PRESENTATION ON

MOULD TOOL DESIGN

Topics :
•Mould shrinkage, Taper, Tolerances
•Cooling system in moulds.
•Split cavities.
•Side core & side cavities
•Moulding of internal undercut.

Presented by : Patel Mahesh Haribhai

Postgraduate Diploma In Tool-Design & CAD/CAM
MOULD SHRINKAGE,
TAPER,
AND TOLERANCES.
 SHRINKAGE-: It is volumetric change of
The material due to temperature difference.

SHRINKAGE INCREASE WITH THE

 Increase of material temperature.

 Increase of mould temperature.
 Increase in section thickness.

SHRINKAGE DECREASE WITH

 Higher cavity pressure (injection press.)
 Longer injection time.
 Presence of filler
 The actual moulding
shrinkage will be based on
the original dimension plus
the shrinkage allowance
 D = [ d*(1+S) ]
S = Shrinkage
allowance (mm. Per mm.)
d = Component
dimension (mm.)
D = Final tool dimension
(mm.)
 COMPONENT TOLERANCE
The tolerance on the component must cover following
three factors in connection with moulding

1-:VARIATION OF SHRINKAGE-: It depends on

cross section and also upon the
particular press condition

2-:MOULD DRAFT(TAPER)-: This is the taper provided

on the tool to facilitate extraction of the moulding

3-: TOLERANCE REQUIRED TO COVER TOOL

MAKING
1-:To ensure possible modification of components of close
tolerance a condition of maximum metal condition
is applied

2-: female forms i.e. cavities are dimension at the bottom of

the cavity and to the minimum size.

tool dimension minimum components size

 at the bottom = + tool maker allowance
of cavity + shrinkage.

3-:male form i.e. punches, plugs, pins etc are also

dimension
at the root of the form or fixed end, and are dimensioned
to the maximum size.
TAPER(DRAFT)
This is almost always provided on male
&Female tools in the line of draw. This mould draft is
desirable for two reason.

1-: To ensure a clean break from the tool faces as the

moulding is ejected.

2-: To prevent the effect of machining & Polishing

marks from forming undercut.
The minimum draft for moulding in general is 0.5-
0.250 per side.
•SHRINKAGE OF COMMANLY
USED MATERIAL

MATERIAL % OF SHRINKAGE
POLYSTYRENE 0.5-0.6
ACRYLIC 0.4-0.8
POLY CARBONATE 0.6-0.8
POLY ACTEAL 1.5-2.5
NYLON 0.4-1.0

POLY PROPYLENE 1.0-2.0

HDPE 1.5-3
LDPE 1.5-2.5
ABS 0.4-0.6
COOLING SYSTEM IN
MOULDS
 •NESSIECITY OF COOLING SYSTEM
IN MOULDS

FACTORS EFFECTING TEMPERATURE

MOULDS
 Type and grade of material
 Length of flow within the impression
 Wall section of the moulding
 Length of feed system
 •TYPICAL TEMPERATURE

MATERIAL CYLINDER MOULD TEMP

TEMP 0C 0C

ABS 230 50
ACETAL 225 100
NYLON 66 280 70
NYLON 66 GF 300 130

POLY ETHYLENE 230 30

POLY PROPYLENE 250 60
PLOYSTYRENE 200 30
POLYCARBONATE 300 70
 • COOLING INTEGER TYPE
CAVITY PLATE
 External connection

 Internal drilling
 • COOLING INTEGER TYPE
CORE PLATE
 BAFFLED STRAIGTH HOLE
SYSTEM
 ANGLE HOLE SYSTEM
 HELICAL COOLING
CHANNELS DESIGN
 • MOULD COOLING
CALCULATION
 HEAT TRANSFERRED FROM MOULD PER
HOUR
 Qm= m*Q
Q= Heat to be transferred per hour (Kj/hr)
m= mass of plastic mat.injected into the
mould per hour (kg/hr)
Q= Total heat content of plastic mat. (kj/kg)
  AMOUNT OF WATER TO BE
CIRCULATED PER HOUR

 Qw= K*mt*(Tout-Tin)*Cp

Qw=rate of heat extracted per hour (kj/h)

mt= rate of water circulated (kg/h)
Cp=sp.heat capacity of water(42000j/kg/k)
(Tout-Tin) usually 3 to 50C
Cooling channel bored in cavity plate K=0.64

Cooling channel bored in backed plate K= 0.5

Cooling channel using copper pipes K=0.1
Since Qw = Qm

m1= m*Q/(Tout-Tin)*Cp
 •SOLIDIFYING TIME

 T= ρ*a/λp*(T mat-Tmould)*(δ2/8)
T= Solidifying time (S)

m= Mass of plastic mat injected per shot

ρ=Density of plastic material (kg/m3)
a= Total heat content of material (0C)
λp=Thermal conductivity of material
δ=Wall thickness of the moulding (m)
Tmat= Injection temp of mould (0C)
Tmould=Temp of mould (0C)
 • LENGTH OF COOLING
CHANNEL

 L(m)= Q1*Z/λs(Tmat-Tmould)2Ac

Q1 =Q/3600 (heat transferred per sec)

Ac = Area of c/s of cooling channel (m2)
SPLIT CAVITIES
• EXAMPLES OF SPLIT
CAVITIES
• BASIC DESIGN OF SPLITS

 SLIDING SPLITS

 ANGLED LIFT SPLITS

• DESIGNS OF SLIDING SPLITS
•NECCESARY ARRANGMENT WHILE SPLIT DESIGN

1-:Guiding split in desired direction.

2-:Actuating splits.

3-: Locking the split in position.

