Topic 3
PLASTICS INJECTION MOULD FUNCTIONS
Functions ............................................................................................ 2
Sprue and Runner System........................................................................................... 6
Core and Cavity Insert ............................................................................................... 26
Venting System ......................................................................................................... 38
Heat Exchange System ............................................................................................. 41
Guiding and Locating System ................................................................................... 53
Ejection Systems ...................................................................................................... 60
Mould Mounting System ............................................................................................ 78
1
Plastics Injection Mould Functions
Terminal Objective:
Identify the different systems in the mould and understand their functions and their
importance to the moulded part.
Functions
Enabling Objectives
Knowledge:
1. Within a mould, there are different functioning systems.
Skills :
1. To identify the different systems in the mould.
2. To explain their functions and their importance to the moulded
part.
2
Introduction
The primary functions are:
1. Receive the molten plastic
2. Distribute the molten plastic
3. Form and shape the plastic product
4. Cool the moulded product
5. Eject the moulded product
3
LM
The secondary functions are:
1. Transmit motion
2. Absorb forces
3. Guide the moulded product
4
To accomplish all these functions, a mould consists of the functional system:
a. Sprue and runner system
b. Core and cavity inserts
c. Venting system
d. Heat exchange system
e. Ejection system
f. Guiding and locating system
g. Mould mounting system
5
Sprue and Runner System
Basic Function
It channels the molten plastic materials from the plasticating unit (barrel) of the
moulding machine and guides it into the mould cavity.
It consists of the following:
1. Sprue
2. Runner
3. Cold Slug
4. Gate
PICTURE 1 : STANDARD SPRUE BUSHING.
PICTURE 2 : THE SPRUE, RUNNER AND GATE POSITION.
6
PICTURE 3 : HOW MATERIAL FLOWS AND COLDWELLS
AND VENTING PROVISIONS
PICTURE 4 : THE GATE POSITION.
7
1. The Sprue
It is formed in the sprue bushing. The contact in surfaces with the machine
nozzle is generally curved. Plain or flat surface is seldom used because they
require higher sealing pressure.
There are some important guidelines to follow:-
a. The sprue diameter should be 0.5mm bigger than the nozzle orifice,
to avoid undercut.
b. The sprue has to be easily remove and therefore, has to be tapered with
recommended draft of 3 included angle (min. of 1 with the best finishing).
c. The sprue must not freeze before the mould cavity is filled, to permit
transmission of pressure.
d. The sprue bushing must be hardened, available as standard item and
easily replaced.
8
PICTURE 1 : STANDARD SPRUE BUSHING
PICTURE 2
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2. The Runners
- It guides and distributes the molten plastic to the gate(s). See figure 3
typical cold runner system for 3 plate mould.
- Generally, there are 2 systems in use. They are:
a. Cold runner system
b. Hot runner system
FIGURE 3 : TYPICAL COLD RUNNER SYSTEM FOR 3-PLATE MOULD
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a. Cold Runner System
- Due to heat loss of the molten plastic when it enters and comes into contact
with the mould plate surface, special geometry for the runner as to be
considered.
- The recommended cross-sections are:
i. circular
ii. parabolic
iii. trapezoidal
- Important - rectangular and semi-circular cross sections should be
avoided whenever possible
- There are some important guidelines to follow:-
i. the plastic melts must be conveyed rapidly to unrestricted into the mould
cavity with at minimum of heat and pressure loss
ii. the plastic melt must enter all gates at the same time, under the same
pressure with the same temperature
iii. the cross-section should be kept at the minimum to reduce
cooling time, but maintain adequate follow-up pressure and
mould filling
iv. the ease of ejection
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CROSS-SECTIONS OF RUNNERS
12
b. Hot-Runner System
- There are some important guidelines to follow:-
i. Sealing of the plastic melt transition point from the nozzle to the runner.
ii. Avoid heat sensitive materials, because of the long flow path of the
manifold unit and high shear velocity of the hot tip gating.
iii. Use of virgin plastic materials, as recycled materials contain
contaminants.
