expan sible injection mould design - core · expansible injection mould design buch cardona, eloi...
TRANSCRIPT
Expan
Expan
Expansible
Part 1 Technical Memory
sible Injection
Part 1 Technical Memory
Injection
Part 1 Technical Memory
2014-2015
Injection Mould Design
Part 1 Technical Memory
Director: Miguel Sánchez
Mould Design
Part 1 Technical Memory
Autor: Eloi Buch Cardona
Director: Miguel Sánchez
Mould Design
Autor: Eloi Buch Cardona
Director: Miguel Sánchez
Mould Design
Autor: Eloi Buch Cardona
Director: Miguel Sánchez-Soto
Expansible Injection Mould DesignBuch Cardona, Eloi
Abstract
Within the next project it is developed a breathing injection mould.
Its main purpose is to prod
techniques such as MuCell® which suppose a great increase of physical properties
regarding other foaming types as well as an important weight and material price
reduction.
The piece it is going to
better foamed polymer investigation.
The mould type is discussed and compared between the core pull system and the
breathing
due its cheaper cost and high quality direct piece production, although lack in terms of size
versatility.
Then, that mould is exhaustively defined and evaluated with all the
mechanizations and thermal treatments need
difficulties of properly predict all the timings and costs.
Expansible Injection Mould DesignBuch Cardona, Eloi
Abstract
Within the next project it is developed a breathing injection mould.
Its main purpose is to prod
techniques such as MuCell® which suppose a great increase of physical properties
regarding other foaming types as well as an important weight and material price
reduction.
The piece it is going to
better foamed polymer investigation.
The mould type is discussed and compared between the core pull system and the
breathing system
due its cheaper cost and high quality direct piece production, although lack in terms of size
versatility.
Then, that mould is exhaustively defined and evaluated with all the
mechanizations and thermal treatments need
difficulties of properly predict all the timings and costs.
Expansible Injection Mould DesignBuch Cardona, Eloi
Abstract
Within the next project it is developed a breathing injection mould.
Its main purpose is to prod
techniques such as MuCell® which suppose a great increase of physical properties
regarding other foaming types as well as an important weight and material price
The piece it is going to be produced is designed to contain several
better foamed polymer investigation.
The mould type is discussed and compared between the core pull system and the
system one. Once properly solved each type it is chosen the b
due its cheaper cost and high quality direct piece production, although lack in terms of size
Then, that mould is exhaustively defined and evaluated with all the
mechanizations and thermal treatments need
difficulties of properly predict all the timings and costs.
Expansible Injection Mould Design
Within the next project it is developed a breathing injection mould.
Its main purpose is to produce plastic pieces that utilize different
techniques such as MuCell® which suppose a great increase of physical properties
regarding other foaming types as well as an important weight and material price
be produced is designed to contain several
better foamed polymer investigation.
The mould type is discussed and compared between the core pull system and the
one. Once properly solved each type it is chosen the b
due its cheaper cost and high quality direct piece production, although lack in terms of size
Then, that mould is exhaustively defined and evaluated with all the
mechanizations and thermal treatments need
difficulties of properly predict all the timings and costs.
Within the next project it is developed a breathing injection mould.
uce plastic pieces that utilize different
techniques such as MuCell® which suppose a great increase of physical properties
regarding other foaming types as well as an important weight and material price
be produced is designed to contain several
The mould type is discussed and compared between the core pull system and the
one. Once properly solved each type it is chosen the b
due its cheaper cost and high quality direct piece production, although lack in terms of size
Then, that mould is exhaustively defined and evaluated with all the
mechanizations and thermal treatments needed. The budget part is orientative due to the
difficulties of properly predict all the timings and costs.
Within the next project it is developed a breathing injection mould.
uce plastic pieces that utilize different
techniques such as MuCell® which suppose a great increase of physical properties
regarding other foaming types as well as an important weight and material price
be produced is designed to contain several
The mould type is discussed and compared between the core pull system and the
one. Once properly solved each type it is chosen the b
due its cheaper cost and high quality direct piece production, although lack in terms of size
Then, that mould is exhaustively defined and evaluated with all the
ed. The budget part is orientative due to the
difficulties of properly predict all the timings and costs.
Within the next project it is developed a breathing injection mould.
uce plastic pieces that utilize different injection
techniques such as MuCell® which suppose a great increase of physical properties
regarding other foaming types as well as an important weight and material price
be produced is designed to contain several future test samples for a
The mould type is discussed and compared between the core pull system and the
one. Once properly solved each type it is chosen the b
due its cheaper cost and high quality direct piece production, although lack in terms of size
Then, that mould is exhaustively defined and evaluated with all the pieces costs as well as
ed. The budget part is orientative due to the
injection foaming
techniques such as MuCell® which suppose a great increase of physical properties
regarding other foaming types as well as an important weight and material price
future test samples for a
The mould type is discussed and compared between the core pull system and the
one. Once properly solved each type it is chosen the breathing mould
due its cheaper cost and high quality direct piece production, although lack in terms of size
pieces costs as well as
ed. The budget part is orientative due to the
2
foaming
techniques such as MuCell® which suppose a great increase of physical properties
regarding other foaming types as well as an important weight and material price
future test samples for a
The mould type is discussed and compared between the core pull system and the
reathing mould
due its cheaper cost and high quality direct piece production, although lack in terms of size
pieces costs as well as
ed. The budget part is orientative due to the
Expansible Injection Mould DesignBuch Cardona, Eloi
Index
Introduction
Objectives
1.Background
2.External conditioning
3.Piece design
4.Mould design
Expansible Injection Mould DesignBuch Cardona, Eloi
Index
Introduction................................................................................................................................
Objectives................................................................................................................................
1.Background...
2.External conditioning
2.1.Injection machine characteristics...
2.2.Material characteristics...
3.Piece design...
3.1 Technical limits...
3.2 The geometry...
3.2.1
3.2.2
3.3 Volume...
3.3.1
3.3.2
4.Mould design
4.1 Core pull system...
4.1.1
4.1.2
4.1.3
4.1.4
Expansible Injection Mould DesignBuch Cardona, Eloi
.............................................................................................................................
.............................................................................................................................
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2.External conditioning.......................................................................................................................
ection machine characteristics...
2.2.Material characteristics...
.....................................................................................................................
3.1 Technical limits...
3.2 The geometry.................................................................................................................
3.2.1 Flexion test ISO 178 [1]
3.2.2 Traction test ISO 527
3.3 Volume..................................................
3.3.1 Perimet
3.3.2 Overflow channel
4.Mould design................................................................................................................................
Core pull system...
4.1.1 Mould operation
4.1.2 Piece position
4.1.2.1 3rd plate...
4.1.2.2 Decentered piece..
4.1.2.3 Decentered nozzle...
4.1.2.4 Decision.
4.1.3 Refrigeration
4.1.4 Ejection
4.1.4.1 Core pull ejector...
4.1.4.2 Plate ejec
4.1.4.3 Decision...
Expansible Injection Mould Design
.............................................................................................................................
.............................................................................................................................
...................................................
....................................................................................................................
ection machine characteristics...
2.2.Material characteristics...................................................................................................
..................................................................................................................
3.1 Technical limits.............................................................
..............................................................................................................
Flexion test ISO 178 [1]
Traction test ISO 527
...............................................
Perimeter extensions
Overflow channel..............
.............................................................................................................................
Core pull system..........................................................................................................
Mould operation...................................................................................
Piece position.......................................................................................
4.1.2.1 3rd plate...
4.1.2.2 Decentered piece..
4.1.2.3 Decentered nozzle...
4.1.2.4 Decision...
Refrigeration..........................................................................................
Ejection.................................................................................................
4.1.4.1 Core pull ejector...
4.1.4.2 Plate ejec
4.1.4.3 Decision...
.............................................................................................................................
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....................................................................................................................
ection machine characteristics................................................................................
................................................................................................
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Flexion test ISO 178 [1]...................
Traction test ISO 527-2 [2].......................................................
........................................................................................................................
extensions................................................................
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4.1.2.1 3rd plate...................................................................................
4.1.2.2 Decentered piece..................................................................
4.1.2.3 Decentered nozzle..............................................................
..............................................................................
.......................................................................................
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4.1.4.1 Core pull ejector............................................................
4.1.4.2 Plate ejection..............................................................................
4.1.4.3 Decision......................................................................................
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Expansible Injection Mould DesignBuch Cardona, Eloi
5.Final mould development
6.Mechanization
7.Thermal treatment
8.Budget resume
9.Conclusions
Acknowledgements
Bibliography
Extra: Ecological footprint
Expansible Injection Mould DesignBuch Cardona, Eloi
4.1.5
4.2 Precise opening system...
4.2.1
4.2.2
4.2.3
4.2.4
4.2.5
4.3 Final decision...
5.Final mould development
5.1.Piece description...
5.1.1.
5.1.2.
5.1.3.
6.Mechanization
7.Thermal treatment
8.Budget resume
9.Conclusions...
Acknowledgements
Bibliography.............................................................
Extra: Ecological footprint
Expansible Injection Mould DesignBuch Cardona, Eloi
4.1.5 Compilation
4.2 Precise opening system...
4.2.1 Mould operation
4.2.2 Piece position
4.2.3 Refrigeration
4.2.4 Piece ejection
4.2.5 Compilation
4.3 Final decision..................................................................................................................
5.Final mould development
5.1.Piece description...
5.1.1.Static part
5.1.2.Mobile part
5.1.3.Other elements
6.Mechanization.......................................................................
7.Thermal treatment....................................................................................................
8.Budget resume..............................................................................................................
......................................................................................................................
Acknowledgements..............................................................................................................
..........................................................
Extra: Ecological footprint
Expansible Injection Mould Design
Compilation..................
4.2 Precise opening system............................................................................................
Mould operation........................................................................................
Piece position..............................................................................................
Refrigeration system
Piece ejection...................................................................................
Compilation......................................................................................
...............................................................................................................
5.Final mould development.............................................................................................
5.1.Piece description............................................................................................
Static part.......................................................................................
Mobile part.........................................................................
Other elements.............................................................................
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Expansible Injection Mould DesignBuch Cardona, Eloi
Introduction
Polym
back to the beginning of the last century. They represented a massive improvement for
some consumption goods that were
repres
lead many industry sectors to modify their products such as the automotive industry that
began lighten
the same. But in this case
savings pleasing both consumers and the increasingly stringent environment regulations
either in production or in product.
Not surprisingly,
achieved an apparent density decrease by containing micro voids in the inside
techniques were called foaming and for that different injection moulds are being needed.
Today there are still numerous
reduction due to the gas voids and to increase the
used in research purposes are needed.
Expansible Injection Mould DesignBuch Cardona, Eloi
Introduction
Polymers are widely used in
back to the beginning of the last century. They represented a massive improvement for
some consumption goods that were
represented also an increase of mechanical properties due its ductility. This advantages
lead many industry sectors to modify their products such as the automotive industry that
began lightening
the same. But in this case
savings pleasing both consumers and the increasingly stringent environment regulations
either in production or in product.
Not surprisingly,
achieved an apparent density decrease by containing micro voids in the inside
techniques were called foaming and for that different injection moulds are being needed.
Today there are still numerous
reduction due to the gas voids and to increase the
used in research purposes are needed.
Expansible Injection Mould DesignBuch Cardona, Eloi
Introduction
ers are widely used in
back to the beginning of the last century. They represented a massive improvement for
some consumption goods that were
ented also an increase of mechanical properties due its ductility. This advantages
lead many industry sectors to modify their products such as the automotive industry that
ing its products in favor of a power increase.
the same. But in this case,
savings pleasing both consumers and the increasingly stringent environment regulations
either in production or in product.
Not surprisingly, next step was lighten
achieved an apparent density decrease by containing micro voids in the inside
techniques were called foaming and for that different injection moulds are being needed.
Today there are still numerous
reduction due to the gas voids and to increase the
used in research purposes are needed.
