 MOULD LOCATION
SPRUE BUSH
The sprue bush is defined as that part of the mould in which sprue is
formed. in practice sprue bush is the connecting member between
the machine nozzle and the mould face, and provides a suitable
aperture through which the material can travel on its way to the
impressions or to the start of the runner system in multi impression
mold. it always be hardened.
The internal aperture of the sprue bush has between 2° and 4°
included taper, which facilitates removal of sprue from the mould at
the end of the molding cycle.

Types of SPRUE BUSH

There are two basic designs of sprue bush which differ only
with the respect to the form of seating between the sprue
bush and the nozzle of the machine

i) Spherical seating sprue bush

ii) Flat seating sprue bush
SPRUE BUSH
 MOULD LOCATION
NOZZLES

Purpose of nozzle is to provide a flow path for

plastic melt from machine cylinder’s to the
mould in simplest design nozzle butts on to
sprue bush of mould.

TYPES OF NOZZLE

• STANDARD NOZZLE

• REVERSE TAPER NOZZLE

• EXTENDED NOZZLE

• SHUT OFF NOZZLE

MOULD VENTING
 VENTING
• When the plastic material enters an impression air is
displaced . Normally the air can be displaced between the two
mating mould plates.

• Plates have a very fine lapped finish the air may be trapped
within the impressions so that mould defects may arise , such
as discoloration, sinks marks , incomplete filling etc.

• Good design practice to provide vent in the mould to allow air

to escape freely.

• It is not usually possible to pre-determinate where the vent

will be required, so the vent is normally machined in the
mould plate once the mould has tried out.

• The size of vent is 0.05mm deep by 3mm wide.

• If greater depth provided, there will be possibility for plastic

melts to pass through the slots and the resultant undesirable
flash mark being left on the molding.
POSITIONS OF VENT
 Venting

25.4 cm of parting line requires

7.6 cm of venting, this is
accomplished with 12 vents, each
0.64 cm wide equally spaced
around the parting line

VENTING for RUNNER

Methodical Approach
to
MOULD DESIGN
FLOW CHART FOR METHODICAL DESIGNING OF INJECTION MOULDS
Part design, Material Selection,
Requirements, Quantity ordered, No. of
Pieces/Time
Types of ejection

Types of mould Pin Blade Stripper Stripper Air Sleeve Valve

Ring plate
Cold runner Hot runner
Types of venting
Layout of cavities

Parting line Core insert Ejector pin Porous metal pin

Star arrangement Symmetrical arrangement In-line arrangement
Mould Material
Selection of Parting Line
Mold base Cores & Cavity Inserts/ Plates
Plain Stepped Angled Profiled Complex Edge

Types of gating Mild Steel Mild Steel Pre-Hardened Steel Hot Die Steel

Anticipated Shrinkage
Sprue Pin Edge Tunnel Fan Film Tab SpokeDiaphragm Ring

Temperature control system

Part Design Gating Processing Condition

Plates Cores,Cavities Type of ejection DESIGN

Oil Water Oil Water
 Steps for Mould Design
At first the mould is selected which depends upon
material used for the product wheather it is
Thermoplastic or Thermoset.

Generally Mould can be selected

• Depending upon the product (profiled / complex
structure) and material being used.

• It can also be as per the wastage of plastic

material/SCRAP.

• Depend upon number of impression, cycle time.

• And for sometimes it is selected by automatic

degating of runner.
THE GENERAL CLASSIFICATION OF
MOULD

a)Injection mould

b)Compression mould

c)Transfer mould

d)Blow mould

e)Rotational mould
 THE GENERAL CLASSIFICATION OF
MOULD
Type of moulds is classified according to shape of the
plastic product.

i) Two plate injection mould

ii) Three plate injection mould

iii) Split injection mould

iv) Mold for threaded component

v) Insulated runner injection mould

vi) Family mould

vii) Hot Runner Mould

Undercut runner
CLASSIFICATION OF MOULD

TWO PLATE MOLD

THREE PLATE MOLD

 Two plate mould

• It consists of two plate containing core and

cavity and has only single daylight. This
type of mould are generally made for those
molding which necessitates large size of
gate.
Two-Plate-Mould
 THREE PLATE INJECTION MOULD
• It has three plates one so called the runner plate attached to the fixed
platen of machine which consists the runner and sprue.

• Second plate so called cavity plate(floating plate) which retains the cavity
in it., and it is an intermediate plate.

• Third plate so called is core plate is fixed in moving half consisting ejection
system in it.

• This mould has two daylight(two opening).because of automatic degading

small gate mark will be produced.
Three plate mould
 CLASSIFICATION OF MOULD
SPLIT TYPE INJECTION MOULD
SPLIT

A mould in which cavity is formed by two (or) more

parts held together by chase bolster during injection
phase.

SPLIT CORE

A Steel core is manufactured in two or more parts to

facilitate the molding of internal undercut components.

