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Product Analysis for mold design
- Prashant PatelGroup no 7 09003029
Objective: For a given product/sample, suggest a mold design which can be used in Injection
Molding for mass production.
Method Description:
Do complete inspection of given product. First find out parting line of a given product. Look for no of dies that is going to be used and how orientation of dies can anyone
have to manufacture product.
Given product is shown below:
Sample is use as a valve for allowing liquid to pass through it. On rotating upper part,one can match the circular hole of upper part with the cylindrical opening of lower
part. And on further rotating upper cap, cylindrical opening can be blocked. In this
fashion, flow of liquid can be controlled.
It consists of two different parts as shown.
Figure 1: (a) Upper part (b) Lower part of the sample
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Upper Part: It has parting line passing through middle of upper handle. Cylindrical shape do
not have parting line which indicates that it is manufactured using single die consist of core as
shown in figure.
Figure 1: Die for cylindrical shape of upper part with core (red colour) for making two side holes.
Upper portion consist of handle, is produced using two dies. Position of gate was unable to find
as the product was not new and it got some scratches. Ejector pin is placed at the top surface of
above die. After placing all three dies and core at the required position, melt plastic is allowed to
fill the cavity through gates and allowed to cool. After cooling, all the dies are removed to get
required product.
The diagram show two dies for producing handle part:
Figure 2: Two dies for producing handle portion of upper part.
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Diagramatic flow of overall process is shown below:
.
Upper Part
Direction of die
Lower Part: Parting line is passing through middle of lower part. It is possible to manufacture
lower part using two dies and two cores. Right die take care of cylindrical opening as shown in
figure. To have hollow structure in the middle, a core has to be move in. Diagram indicates the
clear picture of arrangement:
Figure 3: Arrangements of dies and core for producing lower part.
Left Die
Die for
Cylindrical
art
Right Die
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Diagramatic flow of overall process is shown here:
.
Lower Part
Direction of die
Note: Volume of given sample could not be calculated as the beaker given to measure displaced
water volume was broken by some student.
Location of Gating was found for lower part as it was clearly visible but it was not possible for
upper part to locate gating position.
Suggestions for reducing effective cost:
If instead of curved design at the bottom of handle of upper part of sample (Easily visible in
above figure), we made flat rectangular handle then upper part can be easily produce using two
dies only instead of three dies. In this case, one bottom die will cover cylindrical portion (as itwas in previous one) and one die will take care of whole handle. In present design, whole handle
of upper part cannot be produce in a single die as curved part of handle will block die to come
out after solidification of liquid plastic. Using new design, we can reduce effective cost of
product.
Conclusion: The two half of given sample can be easily manufacture by Injection molding
using design of dies as suggested above. Large no of products can be manufacture by making
large no of cavity in each die.
Left Die
Cylindrical
core
Right Die
with core