HOT RUNNER SYSTEM
13
3. Cold Slugs
Cold runner systems must have cold slug wells, to accommodate cold slugs.
Cold slugs are formed when:-
- The material at the tip of the machine nozzle that is trapped by the cold well
before it enters the cavity.
- The residual material at the machine nozzle loses heat and solidifies before
the next injection cycle starts.
COLD SLUGS
14
COLD SLUGS
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4. The Gate
- The functions of the gate are:
a. To control the flow of the material into the cavity.
b. To permit easy of separation of the moulded product from the runner
system.
c. To permit automatic separation between the moulded product.
- There are classified as:-
i. Unrestricted (direct gate)
- Where the pressure loss is low, however the defects such as
deformation and loss of impact strength may occur, due to residual
stress.
ii. Restricted (all gates except direct gate)
- Where the plastic melt passed at high velocity, generating a large
pressure drop, but part of the pressure loss is converted to frictional
heat which is used to heat the molten plastic.
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- The following are the various type of gates which are commonly used:
a. Direct Gate
- Also known as the sprue gate. It has circular cross section, slightly tapered
and merges with the largest cross-section of the moulded product.
- There are some disadvantages of the this system, which are:
i. The secondary process of cutting off the sprue and the visual
impression of the sprue mark.
ii. The sprue takes much time to cool.
DIRECT GATE
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b. Edge Gate
- Also known as a side gate. A product is gated from the parting line.
- The cross-section of the gate is usually tapered, with some draft or
semi-circular for ease of ejection.
EDGE GATE
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c. Fan Gate
- It is a variation of the edge gate, where the gate width is more than 3 times
the height of the cross-section.
- It is often used in thin-walled product that requires good surface
finishing.
FAN GATE
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d. Pinpoint gate
- Generally used in the 3-plate moulds. It is connected to the cavity by a small
point hole.
- It is usually located centrally in a multi-cavity mould. However, thin walled part
with large surface areas in a single-cavity mould can be moulded with
multiple gates.
- An advantage of this system is the automatic separation of the moulded part
from the runner. During the opening process of the 3-plate mould.
PINPOINT GATE
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e. Disk Gate
- Also known as a diaphragm gate, it allows the uniform filling of the whole
cross-section of the cylindrical or sleeve-like moulding.
- The gate position is generally located centrally.
- The advantage of this system, is that the product will remain round
and concentric.
- The disadvantage is that the gate has to be machined off.
CUTAWAY OF CIRCULAR PART
21
f. Tab Gate
- It is used to avoid moulding defect like jetting, in thick walled products. It is
sometimes used in 3-plate mould where the products are very small, where the
pin point gate is not possible.
- The disadvantage of this system is the secondary process of cutting off or
machining the tab of the moulded product.
TAB GATE
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g. Film Gate
- Also known as flash gate. It is used primarily for moulding parts with large
surfaces and thin walls. It is used when deformation of a product is not
acceptable.
- The disadvantage is the secondary process of removing the runner from the
moulded product is required.
FILM GATE
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h. Ring Gate
- This type of gate is used for tubular-type of mouldings with more
than one impression in a two plate mould.
- The gate provides for a feed all around the external periphery of the
moulding.
- The gate is in the form of a concentric film between the runner and the cavity.
RING GATE
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i. Tunnel Gate
- Also sometimes known as submarine gate (or sub gate).
- It is commonly used in multi-cavity, 2-plate moulds for production of small
parts and to provide automatic in-mould separation of the moulded product
from the runners.
- The cross section of the gate is usually conical and the gate diameter as
small as possible, to facilitate the shearing off between the moulded product
and runner.
TUNNEL GATE
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Core and Cavity Insert
Basic Function
The cavity and core is the heart of the injection mould. This is where the shaping
and forming the plastic product takes place. First the molten plastic flows through
the sprue/runner system or the hot-runner system, then it solidifies in the cavity.
Finally, it is ejected from the core. Generally the cavity is located on the fixed or
stationary halve, while the core is on the movable halve of the mould.