Expansible Injection Mould Design
Introduction
ers are widely used in piece production
back to the beginning of the last century. They represented a massive improvement for
some consumption goods that were notably weight reduced and in some applications
ented also an increase of mechanical properties due its ductility. This advantages
lead many industry sectors to modify their products such as the automotive industry that
its products in favor of a power increase.
a weight reduction represents more efficiency and material
savings pleasing both consumers and the increasingly stringent environment regulations
either in production or in product.
next step was lighten
achieved an apparent density decrease by containing micro voids in the inside
techniques were called foaming and for that different injection moulds are being needed.
Today there are still numerous studies on foaming to improve its obvious resistance
reduction due to the gas voids and to increase the
used in research purposes are needed.
piece production industry but their first applications were
back to the beginning of the last century. They represented a massive improvement for
notably weight reduced and in some applications
ented also an increase of mechanical properties due its ductility. This advantages
lead many industry sectors to modify their products such as the automotive industry that
its products in favor of a power increase.
a weight reduction represents more efficiency and material
savings pleasing both consumers and the increasingly stringent environment regulations
plastic parts which with some different techniques
achieved an apparent density decrease by containing micro voids in the inside
techniques were called foaming and for that different injection moulds are being needed.
studies on foaming to improve its obvious resistance
reduction due to the gas voids and to increase the
industry but their first applications were
back to the beginning of the last century. They represented a massive improvement for
notably weight reduced and in some applications
ented also an increase of mechanical properties due its ductility. This advantages
lead many industry sectors to modify their products such as the automotive industry that
its products in favor of a power increase. Nowadays the struggle is
a weight reduction represents more efficiency and material
savings pleasing both consumers and the increasingly stringent environment regulations
plastic parts which with some different techniques
achieved an apparent density decrease by containing micro voids in the inside
techniques were called foaming and for that different injection moulds are being needed.
studies on foaming to improve its obvious resistance
reduction due to the gas voids and to increase the material savings so moulds that can be
industry but their first applications were
back to the beginning of the last century. They represented a massive improvement for
notably weight reduced and in some applications
ented also an increase of mechanical properties due its ductility. This advantages
lead many industry sectors to modify their products such as the automotive industry that
Nowadays the struggle is
a weight reduction represents more efficiency and material
savings pleasing both consumers and the increasingly stringent environment regulations
plastic parts which with some different techniques
achieved an apparent density decrease by containing micro voids in the inside
techniques were called foaming and for that different injection moulds are being needed.
studies on foaming to improve its obvious resistance
material savings so moulds that can be
industry but their first applications were
back to the beginning of the last century. They represented a massive improvement for
notably weight reduced and in some applications
ented also an increase of mechanical properties due its ductility. This advantages
lead many industry sectors to modify their products such as the automotive industry that
Nowadays the struggle is
a weight reduction represents more efficiency and material
savings pleasing both consumers and the increasingly stringent environment regulations
plastic parts which with some different techniques
achieved an apparent density decrease by containing micro voids in the inside. Those
techniques were called foaming and for that different injection moulds are being needed.
studies on foaming to improve its obvious resistance
material savings so moulds that can be
5
industry but their first applications were
back to the beginning of the last century. They represented a massive improvement for
notably weight reduced and in some applications
ented also an increase of mechanical properties due its ductility. This advantages
lead many industry sectors to modify their products such as the automotive industry that
Nowadays the struggle is still
a weight reduction represents more efficiency and material
savings pleasing both consumers and the increasingly stringent environment regulations
plastic parts which with some different techniques
. Those
techniques were called foaming and for that different injection moulds are being needed.
studies on foaming to improve its obvious resistance
material savings so moulds that can be
Expansible Injection Mould DesignBuch Cardona, Eloi
Objecti
The project is framed in an R & D project
and V
injection foaming techniques.
mould possible for that goal.
Specifically, a breathing mould that consist in having a cavity that increases volume while
opening the mould letting the polymer expand freely without changing the general shape.
That includes the initial evaluation of mould surrounding parameters and chara
as well as multiple
produced needs to be designed as well to contain as much test specimens as possible and
to resemble to large pieces.
It does not go further so it will not
other examples, opinions and previous experiences. Foaming techniques are not discussed
but taken
Project's main structure will be:
specifications given and the CCP own machine disposal.
a conscious evaluation and the appropriate choice being aware of the different li
Expansible Injection Mould DesignBuch Cardona, Eloi
Objecti
The project is framed in an R & D project
VolksWagen
injection foaming techniques.
mould possible for that goal.
ecifically, a breathing mould that consist in having a cavity that increases volume while
opening the mould letting the polymer expand freely without changing the general shape.
That includes the initial evaluation of mould surrounding parameters and chara
as well as multiple
produced needs to be designed as well to contain as much test specimens as possible and
to resemble to large pieces.
It does not go further so it will not
other examples, opinions and previous experiences. Foaming techniques are not discussed
but taken in account for the design.
Project's main structure will be:
- Piece design, which has to adapt to th
specifications given and the CCP own machine disposal.
- Mould design, which includes several different possible variations on the mould,
a conscious evaluation and the appropriate choice being aware of the different li
-Piece description and
Expansible Injection Mould DesignBuch Cardona, Eloi
Objectives
The project is framed in an R & D project
agen which involves the development of
injection foaming techniques.
mould possible for that goal.
ecifically, a breathing mould that consist in having a cavity that increases volume while
opening the mould letting the polymer expand freely without changing the general shape.
That includes the initial evaluation of mould surrounding parameters and chara
as well as multiple ways to resolve the mould and the plans for the chosen one.
produced needs to be designed as well to contain as much test specimens as possible and
to resemble to large pieces.
It does not go further so it will not
other examples, opinions and previous experiences. Foaming techniques are not discussed
in account for the design.
Project's main structure will be:
Piece design, which has to adapt to th
specifications given and the CCP own machine disposal.
Mould design, which includes several different possible variations on the mould,
a conscious evaluation and the appropriate choice being aware of the different li
Piece description and
Expansible Injection Mould Design
The project is framed in an R & D project
which involves the development of
injection foaming techniques. The main objective is to design the maximum accurately
mould possible for that goal.
ecifically, a breathing mould that consist in having a cavity that increases volume while
opening the mould letting the polymer expand freely without changing the general shape.
That includes the initial evaluation of mould surrounding parameters and chara
ways to resolve the mould and the plans for the chosen one.
produced needs to be designed as well to contain as much test specimens as possible and
It does not go further so it will not be produced. Solutions are subjectively chosen based in
other examples, opinions and previous experiences. Foaming techniques are not discussed
in account for the design.
Project's main structure will be:
Piece design, which has to adapt to th
specifications given and the CCP own machine disposal.
Mould design, which includes several different possible variations on the mould,
a conscious evaluation and the appropriate choice being aware of the different li
Piece description and elaboration of plans of the mould chosen.
The project is framed in an R & D project between the
which involves the development of
The main objective is to design the maximum accurately
ecifically, a breathing mould that consist in having a cavity that increases volume while
opening the mould letting the polymer expand freely without changing the general shape.
That includes the initial evaluation of mould surrounding parameters and chara
ways to resolve the mould and the plans for the chosen one.
produced needs to be designed as well to contain as much test specimens as possible and
be produced. Solutions are subjectively chosen based in
other examples, opinions and previous experiences. Foaming techniques are not discussed
Piece design, which has to adapt to th
specifications given and the CCP own machine disposal.
Mould design, which includes several different possible variations on the mould,
a conscious evaluation and the appropriate choice being aware of the different li
laboration of plans of the mould chosen.
between the Centre Català del Plàstic
which involves the development of foamed plastic pieces using different
The main objective is to design the maximum accurately
ecifically, a breathing mould that consist in having a cavity that increases volume while
opening the mould letting the polymer expand freely without changing the general shape.
That includes the initial evaluation of mould surrounding parameters and chara
ways to resolve the mould and the plans for the chosen one.
produced needs to be designed as well to contain as much test specimens as possible and
be produced. Solutions are subjectively chosen based in
other examples, opinions and previous experiences. Foaming techniques are not discussed
Piece design, which has to adapt to the general project in terms of the
specifications given and the CCP own machine disposal.
Mould design, which includes several different possible variations on the mould,
a conscious evaluation and the appropriate choice being aware of the different li
laboration of plans of the mould chosen.
Centre Català del Plàstic
foamed plastic pieces using different
The main objective is to design the maximum accurately
ecifically, a breathing mould that consist in having a cavity that increases volume while
opening the mould letting the polymer expand freely without changing the general shape.
That includes the initial evaluation of mould surrounding parameters and chara
ways to resolve the mould and the plans for the chosen one.
produced needs to be designed as well to contain as much test specimens as possible and
be produced. Solutions are subjectively chosen based in
other examples, opinions and previous experiences. Foaming techniques are not discussed
e general project in terms of the
Mould design, which includes several different possible variations on the mould,
a conscious evaluation and the appropriate choice being aware of the different li
laboration of plans of the mould chosen.
Centre Català del Plàstic (CCP),
foamed plastic pieces using different
The main objective is to design the maximum accurately
ecifically, a breathing mould that consist in having a cavity that increases volume while
opening the mould letting the polymer expand freely without changing the general shape.
That includes the initial evaluation of mould surrounding parameters and characteristics
ways to resolve the mould and the plans for the chosen one. The piece
produced needs to be designed as well to contain as much test specimens as possible and
be produced. Solutions are subjectively chosen based in
other examples, opinions and previous experiences. Foaming techniques are not discussed
e general project in terms of the
Mould design, which includes several different possible variations on the mould,
a conscious evaluation and the appropriate choice being aware of the different limitations.
6
), Seat
foamed plastic pieces using different
The main objective is to design the maximum accurately
ecifically, a breathing mould that consist in having a cavity that increases volume while
opening the mould letting the polymer expand freely without changing the general shape.
cteristics
The piece
produced needs to be designed as well to contain as much test specimens as possible and
be produced. Solutions are subjectively chosen based in
other examples, opinions and previous experiences. Foaming techniques are not discussed
e general project in terms of the
Mould design, which includes several different possible variations on the mould,
mitations.
Expansible Injection Mould DesignBuch Cardona, Eloi
1.Background
Foaming has been an object of study since the early 70's to produce large lightweight
pieces compared to the completely solid ones
added to the polymer that helped in completely filling the volume.
weight, saved material and lightened machine characteristics, but often in exchange for
mechanical properties and surface definition and quality.
Actually, che
SCF (supercritic
pressure.
G.G., 2013]
obtain
Some of the physical agents foaming characteristics are:
•
•
•
•
•
•
•
Some of those characteristics are
maintenance pressure in favor of the inner gas pressure. The structure obtained
resembles to a sandwich one which have solid compact outer layers that provide good
physical properties combined with a microfoa
without reducing significantly the mechanical properties.
Expansible Injection Mould DesignBuch Cardona, Eloi
Background
Foaming has been an object of study since the early 70's to produce large lightweight
pieces compared to the completely solid ones
added to the polymer that helped in completely filling the volume.
weight, saved material and lightened machine characteristics, but often in exchange for
mechanical properties and surface definition and quality.
Actually, chemical blowing agents are being replaced by physical ones that consist in a
SCF (supercritic
pressure. Differences between both systems are
, 2013] and suggest that the microfoaming obtained by the physical agents is the key to
obtain better results in where chemical agents fail to achieve.
Some of the physical agents foaming characteristics are:
• Final piece weight reduction
• Lower processing
• Dimension stability
• Reduction of superficial voids
• Lower cycle time
• Physical properties enhanced
• Usage of blowing agents respectful with the environment
Some of those characteristics are
maintenance pressure in favor of the inner gas pressure. The structure obtained
resembles to a sandwich one which have solid compact outer layers that provide good
physical properties combined with a microfoa
without reducing significantly the mechanical properties.