This type of mould is used for the product like threaded

component, jug with handle etc. it may be two plate or
three plate design.
CLASSIFICATION OF MOULD

TYPES OF ACTUATION OF SPLITS:

i) Finger cam actuation

ii) Dog-leg cam

 INSULATED RUNNER MOULD
This type of mould is of either three plate , two plate or
split type. The main requirement of this mold is to reduce
or to avoids waste of feed system and can be used for
continuous production. The runner is insulated , to keep
the plastics material in molten condition all the time, due
to its heat insulation. This can be gated for centre gated
molding.
Insulated runner
Insulated runner with heating element
 Family Mould

This is a multiple impression mold but all the impression

are differ in configuration.

They may be giving as complete product when assembled

together after molding them.

This reduce numbers of mould to be made for product

which has numbers of parts in it.
 MOULD FOR THREADED COMPONENTS

This type of mould is for threaded components may

be external threads or internal threads in It, which
requires the cavity or core or both to be rotated when
the mould is open.
Mould for Internal threaded
Mould for Internal threaded
Mould for external thread
 HOT RUNNER MOULD
The name given to mould which contains a heated
runner manifold block with in its structure. In this
polymer material will always be melt and it transfer
material into impression without pressure loss and heat
loss.

ADVANTAGES

i) Feed system is not formed, so operator work reduce

ii) Cost of degating feed system and separately, grinding the
material of sprue, runner & gate.
iii) No scrap material is produced
iv) For manually controlled Inj. machine open time is reduced
v) We can incorporate impression in anywhere not only in centre.
 DETERMINATION OF
NUMBER OF CAVITIES
 DETERMINATION OF NUMBER OF CAVITIES:
The numbers of cavities for the mold is
determined in most cases by machine
performance, but sometime by molding shape.

a) Numbers of cavities based on shot

capacity of m/c(Ns)

b) Numbers of cavity based on plasticizing

capacity of m/c(Np)

c) Numbers of cavity based on clamping

capacity of m/c(Nc)
Cost reduction through
design arrangements on
Mould
If the mould is having multi impression and if the
cavities are designed in straight line for 16 or more
impression:

• The plate size will be increased

• Runner length will be increased,
• Size of the mould increased.
• The wastage of feed system (sprue, runner,
gate) material
• Cycle time will increase
• labour cost will increase for degading feed
system
To prevent & save cost the following technique are used:

• Designers should provide correct runner layout

• cavity layout

• calculate the required correct size of the mould

• to avoid feed system formation using hot runner,

insulated runner mould.

• Use local insert wherever applicable (bucket rim for

bottom)
MOULD COOLING
• Fundamental principle of molding is that
material enters mould, where it cools
rapidly to a temperature at which it
solidifies sufficiently to retain the shape of
the impression.

• To maintain the required temperature

between the mould and the plastic material,
water is circulated within the mould .

• These holes or channels are termed flow-

ways or water-ways and the complete
system of flow ways is termed the circuit.
• When using drillings for the circulation of
the coolant, however these must not be
positioned too close to the impression
minimum of 16mm gap is mandatory.

• The layout of a circuit is often complicated

by the fact that flow ways must not be
drilled too close to any other hole in same
mould plate (ejector pins, guide pillars,
guide bushes, inserts)
The temperature of the mould plate of the
integer type is controlled by circulating water
through holes bored in plate.

The holes are normally interconnected to

form a circuit.
To obviate any form of external
connection, the two flow ways can be
inter-connected internally by means of
internal drilling. This forms a U circuit. It
can be useful for narrow cavities.
• Instead of using an internal cross drilling, a milled slot
may be used in conjunction with connecting plate.

• Two drilled flow way holes interconnected by a channel

milled in the side wall of the mould plate to provide
continuous flow path for the coolant.

• A connecting plate is sunk into the side wall and

secured by screws.

• Gasket is provided to prevent leakage of the coolant.

 Rectangular circuit:
Rectangular circuits further internal
settings flow ways are close to all four walls
of the cavity.
 Z-circuit:
• For large-area, shallow cavity above circuits are not
possible.
• Now positioned circuit which is directly below the
cavity.
• Mould plate is drilled, plugged, and baffled.
• This forms the flow path of z-configuration.
 BALANCED Z-CIRCUIT:
• Thus cooling effect is going to be more marked on
left side of mould plate than it will on right side.

• Thus temperature variations across the cavity face.

• For this problem we have to provide balanced Z-

circuit.
 COOLING PLATE SYSTEM:
• Individual coolant plates for four sides are self contained
and each has separate inlet and outlet.

• Coolant plate design suffers from problems with

corrosion and some foreign particles.