The number of cavities are determined by one or all of the following:-
1. Design of product
2. Quality of product
3. Quantity to be produced
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PICTURE 1 , 2 : CAVITY PLATE AND CAVITY INSERTS
PICTURE 1 , 2 : CAVITY PLATE AND CAVITY INSERTS
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1. Cavity Layout
- It should consider these guidelines:
a. All cavities should be filled at the same time, to avoid short mouldings
and flashing
b. Runner flow length should be as short as possible, to avoid pressure
loss and material waste
c. There should be sufficient space between cavities for proper cooling
and ejection
CAVITY LAYOUT
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2. Parting Line
- This is the opening between the cavity and core halves that release the
moulded product and the runner.
- Its position is determined by the following:-
a. mould design or/and
b. product design
- The 2-plate, slider and hot runner moulds usually have a single parting
line. However, 3 plate or stack mould may have more than one parting line.
PARTING LINE
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PARTING LINE
30
3. Cavity Half
- It is the cavity side that provides the desired visual appearance as specified
by the customer.
CAVITY HALF
31
4. Finishing
- The surface finish of the mould gives the product its desired finish appearance.
It also provide an appropriate finish that will allow the removal of product from
the mould.
EXAMPLE OF FINISHING - GROUND SURFACE
32
There are different methods of finishing available:
1. Electric Discharge Machining (EDM) Finish
- It is carried out by an electrode that must match the shape of the product, in an
Electrical Discharge Machine. The surface roughness is determined by the
amount of electrical discharge used to stipple the mould surface.
EDM SURFACE
33
2. Chemical Etching
- Also known as Photo Etching
- The cavity insert is immersed in a solution of etching agent. Using time as a
factor, the chemical will corrode the insert surface, resulting in a distinct
pattern.
ETCHED SURFACE
34
3. Sand Blasting
- Using high-pressure air as a media, fine grade of particles is directed against
the cavity insert. The cavity surface must be polished before sand blasting. It
is considered the cheapest form of texturing, but it can be worn out in a short
time.
SAND BLASTING
35
4. Polishing
- This is done manually using a variety of polishing media.
- The degree of polishing depends on the part requirement.
- For example, a super mirror finish for automotive lighting application, it may
takes up to 8 weeks and requires specially trained mould polisher.
POLISHING
EXAMPLE OF MIRROR POLISHING
36
5. Core Half
- This is normally form the inner wall of the moulded product. The ejector pins,
cavity identification, date-stamp, part name, plastic resin identification and
others are located here.
- Generally, the surface finish is as machined, otherwise specified in the product
drawing.
- When necessary, undercuts are placed to attach the moulded part to this side
for ejection.
CORE HALF
37
Venting System
Why is venting necessary?
If the trapped air is not allowed to escape, then it will be compressed by the
pressure of the incoming material, and is squeezed into the corners of the mould
cavity, where it prevents filling.
The air becomes so compressed, that the temperature will rise to a level that ignites
and burns the surrounding plastic material.
How does it work?
When the mould is closed, it allows trapped air to escape so that the incoming
molten plastic can fill every available section of the mould cavity.
What is a Vent?
It is a shallow groove that is machine ground on the mould cavity and core plate. It is
located at strategic position that will allow trapped air to escape when the mould is
closed. The depth of the vent depends on the types of the plastic material used.
VENT
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Types of Vent
There are 2 types of vent that are commonly used, which are, the parting line vent
and the pin or insert vent.
1. Parting Line Vents
a. The vent grooves are located across the mould surface of either
the core or cavity side that forms the parting line.
b. The grooves can be located wherever suitable for mould making, usually
machine ground which permits easy run-out of the grinding wheel. The shape
should be trapezoidal or rounded to avoid undercuts.
2. Pin and Insert Vents
a. The vent grooves are machine ground and they are located at the
surrounding side of the ejector pin or core and cavity insert.
b. This type of venting is used to ensure ease of filling of deep rib created in the
insert.
MOULD CAVITY PLATE
39
Guidelines to follow:
1. It should be as large as permissible, but not large enough for the plastic material
to enter and create a flash or burr.