Expansible Injection Mould DesignBuch Cardona, Eloi
Background
Foaming has been an object of study since the early 70's to produce large lightweight
pieces compared to the completely solid ones
added to the polymer that helped in completely filling the volume.
weight, saved material and lightened machine characteristics, but often in exchange for
mechanical properties and surface definition and quality.
mical blowing agents are being replaced by physical ones that consist in a
SCF (supercritical state fluid) addition in the melt polymer that expands when reducing
Differences between both systems are
suggest that the microfoaming obtained by the physical agents is the key to
better results in where chemical agents fail to achieve.
Some of the physical agents foaming characteristics are:
Final piece weight reduction
processing temperatures and pressures
Dimension stability
Reduction of superficial voids
Lower cycle time
Physical properties enhanced
Usage of blowing agents respectful with the environment
Some of those characteristics are
maintenance pressure in favor of the inner gas pressure. The structure obtained
resembles to a sandwich one which have solid compact outer layers that provide good
physical properties combined with a microfoa
without reducing significantly the mechanical properties.
Expansible Injection Mould Design
Background
Foaming has been an object of study since the early 70's to produce large lightweight
pieces compared to the completely solid ones
added to the polymer that helped in completely filling the volume.
weight, saved material and lightened machine characteristics, but often in exchange for
mechanical properties and surface definition and quality.
mical blowing agents are being replaced by physical ones that consist in a
fluid) addition in the melt polymer that expands when reducing
Differences between both systems are
suggest that the microfoaming obtained by the physical agents is the key to
better results in where chemical agents fail to achieve.
Some of the physical agents foaming characteristics are:
Final piece weight reduction
emperatures and pressures
Reduction of superficial voids
Physical properties enhanced compared to chemical obtained
Usage of blowing agents respectful with the environment
Some of those characteristics are a direct consequence of the substitution of the
maintenance pressure in favor of the inner gas pressure. The structure obtained
resembles to a sandwich one which have solid compact outer layers that provide good
physical properties combined with a microfoa
without reducing significantly the mechanical properties.
Foaming has been an object of study since the early 70's to produce large lightweight
pieces compared to the completely solid ones. For that chemical blowing agents
added to the polymer that helped in completely filling the volume.
weight, saved material and lightened machine characteristics, but often in exchange for
mechanical properties and surface definition and quality.
mical blowing agents are being replaced by physical ones that consist in a
fluid) addition in the melt polymer that expands when reducing
Differences between both systems are being
suggest that the microfoaming obtained by the physical agents is the key to
better results in where chemical agents fail to achieve.
Some of the physical agents foaming characteristics are:
emperatures and pressures
compared to chemical obtained
Usage of blowing agents respectful with the environment
a direct consequence of the substitution of the
maintenance pressure in favor of the inner gas pressure. The structure obtained
resembles to a sandwich one which have solid compact outer layers that provide good
physical properties combined with a microfoamed core that saves in
without reducing significantly the mechanical properties.
Foaming has been an object of study since the early 70's to produce large lightweight
For that chemical blowing agents
added to the polymer that helped in completely filling the volume.
weight, saved material and lightened machine characteristics, but often in exchange for
mechanical properties and surface definition and quality.
mical blowing agents are being replaced by physical ones that consist in a
fluid) addition in the melt polymer that expands when reducing
being carefully analyzed
suggest that the microfoaming obtained by the physical agents is the key to
better results in where chemical agents fail to achieve.
Some of the physical agents foaming characteristics are:
emperatures and pressures
compared to chemical obtained
Usage of blowing agents respectful with the environment
a direct consequence of the substitution of the
maintenance pressure in favor of the inner gas pressure. The structure obtained
resembles to a sandwich one which have solid compact outer layers that provide good
med core that saves in
without reducing significantly the mechanical properties.
Foaming has been an object of study since the early 70's to produce large lightweight
For that chemical blowing agents
added to the polymer that helped in completely filling the volume. That reduced the final
weight, saved material and lightened machine characteristics, but often in exchange for
mical blowing agents are being replaced by physical ones that consist in a
fluid) addition in the melt polymer that expands when reducing
carefully analyzed
suggest that the microfoaming obtained by the physical agents is the key to
compared to chemical obtained
Usage of blowing agents respectful with the environment (N2 y CO
a direct consequence of the substitution of the
maintenance pressure in favor of the inner gas pressure. The structure obtained
resembles to a sandwich one which have solid compact outer layers that provide good
med core that saves in weight and material
Foaming has been an object of study since the early 70's to produce large lightweight
For that chemical blowing agents
That reduced the final
weight, saved material and lightened machine characteristics, but often in exchange for
mical blowing agents are being replaced by physical ones that consist in a
fluid) addition in the melt polymer that expands when reducing
carefully analyzed [Jaime Francisco
suggest that the microfoaming obtained by the physical agents is the key to
y CO2)
a direct consequence of the substitution of the
maintenance pressure in favor of the inner gas pressure. The structure obtained
resembles to a sandwich one which have solid compact outer layers that provide good
weight and material
7
Foaming has been an object of study since the early 70's to produce large lightweight
were
That reduced the final
weight, saved material and lightened machine characteristics, but often in exchange for
mical blowing agents are being replaced by physical ones that consist in a
fluid) addition in the melt polymer that expands when reducing
[Jaime Francisco
suggest that the microfoaming obtained by the physical agents is the key to
a direct consequence of the substitution of the
maintenance pressure in favor of the inner gas pressure. The structure obtained
resembles to a sandwich one which have solid compact outer layers that provide good
weight and material
Expansible Injection Mould DesignBuch Cardona, Eloi
To make all the tests it is important to have smart designed moulds to
injection tech
Some studies
moulds" and their effect on pieces produced using physical blowing agents.
permit an opening of the machine to give space for the piece to decrease pres
injected gas adapt to the volume.
Although the foaming technology is still being studied, there are already some products
produced by it such as automotive, medical and packaging parts
basically is the MuCell® technolo
molding.
Expansible Injection Mould DesignBuch Cardona, Eloi
To make all the tests it is important to have smart designed moulds to
injection technology
Some studies [Spörrer, 2007]
moulds" and their effect on pieces produced using physical blowing agents.
permit an opening of the machine to give space for the piece to decrease pres
injected gas adapt to the volume.
Although the foaming technology is still being studied, there are already some products
produced by it such as automotive, medical and packaging parts
basically is the MuCell® technolo
molding.
Expansible Injection Mould DesignBuch Cardona, Eloi
To make all the tests it is important to have smart designed moulds to
nology
[Spörrer, 2007]
moulds" and their effect on pieces produced using physical blowing agents.
permit an opening of the machine to give space for the piece to decrease pres
injected gas adapt to the volume.
Although the foaming technology is still being studied, there are already some products
produced by it such as automotive, medical and packaging parts
basically is the MuCell® technolo
Expansible Injection Mould Design
Figure 1
To make all the tests it is important to have smart designed moulds to
[Spörrer, 2007] have proved the efficiency of the so called "breathing
moulds" and their effect on pieces produced using physical blowing agents.
permit an opening of the machine to give space for the piece to decrease pres
injected gas adapt to the volume.
Although the foaming technology is still being studied, there are already some products
produced by it such as automotive, medical and packaging parts
basically is the MuCell® technology by Trexel Inc. that allows SCF added injection
Figure 2 Automotive foamed piece
1 Sandwich structure
To make all the tests it is important to have smart designed moulds to
have proved the efficiency of the so called "breathing
moulds" and their effect on pieces produced using physical blowing agents.
permit an opening of the machine to give space for the piece to decrease pres
Although the foaming technology is still being studied, there are already some products
produced by it such as automotive, medical and packaging parts
gy by Trexel Inc. that allows SCF added injection
Automotive foamed piece
Sandwich structure
To make all the tests it is important to have smart designed moulds to
have proved the efficiency of the so called "breathing
moulds" and their effect on pieces produced using physical blowing agents.
permit an opening of the machine to give space for the piece to decrease pres
Although the foaming technology is still being studied, there are already some products
produced by it such as automotive, medical and packaging parts
gy by Trexel Inc. that allows SCF added injection
Automotive foamed piece
To make all the tests it is important to have smart designed moulds to
have proved the efficiency of the so called "breathing
moulds" and their effect on pieces produced using physical blowing agents.
permit an opening of the machine to give space for the piece to decrease pres
Although the foaming technology is still being studied, there are already some products
produced by it such as automotive, medical and packaging parts. The responsible of that
gy by Trexel Inc. that allows SCF added injection
To make all the tests it is important to have smart designed moulds to empower that
have proved the efficiency of the so called "breathing
moulds" and their effect on pieces produced using physical blowing agents. Those moulds
permit an opening of the machine to give space for the piece to decrease pressure and let
Although the foaming technology is still being studied, there are already some products
. The responsible of that
gy by Trexel Inc. that allows SCF added injection
8
empower that
have proved the efficiency of the so called "breathing
Those moulds
sure and let
Although the foaming technology is still being studied, there are already some products
. The responsible of that
gy by Trexel Inc. that allows SCF added injection
Expansible Injection Mould DesignBuch Cardona, Eloi
2.External conditioning
Some parts of the design of the mould are going to be limited by external agent
the injection machine or the material used, so the proper understanding of these is
essential to understand some decisions taken.
2.1.
Centre Català del Plàstic Injectio
•
•
•
•
•
•
•
Expansible Injection Mould DesignBuch Cardona, Eloi
External conditioning
Some parts of the design of the mould are going to be limited by external agent
the injection machine or the material used, so the proper understanding of these is
essential to understand some decisions taken.
2.1.Injection machine characteristics
Centre Català del Plàstic Injectio
• Injection machine
(SCF) MuCell®.
• Clamping force: 1100 kN.
• Maximum overture: 507mm
• Maximum injection velo
• Injection pressure: 1287 bar.
• Nozzle diameter: 40 mm.
• Maximum injection volume: 250 cm3.
Expansible Injection Mould DesignBuch Cardona, Eloi
External conditioning
Some parts of the design of the mould are going to be limited by external agent
the injection machine or the material used, so the proper understanding of these is
essential to understand some decisions taken.
Injection machine characteristics
Centre Català del Plàstic Injectio
Injection machine Engel Victory 110
(SCF) MuCell®.
Clamping force: 1100 kN.
Maximum overture: 507mm
Maximum injection velo
Injection pressure: 1287 bar.
Nozzle diameter: 40 mm.
Maximum injection volume: 250 cm3.
Expansible Injection Mould Design
External conditioning
Some parts of the design of the mould are going to be limited by external agent
the injection machine or the material used, so the proper understanding of these is
essential to understand some decisions taken.
Injection machine characteristics
Centre Català del Plàstic Injection machine disposal characteristics:
Engel Victory 110
Clamping force: 1100 kN.
Maximum overture: 507mm
Figure
Maximum injection velocity: 754 cm3/s.
Injection pressure: 1287 bar.
Nozzle diameter: 40 mm.
Maximum injection volume: 250 cm3.
External conditioning
Some parts of the design of the mould are going to be limited by external agent
the injection machine or the material used, so the proper understanding of these is
essential to understand some decisions taken.
Injection machine characteristics
n machine disposal characteristics:
Engel Victory 110, equipped with the
Figure 3 Clamping unit
city: 754 cm3/s.
Maximum injection volume: 250 cm3.
External conditioning
Some parts of the design of the mould are going to be limited by external agent
the injection machine or the material used, so the proper understanding of these is
n machine disposal characteristics:
, equipped with the
Clamping unit
Some parts of the design of the mould are going to be limited by external agent
the injection machine or the material used, so the proper understanding of these is
n machine disposal characteristics:
, equipped with the Supercritic Fluid System
Some parts of the design of the mould are going to be limited by external agents such as
the injection machine or the material used, so the proper understanding of these is
Supercritic Fluid System
9
s such as
Supercritic Fluid System
Expansible Injection Mould DesignBuch Cardona, Eloi
•
•
•
Some of the previous
course with not every polymer can those values be achieved so it is very important also
which material is going to be used to properly set the machine to its own possibilities.