• It is common practice to clean channels or holes at

reasonable time intervals.
 ANGLE HOLE SYATEM
Flow ways are drilled at an angle from the underside of
the core plate so that interconnect at point X. every
holes plugged and only one inlet and outlet.
 BAFFLE HOLE SYSTEM
In this holes are drilled right angle to the rear face to the
core plate. Lower end is plugged. The borings are
interconnected to the hole X.
 STEPPED CIRCUIT:
In this cooling system holes are drilled side walls of the
core. parallel to the core face. These holes are carefully
plugged. it should be carefully plugged and finished as
they form part of the impression.
 COOLING BOLSTER:

Holes are drilled through the bolster and are interconnected

either externally or internally to permit the circulation of
the coolant.
 Cooling cavity insert:
Method adopted for cooling cavity insert depends upon
shape of the insert.
All drillings within cavity insert will be drilled, plugged,
and baffled.

Designer should aim only one inlet and one outlet.

 COOLING DEEP CORE INSERT:

By circulating the coolant fluid deeply inside the core

insert can efficient transfer of heat from the core
surface be achieved. DEEP CHAMBER DESIGN
BAFFLED HOLE SYSTEM FOR
SMALL INSERTS:
BUBBLER SYSTEM:
 COOLING FOR DIFFERENT
PRODUCTS:
• For rectangular type of products , we can give u-
circuit, or rectangular type cooling.

• For large shallow cavity components Z-type circuit

is used

• For deep cavity , coolant plate type is used

• For deeper cores if single level circuit not sufficient

angle hole system used

• For small core inserts baffle hole system used

• For deep core inserts bubbler system used

 EJECTION
TECHNIQUES
 Ejection System
• All thermoplastics contract as they solidify and contraction
is towards is centre of lump of plastics

• It gives an indication that shrinkage is creating a force on

core part, hence it is difficult to remove molding from core
and sometime from the cavity, depending upon
configuration of molding.

• For ejection, it needs some force to be applied. This force is

known as ejection force required to eject the component
from core.

• This ejection force open depends on so many factors like,

shrinkage value, frictional force and thermal properties of
plastics.
 Types of Ejection System
• Designer has several injection techniques
from which to choose, but, in general, the
choice will be restricted depending upon the
shape of the molding.

• Ejector system in a mould could be discussed

under three heading namely

• Ejector grid

• Ejector plate assembly

• Basic Method (Types) of Ejection

 Types of Ejection System
Ejector grid

• The ejector grid is that part of the mould

which supports the mould plate and provides
the space in to which the ejector plate
assembly can be fitted and operated.

• This grid is also known as spacer block and

back plate assembly for the mould.

• The grid normally consists of a back plate or

to which a number of convenient shaped of
spacer blocks are mounted.
Types of Ejection System
Ejector grid

Three alternative design

• Inline ejector grid

• Frame type ejector grid

• Circular support block grid

 Types of Ejection System
Ejector Plate Assembly

• Ejector plate assembly is that part of the

mould, to which the ejector elements are
attached.

• Assembly is contained in a pocket formed by

the ejector grid, is directly connected with
the actuating rod to injection molding
machine at the back of moving platten.

• Assembly consists of an ejector back plate,

ejector retaining plate, ejector rod push back
pin or ejector elements, also sprue puller
elements are fixed with this assembly.
Types of Ejection System
Basic Methods of Ejection

• Pin Ejection

• Sleeve Ejection

• Blade Ejection

• Stripper bar ejection

• Stripper plate ejection

• Air ejection
 Types of Ejection System
Basic Methods of Ejection

• The selection of basic technique and their elements

are largely depends upon the component
configuration and moulding thicknesses.

• Although decision of diameter or bearing surface area

of this elements and their number are largely depends
upon mechanical properties of plastics material at
certain temperature and ejection force.

• After getting the ejection force value the ejector pin

diameter or value or other technieque is being
decided.
 Elements
of
Various Techniques
 Ejection Technique
i. Pin Ejection

Ejector Uses
Elements
Simple Pin Most common type of ejection
of any shape of molding
Stepped pin Boss ribs & thin sections
D - Pin For thin wall box type
component
 Ejection Technique
ii Sleeve Ejection

Ejector Elements Uses

For the ejection of
certain types of circular
molding
For the ejection
(usually local) of
Sleeve circular bosses on a
molding of any shape
To provide positive
ejection around a local
core pin forming a hole
in the round molding
 Ejection Technique
iii Blade ejection

Ejector Elements Uses

Mostly for ejection of very
Blade of rectangular slender parts, such as
shape attached to the ribs.
normal pin
For thin walled box type
Bar assembly of molding with more
effective bearing area.
 Ejection Technique
iv Stripper Plate

Ejector Uses
Elements
It is plate having Mostly for circular cavity,
core area as hole which positively adhere
& connected by with core.
either by link or In this full surface of
pin with mould molding at parting surface
moving half is covered by this plate
 Ejection Technique
v Air ejection

Ejector Elements Uses

Value (spring Closed, box type of article,
loaded) where there is no way to
Value headed pin escape the air
and compressed air
Thank You