2. It should be placed at all end of plastic flow path.
3. It should be maintained clean at all time, as plastics tend to leave a small amount
of residue which will plug up the vent.
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Heat Exchange System
Introduction
Thermoplastic materials require a considerable amount of heat input. In order to
produce a uniformly plasticized melt.
Once the plastic melt is shaped into its desired form, a large amount of heat must
be removed to solidify the plastic material so as to enable ejection of product from
the mould.
COOLING SYSTEM
41
HOW FLUIDS FLOW IN A MOULD COOLING CHANNEL
42
Operation of Heat Exchange
Heat from the injected plastic material is removed by a circulating medium,
commonly used is water, through a network of cooling channels in the mould.
The medium used, can be chilled water, but also hot water or oil and there must
always be a temperature difference between the injected plastic and the cooling
medium.
As a rule, the cooling medium must always be colder than the plastic melt.
OPERATION OF HEAT EXCHANGE
43
Types of Heat Exchange
1. Cooling channels
2. Cascades
3. Heat transfer tubes
4. Cooling pin
5. Spiral cores
PICTURE 1 : COOLING CHANNELS
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PICTURE 2 : CASCADES
PICTURE 3 : HEAT TRANSFER TUBES
45
PICTURE 4 : COOLING PINS
PICTURE 5 : SPIRAL CORES
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1. Cooling Channels
In injection moulds, this is the standard method of cooling, whereby the coolant,
usually water passes through a series of holes drilled through the mould plates
and connected by sealing plugs and hoses to form a continuous path.
The coolant will continuously absorbs the heat from the mould plates, which has
absorbs the heat from the hot plastic melt.
This action will keep the mould at the recommended temperature, thus allowing
heat transfer via the coolant to take place and promote gradual cooling of the
moulded product.
COOLING CHANNELS
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2. Cascades
Also known as bubblers it is used to remove heat in difficult places where the
standard cooling channels cannot reach. Example, the plastic pail, where the
core insert is deep drawn.
The bubblers is installed in the centre of the core. The coolant used is usually
water.
In this system, the coolant comes from the main cooling channel, enter the
bottom of the bubbler, flows up through the inner tube, cascades inside the unit
and flows down through the outer tube and exiting back into the main cooling
channel.
CASCADES
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3. Heat Transfer Tubes
Also known as heat pipes, it is generally use to extract heat at the corners of
box-shaped plastic product, where the other systems cannot reach.
The tube is normally made from copper and filled with gas or fluid. They are
either bonded into the mould or mounted with special thermally conductive paste.
HEAT TRANSFER TUBES
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4. Cooling Pins
It is usually used in long, thin part and box-shaped part, where the standard
cooling channels cannot reach. Examples are ballpoint pen housings, tubes,
casings, etc. it works on the conductor principle and is made from thermally
conductive material such as beryllium copper.
The cooling pins are installed in the centre or corners of the core insert and
the base of the cooling pins must be connected to the main cooling channel.
Heat transfer is conducted via the highly conductive metal and the coolant,
usually water, removes the heat away.
STANDARD COOLING PINS
50
CROSS-SECTIONAL VIEW OF COOLING PIN SYSTEM
51
5. Spiral Cores
It is perhaps the most effective cooling system, as the coolant travel along the
spiral groove it generates turbulence and thus promotes greater heat removal.
However due to high cost of this unit, the usage is not popular in the injection
mould industry.
SECTIONAL VIEW OF A SPIRAL CORE COOLING SYSTEM
STANDARD SPIRAL CORES
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Guiding and Locating System
Introduction
Injection moulds are subjected to many forces during the course of the moulding
cycles. The clamping unit opens and closes the mould many times.
Because of this, the mould, which is made up of many plates and components,
have to be guided in such a way that they are accurately aligned and the mould
halves tightly closed during the moulding cycle.
Without a proper guide and locating system, the moulded products will exhibit
deviation in wall thickness and dimensions.