The rest basica
install
2.2.
As said,
one type of polymer nor the same type of injection
material parameters are going to be changed frequently and that is what is needed to be
taken in account while utilizing the mould. In many design terms raw PP values are taken
because it is one of the most used mater
industry as well as because it has one of the greatest contractions of the used polymers
Expansible Injection Mould DesignBuch Cardona, Eloi
• Without hydraulic slidings
• Cold runner preferred.
• Subjection plates size:
Some of the previous
course with not every polymer can those values be achieved so it is very important also
which material is going to be used to properly set the machine to its own possibilities.
The rest basically influence in maximum size and some characteristics for the mould to
install.
2.2.Material characteristics
As said, this project develops a mould to experiment with so it is not destined to have only
one type of polymer nor the same type of injection
material parameters are going to be changed frequently and that is what is needed to be
taken in account while utilizing the mould. In many design terms raw PP values are taken
because it is one of the most used mater
industry as well as because it has one of the greatest contractions of the used polymers
Expansible Injection Mould DesignBuch Cardona, Eloi
Without hydraulic slidings
Cold runner preferred.
Subjection plates size:
Some of the previous information are maximum values taken by experimental tests. Of
course with not every polymer can those values be achieved so it is very important also
which material is going to be used to properly set the machine to its own possibilities.
lly influence in maximum size and some characteristics for the mould to
Material characteristics
this project develops a mould to experiment with so it is not destined to have only
one type of polymer nor the same type of injection
material parameters are going to be changed frequently and that is what is needed to be
taken in account while utilizing the mould. In many design terms raw PP values are taken
because it is one of the most used mater
industry as well as because it has one of the greatest contractions of the used polymers
Expansible Injection Mould Design
Without hydraulic slidings
Cold runner preferred.
Subjection plates size:
Figure
information are maximum values taken by experimental tests. Of
course with not every polymer can those values be achieved so it is very important also
which material is going to be used to properly set the machine to its own possibilities.
lly influence in maximum size and some characteristics for the mould to
Material characteristics
this project develops a mould to experiment with so it is not destined to have only
one type of polymer nor the same type of injection
material parameters are going to be changed frequently and that is what is needed to be
taken in account while utilizing the mould. In many design terms raw PP values are taken
because it is one of the most used mater
industry as well as because it has one of the greatest contractions of the used polymers
Figure 4 Subjection plates
information are maximum values taken by experimental tests. Of
course with not every polymer can those values be achieved so it is very important also
which material is going to be used to properly set the machine to its own possibilities.
lly influence in maximum size and some characteristics for the mould to
this project develops a mould to experiment with so it is not destined to have only
one type of polymer nor the same type of injection
material parameters are going to be changed frequently and that is what is needed to be
taken in account while utilizing the mould. In many design terms raw PP values are taken
because it is one of the most used material in that type of applications in automotive
industry as well as because it has one of the greatest contractions of the used polymers
Subjection plates
information are maximum values taken by experimental tests. Of
course with not every polymer can those values be achieved so it is very important also
which material is going to be used to properly set the machine to its own possibilities.
lly influence in maximum size and some characteristics for the mould to
this project develops a mould to experiment with so it is not destined to have only
one type of polymer nor the same type of injection method. Viscosity, shrinkage and other
material parameters are going to be changed frequently and that is what is needed to be
taken in account while utilizing the mould. In many design terms raw PP values are taken
ial in that type of applications in automotive
industry as well as because it has one of the greatest contractions of the used polymers
information are maximum values taken by experimental tests. Of
course with not every polymer can those values be achieved so it is very important also
which material is going to be used to properly set the machine to its own possibilities.
lly influence in maximum size and some characteristics for the mould to
this project develops a mould to experiment with so it is not destined to have only
method. Viscosity, shrinkage and other
material parameters are going to be changed frequently and that is what is needed to be
taken in account while utilizing the mould. In many design terms raw PP values are taken
ial in that type of applications in automotive
industry as well as because it has one of the greatest contractions of the used polymers
information are maximum values taken by experimental tests. Of
course with not every polymer can those values be achieved so it is very important also
which material is going to be used to properly set the machine to its own possibilities.
lly influence in maximum size and some characteristics for the mould to
this project develops a mould to experiment with so it is not destined to have only
method. Viscosity, shrinkage and other
material parameters are going to be changed frequently and that is what is needed to be
taken in account while utilizing the mould. In many design terms raw PP values are taken
ial in that type of applications in automotive
industry as well as because it has one of the greatest contractions of the used polymers
10
information are maximum values taken by experimental tests. Of
course with not every polymer can those values be achieved so it is very important also
which material is going to be used to properly set the machine to its own possibilities.
lly influence in maximum size and some characteristics for the mould to
this project develops a mould to experiment with so it is not destined to have only
method. Viscosity, shrinkage and other
material parameters are going to be changed frequently and that is what is needed to be
taken in account while utilizing the mould. In many design terms raw PP values are taken
ial in that type of applications in automotive
industry as well as because it has one of the greatest contractions of the used polymers.
Expansible Injection Mould DesignBuch Cardona, Eloi
3.Piece design
To know how the mould is going to be, it is needed first to completely and properl
and design the piece it is going to be produced, otherwise that could provoke mistakes
while designing the mould.
The piece needs to be representative for large ones emul
properly take conclusions without having to ac
Those pieces will be used to take out test specimens in normalized shapes so they will
need to have some dimensions depending on that. Also it will be needed to see how can
they be to resemble to large pieces in terms of flux a
ones.
3.1
For the first step is important to know in which conditions it is going to be worked at, that
will lead us to some general dimensions to decide the final geometry of the piece.
We have a g
pressure given by the machine and the pressure in the material depending on the nozzle
diameter. The nozzle utilized is the Ø 40mm one that consists in a barely 1:1 rate betwee
the values in the graph. As it can be seen, the maximum of the machine is 1700bar, but a
value of 1000bar (100Kg/cm2) is kept as the new working maximum.
Expansible Injection Mould DesignBuch Cardona, Eloi
Piece design
To know how the mould is going to be, it is needed first to completely and properl
and design the piece it is going to be produced, otherwise that could provoke mistakes
while designing the mould.
The piece needs to be representative for large ones emul
properly take conclusions without having to ac
Those pieces will be used to take out test specimens in normalized shapes so they will
need to have some dimensions depending on that. Also it will be needed to see how can
they be to resemble to large pieces in terms of flux a
ones.
Technical limits
For the first step is important to know in which conditions it is going to be worked at, that
will lead us to some general dimensions to decide the final geometry of the piece.
We have a graph of the injection machine in which it can be seen the relation between the
pressure given by the machine and the pressure in the material depending on the nozzle
diameter. The nozzle utilized is the Ø 40mm one that consists in a barely 1:1 rate betwee
the values in the graph. As it can be seen, the maximum of the machine is 1700bar, but a
value of 1000bar (100Kg/cm2) is kept as the new working maximum.
Expansible Injection Mould DesignBuch Cardona, Eloi
Piece design
To know how the mould is going to be, it is needed first to completely and properl
and design the piece it is going to be produced, otherwise that could provoke mistakes
while designing the mould.
The piece needs to be representative for large ones emul
properly take conclusions without having to ac
Those pieces will be used to take out test specimens in normalized shapes so they will
need to have some dimensions depending on that. Also it will be needed to see how can
they be to resemble to large pieces in terms of flux a
Technical limits
For the first step is important to know in which conditions it is going to be worked at, that
will lead us to some general dimensions to decide the final geometry of the piece.
raph of the injection machine in which it can be seen the relation between the
pressure given by the machine and the pressure in the material depending on the nozzle
diameter. The nozzle utilized is the Ø 40mm one that consists in a barely 1:1 rate betwee
the values in the graph. As it can be seen, the maximum of the machine is 1700bar, but a
value of 1000bar (100Kg/cm2) is kept as the new working maximum.
Expansible Injection Mould Design
Piece design
To know how the mould is going to be, it is needed first to completely and properl
and design the piece it is going to be produced, otherwise that could provoke mistakes
The piece needs to be representative for large ones emul
properly take conclusions without having to ac
Those pieces will be used to take out test specimens in normalized shapes so they will
need to have some dimensions depending on that. Also it will be needed to see how can
they be to resemble to large pieces in terms of flux a
For the first step is important to know in which conditions it is going to be worked at, that
will lead us to some general dimensions to decide the final geometry of the piece.
raph of the injection machine in which it can be seen the relation between the
pressure given by the machine and the pressure in the material depending on the nozzle
diameter. The nozzle utilized is the Ø 40mm one that consists in a barely 1:1 rate betwee
the values in the graph. As it can be seen, the maximum of the machine is 1700bar, but a
value of 1000bar (100Kg/cm2) is kept as the new working maximum.
To know how the mould is going to be, it is needed first to completely and properl
and design the piece it is going to be produced, otherwise that could provoke mistakes
The piece needs to be representative for large ones emul
properly take conclusions without having to actually produce large pieces.
Those pieces will be used to take out test specimens in normalized shapes so they will
need to have some dimensions depending on that. Also it will be needed to see how can
they be to resemble to large pieces in terms of flux a
For the first step is important to know in which conditions it is going to be worked at, that
will lead us to some general dimensions to decide the final geometry of the piece.
raph of the injection machine in which it can be seen the relation between the
pressure given by the machine and the pressure in the material depending on the nozzle
diameter. The nozzle utilized is the Ø 40mm one that consists in a barely 1:1 rate betwee
the values in the graph. As it can be seen, the maximum of the machine is 1700bar, but a
value of 1000bar (100Kg/cm2) is kept as the new working maximum.
To know how the mould is going to be, it is needed first to completely and properl
and design the piece it is going to be produced, otherwise that could provoke mistakes
The piece needs to be representative for large ones emulat
tually produce large pieces.
Those pieces will be used to take out test specimens in normalized shapes so they will
need to have some dimensions depending on that. Also it will be needed to see how can
they be to resemble to large pieces in terms of flux and regularity that often lack in small
For the first step is important to know in which conditions it is going to be worked at, that
will lead us to some general dimensions to decide the final geometry of the piece.
raph of the injection machine in which it can be seen the relation between the
pressure given by the machine and the pressure in the material depending on the nozzle
diameter. The nozzle utilized is the Ø 40mm one that consists in a barely 1:1 rate betwee
the values in the graph. As it can be seen, the maximum of the machine is 1700bar, but a
value of 1000bar (100Kg/cm2) is kept as the new working maximum.
To know how the mould is going to be, it is needed first to completely and properl
and design the piece it is going to be produced, otherwise that could provoke mistakes
ating their characteristics to
tually produce large pieces.
Those pieces will be used to take out test specimens in normalized shapes so they will
need to have some dimensions depending on that. Also it will be needed to see how can
nd regularity that often lack in small
For the first step is important to know in which conditions it is going to be worked at, that
will lead us to some general dimensions to decide the final geometry of the piece.
raph of the injection machine in which it can be seen the relation between the
pressure given by the machine and the pressure in the material depending on the nozzle
diameter. The nozzle utilized is the Ø 40mm one that consists in a barely 1:1 rate betwee
the values in the graph. As it can be seen, the maximum of the machine is 1700bar, but a
value of 1000bar (100Kg/cm2) is kept as the new working maximum.
To know how the mould is going to be, it is needed first to completely and properly define
and design the piece it is going to be produced, otherwise that could provoke mistakes
their characteristics to
tually produce large pieces.