 • METHODS OF ACTUATION
SPLIT
 SLIDING SPLITS
 CAM 1-:FINGER CAM
2-: DOG LEG CAM
3-:CAM TRACK

 SPRING
 HYDRAULIC

 ANGLE LIFT SPLIT

 ANGLED GUIDED DOWEL
 CAM TRACK
 SPRING
• FINGER CAM ACTUATION
• INTERMEDIATENT
POSITION
• SPLIT FULLY OPENED
 •FINGER CAM ACTUATION SPLIT
MOVEMENT CALCULATION
•The distance traversed by each
split across the face of the mould
plate is determine by the length
and angle of the finger cam

 L=(M /sin Φ) + (2c /sin 2Φ)

L=splits movement,
Φ=angle of finger cam ,
c=clearance.
The operating angle varies from
100 to 250.
• DOG LEG CAM ACTUATION
•INTERMETENT POSITION
• FULLY OPENED POSITION
 • DOG LEG CAM SPLIT
CALCULATION
Calculating the opening movement,
length of cam, Delay period.

M= La*tan Φ –c
La= (M+c)/ tan Φ
D = (Ls-c) + (c/ tan Φ)

M= Movement of each split

La= angled length of cam
Ls= Straight length of cam
Φ = cam angle,
c= Clearance,
D= delay,
E=length of straight portion of the hole.
Operating angle varies from 100 to 250.
•CAM TRACK ACTUATION
• FULLY OPENED POSITION
 • CAM TRACK SPLIT MOVEMENT
CALCULATION
 M = La*tanΦ – c
 La = M + c/tan Φ
 D =Ls + c/tanΦ + r*( 1/tanΦ – 1/sinΦ)

M= movement of each split,

La=angled Length of cam track,
Ls= Straight length of the cam
track,
Φ= cam track angle,
c= clearance,
D= delay,
r= radius of boss.
operating angle varies from 100 to 400.
• HYDRAULIC ACTUATION OF
LARGE SPLITS
•SPLIT LOCKING ARRANGEMENT

NESSECIETY-:During actual injection phase as

high pressure developed within the impression will
tend to force them a part. To resist pressure some
mean of locking is provided.

 TWO BASIC DESIGN OF CHASE BOLSTER ARE

1-:OPENED CHANNEL 2-:ENCLOSED CHANNEL

 LOCKING HEELS-: Resultant projection on either side

of plate
• SPLIT LOCKING
ARRANGEMENT
 •SPLIT SAFETY
ARRANGEMENTS

 Safety feature are nessecary

in moulds with can actuation

 Split may move out of

alignment by shock,
vibration, gravity

 Spring detent method

 M=distance between the

plunger and the
depression is equal
To split movement
 SPRING LOADED
METHOD
• ANGLED LIFT SPLITS
• ANGLED GUIDE DOWEL
ACTUATING SYSTEM

MOULD CLOSED
MOULD OPENED,SPLIT ACTUATED BY
EJECTOR SYSTEM
• SIDE CORES & SIDE
CAVITIES
• PRINCIPLE OF SIDE CORES
• EXAMPLES OF SIDE CORE
&SIDE CAVITY
• COMPARSION OF SIDE CORE
DESIGN & SPLIT DESIGN

SPLIT DESIGN
In spilt design long slender core which forms hole is
exposed and is liable to bent, causing serious
consequences when split is closed.

In side core -:long slender rod core is guided at all

the time in one of the mould plate

Great saving in mould height is achieved as

compared with the split method.
SIDE CORE DESIGN
• CONDITION FOR USE OF ANGLE
SIDE CORE
• ANGLED WITHDRAWAL SIDE
CORE
 • CURVED SIDE CORE

The curved side core is a

Particular type of side
Core where core is with
Draw along the arc of
Circle
• Generally rack &pinion
method of actuation is used.
• MOULDING INTERNAL
UNDERCUT
• EXAMPLES OF INTERNAL
UNDERCUTS COMPONENTS
 DEFINATION-: An internal undercut is any restriction which
prevents a moulding from being
extracted from the core in line of draw
FORM PINS-:A components which has a local
undercut portion can be successfully molded in the
conventional mould by incorporating the under form on
a form pin.
FORM PINS FOR UNDERCUT COMPONENTS
Examples a -:small pro
-Jection on one of inner
wall.

Examples b -:recess in a
similar position.
• UNDERCUT ON ONE
INTERNAL WALL
ONLY
• FORM PIN-STRAIGHT
ACTION

• FORM PIN-:ANGLED
ACTION
 M= E* TAN Φ
M= The withdrawing
movement
E= Ejection movement
Φ=Fitting angle of the
form pin
 • SPLIT CORES
 REQUIRMENT OF SPLIT CORE
The split core design is used for component which have
extensive internal undercut that cannot be incorporate form
pin

 TYPES SPLIT CORE DESIGN

1-:STRAIGTH ACTION-:Used for component which an
external undercut on one wall only.

2-:ANGLED ACTION -: Spilt core is caused to move inwards

during the ejection strokes there by withdrawing the
restriction & allowing moulding to be extracted in line of
draw. Used for components having undercut on opposite
wall &on only one wall.
 SPILT CORE DESIGN
 STRAIGTH ACTION

 ANGLED ACTION
 • UNDERCUT ON DIRECTLY
OPPOSITE
FACES

• TWIN SPLIT CORE FOR RELIEVING UNDERCUTS ON

 • STRIPPING INTERNAL
UNDERCUT
 Factors on which strpping depends upon
1-: the shape of the undercut
2-: the elasticity of the material
3-: expansion of external forms during ejection
•COMMON METHOD USED FOR
STRIPPING
 Valve ejection design
 Stripper plate design
 Sleeve ejection design

• VALVE EJECTOR METHOD

STRIPPER PLATE EJECTION
Thank you……..