GUIDING AND LOCATING RING
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Types of Guide
1. Locating with the plasticizing unit
2. Internal guide of an injection mould
3. High precision guide on injection mould
Locating with the Plasticizing Unit
Precise alignment is mandatory. Otherwise the machine nozzle will not be
completely sealed by the sprue bushing and leaking of plastic material will cause
undercuts to occur. It will then interrupt the moulding cycle.
For this purpose, the mould is equipped with a flange-like locating ring, which keep
the sprue bushing in the mould and matches the corresponding opening in the
machine platen.
PICTURE 1 : LOCATING WITH PLASTICISING UNIT
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PICTURE 2 : SECTIONAL VIEW OF THE INTERNAL GUIDING SYSTEM
PICTURE 3 : SECTIONAL VIEW OF THE TAPER - LOCK ASSEMBLY
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LOCATING WITH PLASTICISING UNIT
STANDARD LOCATING RING
56
Internal Guides of an Injection Mould
The mould halves themselves have to be guided internally to obtain the accuracy.
The most common method of alignment is the use of leader pins, usually in
combination with leader pin bushing, support pins and bushings.
For this purpose, one mould halve is fitted with leader pins while the other halve is
fitted with leader bushings and locating sleeves.
The tolerances of the commercially available leader pins and bushings are
adequate for most injection moulds. This will ensure a constant and accurate
alignment of both halves of the mould without shifting during the moulding cycle.
Effective alignment is possible if close tolerances are kept between the leader pins
and corresponding holes. However, this causes considerable wear. Thus the pins
and bushing must be constantly lubricated.
INTERNAL GUIDES OF AN INJECTION MOULD
57
SECTIONAL VIEW OF INTERNAL GUIDING SYSTEM
58
High Precision Guide on Injection Mould
For high precision mould or very thin wall mouldings, there are some methods to
further increase the internal alignment. This is based upon the wedge principle.
Conical fit of core and cavity, called taper lock, is the most common method used.
This method is quite simple.
TAPER LOCKS
SECTIONAL VIEW OF THE TAPER-LOCK ASSEMBLY
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Ejection Systems
Introduction
After the moulded product has solidified and cooled down, it has to be removed from
the mould by the ejector system.
EJECTION SYSTEMS
60
Ejector System Components
It is an arrangement of components, for example, ejector pins, ejector plate,
retainer plate, return mechanism etc.
That is normally housed at the core side (movable halve) of the mould, that
actuates after the mould has opened.
SINGLE SPRING RETURN SYSTEM
61
Ejector System Operations
Mould opening causes the mechanically actuated ejector systems to be moved
towards the parting line and to eject the moulded article.
Precondition for this procedure is to ensure that the moulded article stays on the
core (movable) side.
This can be achieved by undercuts or by letting the moulded product shrink onto
the core.
Figure shows the systematic presentation of the ejection process initiated by the
opening stroke of the machine.
THREE-PLATE MOULD OPENED
62
THREE-PLATE MOULD CLOSED
63
Types of Ejector Systems
1. Ejector Pin
2. Ejector Sleeve
3. Ejector Blade
4. Stripper Plate
5. Stripper Bar and Stripper Ring
6. Valve Ejection
7. Poppet Ejection
PICTURE 1 : EJECTOR PIN
64
PICTURE 2 : EJECTOR SLEEVE
PICTURE 3 : EJECTOR BLADE
65
PICTURE 4 : STRIPPER PLATE
PICTURE 5 : STRIPPER BAR AND STRIPPER RING
66
PICTURE 6 : VALVE EJECTION
PICTURE 7 : POPPET EJECTION
67
1. Ejector Pin
This is one of the most common types of ejector used and the simplest to
incorporate into a mould. They are usually round and available in various
diameters and length.
The advantage is that they are relatively cheap and easy to use.
However, the disadvantage is that they can cause deformation, if the moulded
article is not rigid enough during ejection.
Moreover, they leave behind witness-mark, which may be objectable and
therefore their locations must be carefully considered.
STANDARD EJECTOR PINS
68
EJECTION BY EJECTOR PINS
69
2. Ejector Sleeve
This is used to eject circular feature like boss or pillar or provide positive ejection
around a core pin forming a round hole in the moulded product.