Those pieces will be used to take out test specimens in normalized shapes so they will
need to have some dimensions depending on that. Also it will be needed to see how can
nd regularity that often lack in small
For the first step is important to know in which conditions it is going to be worked at, that
will lead us to some general dimensions to decide the final geometry of the piece.
raph of the injection machine in which it can be seen the relation between the
pressure given by the machine and the pressure in the material depending on the nozzle
diameter. The nozzle utilized is the Ø 40mm one that consists in a barely 1:1 rate betwee
the values in the graph. As it can be seen, the maximum of the machine is 1700bar, but a
11
y define
and design the piece it is going to be produced, otherwise that could provoke mistakes
their characteristics to
Those pieces will be used to take out test specimens in normalized shapes so they will
need to have some dimensions depending on that. Also it will be needed to see how can
nd regularity that often lack in small
For the first step is important to know in which conditions it is going to be worked at, that
raph of the injection machine in which it can be seen the relation between the
pressure given by the machine and the pressure in the material depending on the nozzle
diameter. The nozzle utilized is the Ø 40mm one that consists in a barely 1:1 rate between
the values in the graph. As it can be seen, the maximum of the machine is 1700bar, but a
Expansible Injection Mould DesignBuch Cardona, Eloi
This value is set as the new maxi
is going to be used and the viscosity can be higher in some types causing an extra pressure
need, but in similar characteristics pieces the work pressure has been usually near the
400bar.
In each of la
problems that appear when work is done near any limit and that also provides an
assurance to minimize further flaws or mistakes.
Expansible Injection Mould DesignBuch Cardona, Eloi
This value is set as the new maxi
is going to be used and the viscosity can be higher in some types causing an extra pressure
need, but in similar characteristics pieces the work pressure has been usually near the
400bar.
In each of last decisions we assumed a high Security Factor in order to prevent the
problems that appear when work is done near any limit and that also provides an
assurance to minimize further flaws or mistakes.
Expansible Injection Mould DesignBuch Cardona, Eloi
This value is set as the new maxi
is going to be used and the viscosity can be higher in some types causing an extra pressure
need, but in similar characteristics pieces the work pressure has been usually near the
st decisions we assumed a high Security Factor in order to prevent the
problems that appear when work is done near any limit and that also provides an
assurance to minimize further flaws or mistakes.
Expansible Injection Mould Design
Figure 5 Graph with pressure relation
This value is set as the new maximum keeping in mind that more than one type of plastic
is going to be used and the viscosity can be higher in some types causing an extra pressure
need, but in similar characteristics pieces the work pressure has been usually near the
st decisions we assumed a high Security Factor in order to prevent the
problems that appear when work is done near any limit and that also provides an
assurance to minimize further flaws or mistakes.
Graph with pressure relation
mum keeping in mind that more than one type of plastic
is going to be used and the viscosity can be higher in some types causing an extra pressure
need, but in similar characteristics pieces the work pressure has been usually near the
st decisions we assumed a high Security Factor in order to prevent the
problems that appear when work is done near any limit and that also provides an
assurance to minimize further flaws or mistakes.
Graph with pressure relation
mum keeping in mind that more than one type of plastic
is going to be used and the viscosity can be higher in some types causing an extra pressure
need, but in similar characteristics pieces the work pressure has been usually near the
st decisions we assumed a high Security Factor in order to prevent the
problems that appear when work is done near any limit and that also provides an
mum keeping in mind that more than one type of plastic
is going to be used and the viscosity can be higher in some types causing an extra pressure
need, but in similar characteristics pieces the work pressure has been usually near the
st decisions we assumed a high Security Factor in order to prevent the
problems that appear when work is done near any limit and that also provides an
mum keeping in mind that more than one type of plastic
is going to be used and the viscosity can be higher in some types causing an extra pressure
need, but in similar characteristics pieces the work pressure has been usually near the
st decisions we assumed a high Security Factor in order to prevent the
problems that appear when work is done near any limit and that also provides an
12
mum keeping in mind that more than one type of plastic
is going to be used and the viscosity can be higher in some types causing an extra pressure
need, but in similar characteristics pieces the work pressure has been usually near the
st decisions we assumed a high Security Factor in order to prevent the
problems that appear when work is done near any limit and that also provides an
Expansible Injection Mould DesignBuch Cardona, Eloi
Once the maximum pressure on the material is obtained
strength of the machine (1100 kN) we can obtain the maximum projected area of the piece
we are designing.
As I said before, we were assuming
at last some variations are allowed.
3.2
A rectangular shape is ideal for the test specimens extraction but other characteristics
need to be also taken into account.
Next step
satisfy the purpose of the project.
distribution of the flux through the piece.
zone.
Expansible Injection Mould DesignBuch Cardona, Eloi
Once the maximum pressure on the material is obtained
strength of the machine (1100 kN) we can obtain the maximum projected area of the piece
we are designing.
Projected
As I said before, we were assuming
at last some variations are allowed.
The geometry
A rectangular shape is ideal for the test specimens extraction but other characteristics
need to be also taken into account.
Next step then, is
satisfy the purpose of the project.
- Lateral entrance, preferred to a central entrance because permits a better
distribution of the flux through the piece.
- "Fan" entrance, prov
zone.
- No runners, fact that simplifies the mould as it is soon explained.
Expansible Injection Mould DesignBuch Cardona, Eloi
Once the maximum pressure on the material is obtained
strength of the machine (1100 kN) we can obtain the maximum projected area of the piece
we are designing.
ProjectedArea
As I said before, we were assuming
at last some variations are allowed.
The geometry
A rectangular shape is ideal for the test specimens extraction but other characteristics
need to be also taken into account.
is finally define the geometry wanted and discuss its measures to correctly
satisfy the purpose of the project.
Lateral entrance, preferred to a central entrance because permits a better
distribution of the flux through the piece.
"Fan" entrance, prov
No runners, fact that simplifies the mould as it is soon explained.
Figure
Expansible Injection Mould Design
Once the maximum pressure on the material is obtained
strength of the machine (1100 kN) we can obtain the maximum projected area of the piece
Area � Pressure
A � 1000
A
As I said before, we were assuming a great SF and the values obtained are used as limit, so
at last some variations are allowed.
A rectangular shape is ideal for the test specimens extraction but other characteristics
need to be also taken into account.
finally define the geometry wanted and discuss its measures to correctly
satisfy the purpose of the project.
Lateral entrance, preferred to a central entrance because permits a better
distribution of the flux through the piece.
"Fan" entrance, provides a better flux distribution especially in the near
No runners, fact that simplifies the mould as it is soon explained.
Figure 6 Approximate geometry and flux direction
Once the maximum pressure on the material is obtained
strength of the machine (1100 kN) we can obtain the maximum projected area of the piece
PressureonMaterial
1000Kg/cm2 �
A � 110cm2
a great SF and the values obtained are used as limit, so
A rectangular shape is ideal for the test specimens extraction but other characteristics
finally define the geometry wanted and discuss its measures to correctly
Lateral entrance, preferred to a central entrance because permits a better
distribution of the flux through the piece.
ides a better flux distribution especially in the near
No runners, fact that simplifies the mould as it is soon explained.
Approximate geometry and flux direction
Once the maximum pressure on the material is obtained and using the known maximum
strength of the machine (1100 kN) we can obtain the maximum projected area of the piece
Material � Machine
110000Kg
2
a great SF and the values obtained are used as limit, so
A rectangular shape is ideal for the test specimens extraction but other characteristics
finally define the geometry wanted and discuss its measures to correctly
Lateral entrance, preferred to a central entrance because permits a better
ides a better flux distribution especially in the near
No runners, fact that simplifies the mould as it is soon explained.
Approximate geometry and flux direction
and using the known maximum
strength of the machine (1100 kN) we can obtain the maximum projected area of the piece
MachineStrength
a great SF and the values obtained are used as limit, so
A rectangular shape is ideal for the test specimens extraction but other characteristics
finally define the geometry wanted and discuss its measures to correctly
Lateral entrance, preferred to a central entrance because permits a better
ides a better flux distribution especially in the near
No runners, fact that simplifies the mould as it is soon explained.
Approximate geometry and flux direction
and using the known maximum
strength of the machine (1100 kN) we can obtain the maximum projected area of the piece
Strength
a great SF and the values obtained are used as limit, so
A rectangular shape is ideal for the test specimens extraction but other characteristics
finally define the geometry wanted and discuss its measures to correctly
Lateral entrance, preferred to a central entrance because permits a better
ides a better flux distribution especially in the near-entrance
13
and using the known maximum
strength of the machine (1100 kN) we can obtain the maximum projected area of the piece
a great SF and the values obtained are used as limit, so
A rectangular shape is ideal for the test specimens extraction but other characteristics
finally define the geometry wanted and discuss its measures to correctly
Lateral entrance, preferred to a central entrance because permits a better
entrance
Expansible Injection Mould DesignBuch Cardona, Eloi
It is good to remember that the aim of the piece is to represent large pieces so the design is
often bad for
It also have to be noticed some of the uses the piece is going to have such as test
specimens which are regulated by ISO norms.
In those cases we have to take the expanded value of thickness for t
3.2.1
The only specification for this test is that accomplishes:
Where
Expansible Injection Mould DesignBuch Cardona, Eloi
It is good to remember that the aim of the piece is to represent large pieces so the design is
often bad for its own production, but helpful to achieve its main goal.
It also have to be noticed some of the uses the piece is going to have such as test
specimens which are regulated by ISO norms.
In those cases we have to take the expanded value of thickness for t
.2.1 Flexion test ISO 178 [1]
The only specification for this test is that accomplishes:
Where
-l is the maximum length of the specimen
-h is the final thickness
Expansible Injection Mould DesignBuch Cardona, Eloi
It is good to remember that the aim of the piece is to represent large pieces so the design is
its own production, but helpful to achieve its main goal.
It also have to be noticed some of the uses the piece is going to have such as test
specimens which are regulated by ISO norms.
In those cases we have to take the expanded value of thickness for t
Flexion test ISO 178 [1]
The only specification for this test is that accomplishes:
maximum length of the specimen
is the final thickness
Expansible Injection Mould Design
It is good to remember that the aim of the piece is to represent large pieces so the design is
its own production, but helpful to achieve its main goal.
It also have to be noticed some of the uses the piece is going to have such as test
specimens which are regulated by ISO norms.
In those cases we have to take the expanded value of thickness for t
Flexion test ISO 178 [1]
The only specification for this test is that accomplishes:
maximum length of the specimen
is the final thickness
Figure
It is good to remember that the aim of the piece is to represent large pieces so the design is
its own production, but helpful to achieve its main goal.
It also have to be noticed some of the uses the piece is going to have such as test
specimens which are regulated by ISO norms.
In those cases we have to take the expanded value of thickness for t
The only specification for this test is that accomplishes:
l � 20h
maximum length of the specimen
Figure 7 Flexion test
It is good to remember that the aim of the piece is to represent large pieces so the design is
its own production, but helpful to achieve its main goal.
It also have to be noticed some of the uses the piece is going to have such as test
In those cases we have to take the expanded value of thickness for t
The only specification for this test is that accomplishes:
Flexion test
It is good to remember that the aim of the piece is to represent large pieces so the design is
its own production, but helpful to achieve its main goal.
It also have to be noticed some of the uses the piece is going to have such as test
In those cases we have to take the expanded value of thickness for the calculations.
It is good to remember that the aim of the piece is to represent large pieces so the design is
It also have to be noticed some of the uses the piece is going to have such as test
he calculations.
14
It is good to remember that the aim of the piece is to represent large pieces so the design is
It also have to be noticed some of the uses the piece is going to have such as test
Expansible Injection Mould DesignBuch Cardona, Eloi
Therefore
3.2.2
For type 1A the minimum length is 150 mm which is too much but for types 1BA, 1BB and
5A, 5B the requirements are
The rest of the measures are tabulated in the norm, maximum size is the value that can
affect directly to the piece.
It is important to accomplish as much types as possible for being able to do as much tests
as wanted.
Expansible Injection Mould DesignBuch Cardona, Eloi
Therefore
.2.2 Traction test ISO 527
For type 1A the minimum length is 150 mm which is too much but for types 1BA, 1BB and
5B the requirements are
The rest of the measures are tabulated in the norm, maximum size is the value that can
affect directly to the piece.
It is important to accomplish as much types as possible for being able to do as much tests
as wanted.
Expansible Injection Mould DesignBuch Cardona, Eloi
Final thickness (mm)
Traction test ISO 527
For type 1A the minimum length is 150 mm which is too much but for types 1BA, 1BB and
5B the requirements are
The rest of the measures are tabulated in the norm, maximum size is the value that can
affect directly to the piece.
It is important to accomplish as much types as possible for being able to do as much tests
Expansible Injection Mould Design
al thickness (mm)
3
4
5
6
Traction test ISO 527-2 [2]
Figure 8 Traction test sample sizes
For type 1A the minimum length is 150 mm which is too much but for types 1BA, 1BB and
5B the requirements are
lmax
lmax
The rest of the measures are tabulated in the norm, maximum size is the value that can
It is important to accomplish as much types as possible for being able to do as much tests
al thickness (mm) Maximum length (mm)
2 [2]
Traction test sample sizes
For type 1A the minimum length is 150 mm which is too much but for types 1BA, 1BB and
lmax � 35""
lmax � 75""
The rest of the measures are tabulated in the norm, maximum size is the value that can
It is important to accomplish as much types as possible for being able to do as much tests
Maximum length (mm)
60
80
100
120
Traction test sample sizes
For type 1A the minimum length is 150 mm which is too much but for types 1BA, 1BB and
""
""
The rest of the measures are tabulated in the norm, maximum size is the value that can
It is important to accomplish as much types as possible for being able to do as much tests
Maximum length (mm)
For type 1A the minimum length is 150 mm which is too much but for types 1BA, 1BB and
The rest of the measures are tabulated in the norm, maximum size is the value that can
It is important to accomplish as much types as possible for being able to do as much tests
For type 1A the minimum length is 150 mm which is too much but for types 1BA, 1BB and
The rest of the measures are tabulated in the norm, maximum size is the value that can
It is important to accomplish as much types as possible for being able to do as much tests
15
For type 1A the minimum length is 150 mm which is too much but for types 1BA, 1BB and
The rest of the measures are tabulated in the norm, maximum size is the value that can
It is important to accomplish as much types as possible for being able to do as much tests
Expansible Injection Mould DesignBuch Cardona, Eloi
With that in mind
previous conditions and characteristics.
s1 (mm)
Maximum length (s2) is set at 150mm due to the increased amount of pressure needed in
higher values in the injection process caused by an excessive path for the polymer and its
overcooling effect.
That is because it favor orientation effects, which means that most of the polymer used is
oriented towards the same direction, also to achieve a fully developed flux, which will
make it resemble to
which consists in the non desirable effect of larger gas bobble size on the entrance.
It is needed to take in account the shrinkage of the material, which in terms of PP is
around 1.2%, t
dimension when cooled.
Expansible Injection Mould DesignBuch Cardona, Eloi
With that in mind
previous conditions and characteristics.
Side values
s1 (mm)
70
80
90
100
110
120
Maximum length (s2) is set at 150mm due to the increased amount of pressure needed in
higher values in the injection process caused by an excessive path for the polymer and its
overcooling effect.
-Highlighted values are preferred
- Pieces with a high length/wide relation are preferred
That is because it favor orientation effects, which means that most of the polymer used is
oriented towards the same direction, also to achieve a fully developed flux, which will
make it resemble to
which consists in the non desirable effect of larger gas bobble size on the entrance.
It is needed to take in account the shrinkage of the material, which in terms of PP is
around 1.2%, to properly oversize the mould injection cavity finally obtaining the desired
dimension when cooled.
Expansible Injection Mould DesignBuch Cardona, Eloi
With that in mind we begin to search for the optimum size of the piece, achieving the
previous conditions and characteristics.
Side values
s2 (mm)
143
125
111
100
91
83
Maximum length (s2) is set at 150mm due to the increased amount of pressure needed in
higher values in the injection process caused by an excessive path for the polymer and its
overcooling effect.
Highlighted values are preferred
Pieces with a high length/wide relation are preferred
That is because it favor orientation effects, which means that most of the polymer used is
oriented towards the same direction, also to achieve a fully developed flux, which will
make it resemble to large pieces, and to homogenize the foam without "entrance effect",
which consists in the non desirable effect of larger gas bobble size on the entrance.
It is needed to take in account the shrinkage of the material, which in terms of PP is
o properly oversize the mould injection cavity finally obtaining the desired
dimension when cooled. When using other materials it is going to be taken into account
Expansible Injection Mould Design
we begin to search for the optimum size of the piece, achieving the
previous conditions and characteristics.
Projected Area
Maximum length (s2) is set at 150mm due to the increased amount of pressure needed in
higher values in the injection process caused by an excessive path for the polymer and its
Highlighted values are preferred
Pieces with a high length/wide relation are preferred
That is because it favor orientation effects, which means that most of the polymer used is
oriented towards the same direction, also to achieve a fully developed flux, which will
large pieces, and to homogenize the foam without "entrance effect",
which consists in the non desirable effect of larger gas bobble size on the entrance.
It is needed to take in account the shrinkage of the material, which in terms of PP is
o properly oversize the mould injection cavity finally obtaining the desired
When using other materials it is going to be taken into account
Figure
we begin to search for the optimum size of the piece, achieving the
previous conditions and characteristics.
Projected Area
mm2
10000
10000
10000
10000
10000
10000
Maximum length (s2) is set at 150mm due to the increased amount of pressure needed in
higher values in the injection process caused by an excessive path for the polymer and its
Highlighted values are preferred
Pieces with a high length/wide relation are preferred
That is because it favor orientation effects, which means that most of the polymer used is
oriented towards the same direction, also to achieve a fully developed flux, which will
large pieces, and to homogenize the foam without "entrance effect",
which consists in the non desirable effect of larger gas bobble size on the entrance.
It is needed to take in account the shrinkage of the material, which in terms of PP is
o properly oversize the mould injection cavity finally obtaining the desired
When using other materials it is going to be taken into account
Figure 9 Size values
we begin to search for the optimum size of the piece, achieving the
Projected Area
Maximum length (s2) is set at 150mm due to the increased amount of pressure needed in
higher values in the injection process caused by an excessive path for the polymer and its
Pieces with a high length/wide relation are preferred
That is because it favor orientation effects, which means that most of the polymer used is
oriented towards the same direction, also to achieve a fully developed flux, which will
large pieces, and to homogenize the foam without "entrance effect",
which consists in the non desirable effect of larger gas bobble size on the entrance.
It is needed to take in account the shrinkage of the material, which in terms of PP is
o properly oversize the mould injection cavity finally obtaining the desired
When using other materials it is going to be taken into account
Size values
we begin to search for the optimum size of the piece, achieving the
Maximum length (s2) is set at 150mm due to the increased amount of pressure needed in
higher values in the injection process caused by an excessive path for the polymer and its
Pieces with a high length/wide relation are preferred
That is because it favor orientation effects, which means that most of the polymer used is
oriented towards the same direction, also to achieve a fully developed flux, which will
large pieces, and to homogenize the foam without "entrance effect",
which consists in the non desirable effect of larger gas bobble size on the entrance.
It is needed to take in account the shrinkage of the material, which in terms of PP is
o properly oversize the mould injection cavity finally obtaining the desired
When using other materials it is going to be taken into account
we begin to search for the optimum size of the piece, achieving the
Maximum length (s2) is set at 150mm due to the increased amount of pressure needed in
higher values in the injection process caused by an excessive path for the polymer and its
That is because it favor orientation effects, which means that most of the polymer used is
oriented towards the same direction, also to achieve a fully developed flux, which will
large pieces, and to homogenize the foam without "entrance effect",
which consists in the non desirable effect of larger gas bobble size on the entrance.
It is needed to take in account the shrinkage of the material, which in terms of PP is
o properly oversize the mould injection cavity finally obtaining the desired
When using other materials it is going to be taken into account
16
we begin to search for the optimum size of the piece, achieving the
Maximum length (s2) is set at 150mm due to the increased amount of pressure needed in
higher values in the injection process caused by an excessive path for the polymer and its
That is because it favor orientation effects, which means that most of the polymer used is
oriented towards the same direction, also to achieve a fully developed flux, which will
large pieces, and to homogenize the foam without "entrance effect",
It is needed to take in account the shrinkage of the material, which in terms of PP is
o properly oversize the mould injection cavity finally obtaining the desired
When using other materials it is going to be taken into account
Expansible Injection Mould DesignBuch Cardona, Eloi
that part of the design because contractions are not the same so won't be the pieces
neither
3.3
Finally, we have to check if the volume reaches the experimentally obtained value of
minimum volume in MuCell injection to make it reliable and constant of 50cm3.
The value chosen in this case
of injection volume, because the further expansion of 1 or 2 mm of the foam does not
influence in injected volume, consequently some solutions are presented to try to solve
that.
3.3.1
It consists in aggregate perpendicular thin extensions to the piece along its perimeter in
order to prevent a Projected Area increase, but they need to be cut afterwards.
Expansible Injection Mould DesignBuch Cardona, Eloi
that part of the design because contractions are not the same so won't be the pieces
neither.
Volume
Finally, we have to check if the volume reaches the experimentally obtained value of
minimum volume in MuCell injection to make it reliable and constant of 50cm3.
The value chosen in this case
of injection volume, because the further expansion of 1 or 2 mm of the foam does not
influence in injected volume, consequently some solutions are presented to try to solve
.3.1 Perimetral
It consists in aggregate perpendicular thin extensions to the piece along its perimeter in
order to prevent a Projected Area increase, but they need to be cut afterwards.
Expansible Injection Mould DesignBuch Cardona, Eloi
that part of the design because contractions are not the same so won't be the pieces
Finally, we have to check if the volume reaches the experimentally obtained value of
minimum volume in MuCell injection to make it reliable and constant of 50cm3.
The value chosen in this case
of injection volume, because the further expansion of 1 or 2 mm of the foam does not
influence in injected volume, consequently some solutions are presented to try to solve
Perimetral extensions
It consists in aggregate perpendicular thin extensions to the piece along its perimeter in
order to prevent a Projected Area increase, but they need to be cut afterwards.
Expansible Injection Mould Design
that part of the design because contractions are not the same so won't be the pieces
Finally, we have to check if the volume reaches the experimentally obtained value of
minimum volume in MuCell injection to make it reliable and constant of 50cm3.
Thickness(mm)
2
3
4
The value chosen in this case is the 2mm thick piece which means that we have a problem
of injection volume, because the further expansion of 1 or 2 mm of the foam does not
influence in injected volume, consequently some solutions are presented to try to solve
extensions
It consists in aggregate perpendicular thin extensions to the piece along its perimeter in
order to prevent a Projected Area increase, but they need to be cut afterwards.
that part of the design because contractions are not the same so won't be the pieces
Finally, we have to check if the volume reaches the experimentally obtained value of
minimum volume in MuCell injection to make it reliable and constant of 50cm3.
Thickness(mm) Volume(cm3)
20
30
40
is the 2mm thick piece which means that we have a problem
of injection volume, because the further expansion of 1 or 2 mm of the foam does not
influence in injected volume, consequently some solutions are presented to try to solve
It consists in aggregate perpendicular thin extensions to the piece along its perimeter in
order to prevent a Projected Area increase, but they need to be cut afterwards.
that part of the design because contractions are not the same so won't be the pieces
Finally, we have to check if the volume reaches the experimentally obtained value of
minimum volume in MuCell injection to make it reliable and constant of 50cm3.