They are hollow and round and available in many diameters and lengths.
The disadvantages are they are quite expensive and difficult to maintain due to
frictional wear.
They cause deformation if moulded article is not rigid during ejection, and leave
witness mark.
STANDARD EJECTOR SLEEVES
70
EJECTION BY EJECTOR SLEEVE
71
3. Ejector Blade
It is generally used to eject thin-walled features like ribs. They are generally
round ejector pins, flattened at the front, whose bending strength declines as the
cross-section decreases.
The flat section of the ejector must be guided to ensure proper functioning.
They are expensive and difficult to maintain.
STANDARD EJECTOR BLADES
72
EJECTION TECHNIQUE BY EJECTOR BLADE
73
4. Stripper Plate
It is used on product with large surface area and where witness line is allowed. It
is an additional mould plate mounted between the core and cavity plate.
Its shape and size depends on the product design, usually surrounding the
product circumference.
However it should be used where the product at the parting line has a shape that
can be easily generated by machining.
The advantages are that the ejection force is evenly distributed and witness line
is less noticeable.
2-PLATE MOULD WITH STRIPPER PLATE EJECTION SYSTEM
74
5. Stripper Bar and Ring
They are hardened inserts assembled onto the core retainer plate. It is used
particularly for thin-walled box shaped and circular or cup-type plastic products.
However the point of ejection is limited to along the thin wall section of the
moulded product and the witness line is less noticeable.
The advantage is that they will wear less than a softer stripper plate and are
easier to replace in case of damage.
STRIPPER RING EJECTION
75
6. Valve Ejection
It is basically a large diameter ejector pin and is used for the ejection of large
surface plastic part, where the standard ejector pin is not practical.
The advantage in this system is that distortion is minimized due to the large
effective area of ejection.
EJECTION BY VALVE EJECTOR
76
7. Poppet Ejection
This is the oldest method of air ejection. It can be used for cup-shaped products.
During injection, the poppet sits tightly on the taper seat in the tip of the core,
thus preventing plastic from entering into the air-channels system.
During mould opening the poppet moves forward mechanically and allows the
air to enter.
The compressed air pushes and enters the space between the core and the
moulded article, then create air pressure to push it free from the core.
POPPET EJECTION
77
Mould Mounting System
Introduction
Types of Mount
1. Direct mount.
2. Indirect mount.
3. Quick mount.
The injection moulding process involves high pressure clamping, injection of molten
plastics and numerous mechanical movements, and these are done repeatedly,
depending on the volume of parts to be produced.
Therefore securing the mould onto the machine platens is conceded as a primary task.
MOULD MOUNTING SYSTEM
78
1. Direct Mount
In principle, holes are provided in each mould halves to correspond with the
holes tapped in the moulding machines platen.
Bolts are then used to directly secure the mould to the platen. Most
manufacturers adopt a standard hole-layout for their injection moulding
machines; therefore a mould design can normally be fitted to another machine of
similar size.
DIRECT MOULD MOUNTING TECHNIQUE
79
MOULDING MACHINES PLATEN LAYOUT
80
2. Indirect Mount
With this design, the attachment of the mould to the machine is by the means of
a clamp plate.
It is used when it is not possible to provide hole position according the platen
hole-layout, due to constraints in the mould mounting plate.
Sometimes, it is used when the mould is mounted on a different moulding
machine, than the one originally planned for.
INDIRECT MOUNT CLAMPING SYSTEM
81
CLAMPING SYSTEM
82
MOULD CLAMP
83
3. Quick Mount
Also known as the quick mould change, such systems, although available, is not
popular among plastics moulders.
This is probably due to lack of compatibility, inflexibility of the system and of
course, high cost. For this system to work, the mould mounting plate must
be standardized for a particular machine.
A locking device is mounted onto the machine fixed and moveable platen. The
mould is then locked in position, normally the machine centre.
A TYPICAL QUICK MOULD CLAMPING SYSTEM
QUICK CLAMP SYSTEM
85