Volume(cm3)
is the 2mm thick piece which means that we have a problem
of injection volume, because the further expansion of 1 or 2 mm of the foam does not
influence in injected volume, consequently some solutions are presented to try to solve
It consists in aggregate perpendicular thin extensions to the piece along its perimeter in
order to prevent a Projected Area increase, but they need to be cut afterwards.
that part of the design because contractions are not the same so won't be the pieces
Finally, we have to check if the volume reaches the experimentally obtained value of
minimum volume in MuCell injection to make it reliable and constant of 50cm3.
is the 2mm thick piece which means that we have a problem
of injection volume, because the further expansion of 1 or 2 mm of the foam does not
influence in injected volume, consequently some solutions are presented to try to solve
It consists in aggregate perpendicular thin extensions to the piece along its perimeter in
order to prevent a Projected Area increase, but they need to be cut afterwards.
that part of the design because contractions are not the same so won't be the pieces
Finally, we have to check if the volume reaches the experimentally obtained value of
minimum volume in MuCell injection to make it reliable and constant of 50cm3.
is the 2mm thick piece which means that we have a problem
of injection volume, because the further expansion of 1 or 2 mm of the foam does not
influence in injected volume, consequently some solutions are presented to try to solve
It consists in aggregate perpendicular thin extensions to the piece along its perimeter in
order to prevent a Projected Area increase, but they need to be cut afterwards.
17
that part of the design because contractions are not the same so won't be the pieces
Finally, we have to check if the volume reaches the experimentally obtained value of
is the 2mm thick piece which means that we have a problem
of injection volume, because the further expansion of 1 or 2 mm of the foam does not
influence in injected volume, consequently some solutions are presented to try to solve
It consists in aggregate perpendicular thin extensions to the piece along its perimeter in
Expansible Injection Mould DesignBuch Cardona, Eloi
If we take th
and thick values of 20mm and 3mm respectively, we obtain a total length needed of
Thickness(mm)
2
3
4
Which in our case surpasses the perimeter which means that larger extensions are
needed
As it can be seen, the large dimension needed and the further complicated process of
cutting them off from each piece m
option for its
3.3.2
Consists in an extra cavity added on the furthest part of the piece (considering "near" the
entrance) to easily solve the volume problem.
Expansible Injection Mould DesignBuch Cardona, Eloi
If we take the value of the perimeter of the preferred piece size and giving a constant wide
and thick values of 20mm and 3mm respectively, we obtain a total length needed of
Thickness(mm) Volume(cm3)
20
30
40
Which in our case surpasses the perimeter which means that larger extensions are
needed.
As it can be seen, the large dimension needed and the further complicated process of
cutting them off from each piece m
option for its easier
.3.2 Overflow channel
Consists in an extra cavity added on the furthest part of the piece (considering "near" the
entrance) to easily solve the volume problem.
Expansible Injection Mould DesignBuch Cardona, Eloi
e value of the perimeter of the preferred piece size and giving a constant wide
and thick values of 20mm and 3mm respectively, we obtain a total length needed of
Volume(cm3)
20
30
40
Which in our case surpasses the perimeter which means that larger extensions are
As it can be seen, the large dimension needed and the further complicated process of
cutting them off from each piece m
easier production.
Overflow channel
Consists in an extra cavity added on the furthest part of the piece (considering "near" the
entrance) to easily solve the volume problem.
Expansible Injection Mould Design
Figure 10
e value of the perimeter of the preferred piece size and giving a constant wide
and thick values of 20mm and 3mm respectively, we obtain a total length needed of
Volume needed (cm3)
30
20
10
Which in our case surpasses the perimeter which means that larger extensions are
As it can be seen, the large dimension needed and the further complicated process of
cutting them off from each piece make this option less desirable.
production.
Overflow channel
Consists in an extra cavity added on the furthest part of the piece (considering "near" the
entrance) to easily solve the volume problem.
10 Piece with extensions
e value of the perimeter of the preferred piece size and giving a constant wide
and thick values of 20mm and 3mm respectively, we obtain a total length needed of
Volume needed (cm3) Extensions total length(mm)
500
333
167
Which in our case surpasses the perimeter which means that larger extensions are
As it can be seen, the large dimension needed and the further complicated process of
ake this option less desirable.
Consists in an extra cavity added on the furthest part of the piece (considering "near" the
entrance) to easily solve the volume problem.
Piece with extensions
e value of the perimeter of the preferred piece size and giving a constant wide
and thick values of 20mm and 3mm respectively, we obtain a total length needed of
Extensions total length(mm)
500
333
167
Which in our case surpasses the perimeter which means that larger extensions are
As it can be seen, the large dimension needed and the further complicated process of
ake this option less desirable.
Consists in an extra cavity added on the furthest part of the piece (considering "near" the
e value of the perimeter of the preferred piece size and giving a constant wide
and thick values of 20mm and 3mm respectively, we obtain a total length needed of
Extensions total length(mm)
Which in our case surpasses the perimeter which means that larger extensions are
As it can be seen, the large dimension needed and the further complicated process of
ake this option less desirable. However, it is a good
Consists in an extra cavity added on the furthest part of the piece (considering "near" the
e value of the perimeter of the preferred piece size and giving a constant wide
and thick values of 20mm and 3mm respectively, we obtain a total length needed of
Perimeter(mm)
410
410
410
Which in our case surpasses the perimeter which means that larger extensions are
As it can be seen, the large dimension needed and the further complicated process of
However, it is a good
Consists in an extra cavity added on the furthest part of the piece (considering "near" the
18
e value of the perimeter of the preferred piece size and giving a constant wide
Perimeter(mm)
Which in our case surpasses the perimeter which means that larger extensions are
As it can be seen, the large dimension needed and the further complicated process of
However, it is a good
Consists in an extra cavity added on the furthest part of the piece (considering "near" the
Expansible Injection Mould DesignBuch Cardona, Eloi
It represents a great improvement to the extensions system in terms of facility of later
treatment, a single cut would be enough.
However, it is not possible to put it where it has no negative pr
overcomplicating the mould so that is why it is placed on the furthest part of the piece
where if there is not enough pressure it is not going to be filled. This solution represent
the best option considering that it is still go
the design.
Expansible Injection Mould DesignBuch Cardona, Eloi
presents a great improvement to the extensions system in terms of facility of later
treatment, a single cut would be enough.
However, it is not possible to put it where it has no negative pr
overcomplicating the mould so that is why it is placed on the furthest part of the piece
where if there is not enough pressure it is not going to be filled. This solution represent
the best option considering that it is still go
the design.
Expansible Injection Mould DesignBuch Cardona, Eloi
presents a great improvement to the extensions system in terms of facility of later
treatment, a single cut would be enough.
However, it is not possible to put it where it has no negative pr
overcomplicating the mould so that is why it is placed on the furthest part of the piece
where if there is not enough pressure it is not going to be filled. This solution represent
the best option considering that it is still go
Expansible Injection Mould Design
presents a great improvement to the extensions system in terms of facility of later
treatment, a single cut would be enough.
Figure 11 Piece with overflow channel
However, it is not possible to put it where it has no negative pr
overcomplicating the mould so that is why it is placed on the furthest part of the piece
where if there is not enough pressure it is not going to be filled. This solution represent
the best option considering that it is still go
presents a great improvement to the extensions system in terms of facility of later
treatment, a single cut would be enough.
Piece with overflow channel
However, it is not possible to put it where it has no negative pr
overcomplicating the mould so that is why it is placed on the furthest part of the piece
where if there is not enough pressure it is not going to be filled. This solution represent
the best option considering that it is still good because of all the SF taken on first steps of
presents a great improvement to the extensions system in terms of facility of later
Piece with overflow channel
However, it is not possible to put it where it has no negative pr
overcomplicating the mould so that is why it is placed on the furthest part of the piece
where if there is not enough pressure it is not going to be filled. This solution represent
od because of all the SF taken on first steps of
presents a great improvement to the extensions system in terms of facility of later
Piece with overflow channel
However, it is not possible to put it where it has no negative projected area effect without
overcomplicating the mould so that is why it is placed on the furthest part of the piece
where if there is not enough pressure it is not going to be filled. This solution represent
od because of all the SF taken on first steps of
presents a great improvement to the extensions system in terms of facility of later
ojected area effect without
overcomplicating the mould so that is why it is placed on the furthest part of the piece
where if there is not enough pressure it is not going to be filled. This solution represent
od because of all the SF taken on first steps of
19
presents a great improvement to the extensions system in terms of facility of later
ojected area effect without
overcomplicating the mould so that is why it is placed on the furthest part of the piece
where if there is not enough pressure it is not going to be filled. This solution represent
od because of all the SF taken on first steps of
Static
-Nozzle entrance
Mobile part
-ejection system
-refrigeration system
Expansible Injection Mould DesignBuch Cardona, Eloi
4.Mould design
In this part there are going to be developed some solutions for the mould as well as the
reason for the chosen ones.
As it has been seen, the produced piece is simple and that
is taken the mould that typically produce it (without the foaming process of course) as the
base to the solutions presented.
The traditional mould looks like
In whi
has to be changed in order to achieve the desired foaming technique.
achieved is a foaming only in terms of thickness while conserving the other size v
Static part
Nozzle entrance
Mobile part
ejection system
refrigeration system
Expansible Injection Mould DesignBuch Cardona, Eloi
Mould design
In this part there are going to be developed some solutions for the mould as well as the
reason for the chosen ones.
As it has been seen, the produced piece is simple and that
is taken the mould that typically produce it (without the foaming process of course) as the
base to the solutions presented.
The traditional mould looks like
In which we can see the parts function
has to be changed in order to achieve the desired foaming technique.
achieved is a foaming only in terms of thickness while conserving the other size v
Expansible Injection Mould DesignBuch Cardona, Eloi
Mould design
In this part there are going to be developed some solutions for the mould as well as the
reason for the chosen ones.
As it has been seen, the produced piece is simple and that
is taken the mould that typically produce it (without the foaming process of course) as the
base to the solutions presented.
The traditional mould looks like
ch we can see the parts function
has to be changed in order to achieve the desired foaming technique.
achieved is a foaming only in terms of thickness while conserving the other size v
Expansible Injection Mould Design
Mould design
In this part there are going to be developed some solutions for the mould as well as the
reason for the chosen ones.
As it has been seen, the produced piece is simple and that
is taken the mould that typically produce it (without the foaming process of course) as the
base to the solutions presented.
The traditional mould looks like
Figure
ch we can see the parts function
has to be changed in order to achieve the desired foaming technique.
achieved is a foaming only in terms of thickness while conserving the other size v
Partition line
In this part there are going to be developed some solutions for the mould as well as the
As it has been seen, the produced piece is simple and that
is taken the mould that typically produce it (without the foaming process of course) as the
Figure 12 Mould structure
ch we can see the parts function-defined. Note that
has to be changed in order to achieve the desired foaming technique.
achieved is a foaming only in terms of thickness while conserving the other size v
Partition line
In this part there are going to be developed some solutions for the mould as well as the
As it has been seen, the produced piece is simple and that simplifies the solution as well. It
is taken the mould that typically produce it (without the foaming process of course) as the
Mould structure
defined. Note that at least
has to be changed in order to achieve the desired foaming technique.
achieved is a foaming only in terms of thickness while conserving the other size v
In this part there are going to be developed some solutions for the mould as well as the
simplifies the solution as well. It
is taken the mould that typically produce it (without the foaming process of course) as the
at least the piece housing
has to be changed in order to achieve the desired foaming technique. What is needed to be
achieved is a foaming only in terms of thickness while conserving the other size v
In this part there are going to be developed some solutions for the mould as well as the
simplifies the solution as well. It
is taken the mould that typically produce it (without the foaming process of course) as the
piece housing
What is needed to be
achieved is a foaming only in terms of thickness while conserving the other size values.
20
In this part there are going to be developed some solutions for the mould as well as the
simplifies the solution as well. It
is taken the mould that typically produce it (without the foaming process of course) as the
piece housing part
What is needed to be
alues.
Piece housing
Ejection plate
housing
Ejection plates
Expansible Injection Mould DesignBuch Cardona, Eloi
For that there are presented two general systems.
Each one have its own solutions for every part of the mould and in the end is able to do the
job. In that point it is nee
which is going to be manufactured.
4.1
4.1.1
Also known as "noyos",
guides to pieces or
synchronized with it which controls
In this case the cell pull need to be into a direction that cannot be controlled directly so the
piston controls
lowers the
Expansible Injection Mould DesignBuch Cardona, Eloi
For that there are presented two general systems.
-Core pull system
-Precise opening system
Each one have its own solutions for every part of the mould and in the end is able to do the
job. In that point it is nee
which is going to be manufactured.
Core pull system
.1.1 Mould operation
Also known as "noyos",
guides to pieces or
synchronized with it which controls
In this case the cell pull need to be into a direction that cannot be controlled directly so the
piston controls
lowers the core pull.
Expansible Injection Mould DesignBuch Cardona, Eloi
For that there are presented two general systems.
Core pull system
Precise opening system
Each one have its own solutions for every part of the mould and in the end is able to do the
job. In that point it is needed to properly evaluate the final characteristics and choose one
which is going to be manufactured.
Figure 13
Core pull system
ould operation
Also known as "noyos", traditionally
guides to pieces or adding
synchronized with it which controls
In this case the cell pull need to be into a direction that cannot be controlled directly so the
both the initial and the final thickness by actuating i
core pull.
Expansible Injection Mould Design
For that there are presented two general systems.
Precise opening system (also known as breathing system)
Each one have its own solutions for every part of the mould and in the end is able to do the
ded to properly evaluate the final characteristics and choose one
which is going to be manufactured.
13 Breathing m
ould operation
traditionally
adding a piston conducted by the same machine or externally
synchronized with it which controls directly a cell pull that moves when required.
In this case the cell pull need to be into a direction that cannot be controlled directly so the
the initial and the final thickness by actuating i
For that there are presented two general systems.
(also known as breathing system)
Each one have its own solutions for every part of the mould and in the end is able to do the
ded to properly evaluate the final characteristics and choose one
mould and cel
the system consists in
a piston conducted by the same machine or externally
directly a cell pull that moves when required.
In this case the cell pull need to be into a direction that cannot be controlled directly so the
the initial and the final thickness by actuating i
(also known as breathing system)
Each one have its own solutions for every part of the mould and in the end is able to do the
ded to properly evaluate the final characteristics and choose one
ll pull foaming
the system consists in
a piston conducted by the same machine or externally
directly a cell pull that moves when required.
In this case the cell pull need to be into a direction that cannot be controlled directly so the
the initial and the final thickness by actuating i
(also known as breathing system)
Each one have its own solutions for every part of the mould and in the end is able to do the
ded to properly evaluate the final characteristics and choose one
g systems
the system consists in having some mechanical
a piston conducted by the same machine or externally
directly a cell pull that moves when required.
In this case the cell pull need to be into a direction that cannot be controlled directly so the
the initial and the final thickness by actuating in a wedge that lifts or
Each one have its own solutions for every part of the mould and in the end is able to do the
ded to properly evaluate the final characteristics and choose one
having some mechanical
a piston conducted by the same machine or externally
directly a cell pull that moves when required.
In this case the cell pull need to be into a direction that cannot be controlled directly so the
n a wedge that lifts or
21
Each one have its own solutions for every part of the mould and in the end is able to do the
ded to properly evaluate the final characteristics and choose one
having some mechanical
a piston conducted by the same machine or externally
In this case the cell pull need to be into a direction that cannot be controlled directly so the
n a wedge that lifts or
Expansible Injection Mould DesignBuch Cardona, Eloi
The wedge needs to be attached to the cell pull which at the same time needs to be driven
through
thermally treated preventing the sliding surface from scoring due to the high pressures
applied.
That leads to the need of a mechanical limit system for the piston to reproduce e
same size each time because when working in terms of few mm the mismatches of a
control system can be very relevant.
This makes this system the most useful one providing endless possibilities in terms of
different tests in both initial injectio
with
from the traditional injection process, the mould stay clamped and it is the piston what
makes the rest.
Once desc
4.1.2
Taking in account the piece size and the injection machine size, it is easy to conclude that it
is only going to be produced one piece at a time.
In order to make the piece
so it is going to be decompensated and there are three different solutions.
Expansible Injection Mould DesignBuch Cardona, Eloi
The wedge needs to be attached to the cell pull which at the same time needs to be driven
through a cavity impeding unwanted movements. The union of both need to be specially
thermally treated preventing the sliding surface from scoring due to the high pressures
applied.
That leads to the need of a mechanical limit system for the piston to reproduce e
same size each time because when working in terms of few mm the mismatches of a
control system can be very relevant.
This makes this system the most useful one providing endless possibilities in terms of
different tests in both initial injectio
with a foaming technique
from the traditional injection process, the mould stay clamped and it is the piston what
makes the rest.
Once described the main operation some other issues need to be solved
.1.2 Piece position
Taking in account the piece size and the injection machine size, it is easy to conclude that it
is only going to be produced one piece at a time.
In order to make the piece
so it is going to be decompensated and there are three different solutions.
Expansible Injection Mould DesignBuch Cardona, Eloi
The wedge needs to be attached to the cell pull which at the same time needs to be driven
a cavity impeding unwanted movements. The union of both need to be specially
thermally treated preventing the sliding surface from scoring due to the high pressures
That leads to the need of a mechanical limit system for the piston to reproduce e
same size each time because when working in terms of few mm the mismatches of a
control system can be very relevant.
This makes this system the most useful one providing endless possibilities in terms of
different tests in both initial injectio
a foaming technique can adopt this system because it is the only thing that differs
from the traditional injection process, the mould stay clamped and it is the piston what
ribed the main operation some other issues need to be solved
iece position
Taking in account the piece size and the injection machine size, it is easy to conclude that it
is only going to be produced one piece at a time.
In order to make the piece
so it is going to be decompensated and there are three different solutions.
Expansible Injection Mould Design
Figure 14
The wedge needs to be attached to the cell pull which at the same time needs to be driven
a cavity impeding unwanted movements. The union of both need to be specially
thermally treated preventing the sliding surface from scoring due to the high pressures
That leads to the need of a mechanical limit system for the piston to reproduce e
same size each time because when working in terms of few mm the mismatches of a
control system can be very relevant.
This makes this system the most useful one providing endless possibilities in terms of
different tests in both initial injection and foaming thickness. Also almost every machine
can adopt this system because it is the only thing that differs
from the traditional injection process, the mould stay clamped and it is the piston what
ribed the main operation some other issues need to be solved
Taking in account the piece size and the injection machine size, it is easy to conclude that it
is only going to be produced one piece at a time.
more suitable to its function the entrance was set on one side
so it is going to be decompensated and there are three different solutions.
Cell pull/Wedge system
The wedge needs to be attached to the cell pull which at the same time needs to be driven
a cavity impeding unwanted movements. The union of both need to be specially
thermally treated preventing the sliding surface from scoring due to the high pressures
That leads to the need of a mechanical limit system for the piston to reproduce e
same size each time because when working in terms of few mm the mismatches of a
This makes this system the most useful one providing endless possibilities in terms of
n and foaming thickness. Also almost every machine
can adopt this system because it is the only thing that differs
from the traditional injection process, the mould stay clamped and it is the piston what
ribed the main operation some other issues need to be solved
Taking in account the piece size and the injection machine size, it is easy to conclude that it
is only going to be produced one piece at a time.
more suitable to its function the entrance was set on one side
so it is going to be decompensated and there are three different solutions.
Cell pull/Wedge system
The wedge needs to be attached to the cell pull which at the same time needs to be driven
a cavity impeding unwanted movements. The union of both need to be specially
thermally treated preventing the sliding surface from scoring due to the high pressures
That leads to the need of a mechanical limit system for the piston to reproduce e
same size each time because when working in terms of few mm the mismatches of a
This makes this system the most useful one providing endless possibilities in terms of
n and foaming thickness. Also almost every machine
can adopt this system because it is the only thing that differs
from the traditional injection process, the mould stay clamped and it is the piston what
ribed the main operation some other issues need to be solved
Taking in account the piece size and the injection machine size, it is easy to conclude that it
more suitable to its function the entrance was set on one side
so it is going to be decompensated and there are three different solutions.
The wedge needs to be attached to the cell pull which at the same time needs to be driven
a cavity impeding unwanted movements. The union of both need to be specially
thermally treated preventing the sliding surface from scoring due to the high pressures
That leads to the need of a mechanical limit system for the piston to reproduce e
same size each time because when working in terms of few mm the mismatches of a
This makes this system the most useful one providing endless possibilities in terms of
n and foaming thickness. Also almost every machine
can adopt this system because it is the only thing that differs
from the traditional injection process, the mould stay clamped and it is the piston what
ribed the main operation some other issues need to be solved
Taking in account the piece size and the injection machine size, it is easy to conclude that it
more suitable to its function the entrance was set on one side
so it is going to be decompensated and there are three different solutions.
The wedge needs to be attached to the cell pull which at the same time needs to be driven
a cavity impeding unwanted movements. The union of both need to be specially
thermally treated preventing the sliding surface from scoring due to the high pressures
That leads to the need of a mechanical limit system for the piston to reproduce exactly the
same size each time because when working in terms of few mm the mismatches of a
This makes this system the most useful one providing endless possibilities in terms of
n and foaming thickness. Also almost every machine
can adopt this system because it is the only thing that differs
from the traditional injection process, the mould stay clamped and it is the piston what
Taking in account the piece size and the injection machine size, it is easy to conclude that it
more suitable to its function the entrance was set on one side
22
The wedge needs to be attached to the cell pull which at the same time needs to be driven
a cavity impeding unwanted movements. The union of both need to be specially
thermally treated preventing the sliding surface from scoring due to the high pressures
xactly the
same size each time because when working in terms of few mm the mismatches of a
This makes this system the most useful one providing endless possibilities in terms of
n and foaming thickness. Also almost every machine
can adopt this system because it is the only thing that differs
from the traditional injection process, the mould stay clamped and it is the piston what
Taking in account the piece size and the injection machine size, it is easy to conclude that it
more suitable to its function the entrance was set on one side
Expansible Injection Mould DesignBuch Cardona, Eloi
4.1.2.1
When a mould is decompensated, usually tends to get damaged by its use, having
problems in closi
centralizing the it to the entrance, but as it has been explained before, it is needed a lateral
entrance for the flux to develop correctly through the piece so a corridor is added f
nozzle to the side of the piece.
In that case, what is done is add the called 3rd plate which have mechanized only the
corridor and which have to be moved to remove it at the same time that it is extracted
from the piece.
This system adds some technical difficulties and extra pieces which can increase the whole
price but it is an assurance for large production series which need good durability for the
mould.
4.1.2.2
Although it can be a cause of harm of the mould, having the piece decompensated is not
that bad if only a few pieces are going to be produced and of this reduced sizes. A direct
Expansible Injection Mould DesignBuch Cardona, Eloi
.1.2.1 3rd plate
When a mould is decompensated, usually tends to get damaged by its use, having
problems in closi
centralizing the it to the entrance, but as it has been explained before, it is needed a lateral
entrance for the flux to develop correctly through the piece so a corridor is added f
nozzle to the side of the piece.
In that case, what is done is add the called 3rd plate which have mechanized only the
corridor and which have to be moved to remove it at the same time that it is extracted
from the piece.
This system adds some technical difficulties and extra pieces which can increase the whole
price but it is an assurance for large production series which need good durability for the
mould.
.1.2.2 Decentered piec
Although it can be a cause of harm of the mould, having the piece decompensated is not
that bad if only a few pieces are going to be produced and of this reduced sizes. A direct
3rd plate
Expansible Injection Mould DesignBuch Cardona, Eloi
3rd plate
When a mould is decompensated, usually tends to get damaged by its use, having
problems in closing basically. To solve that one what is needed is to balance the piece by
centralizing the it to the entrance, but as it has been explained before, it is needed a lateral
entrance for the flux to develop correctly through the piece so a corridor is added f
nozzle to the side of the piece.
In that case, what is done is add the called 3rd plate which have mechanized only the
corridor and which have to be moved to remove it at the same time that it is extracted
This system adds some technical difficulties and extra pieces which can increase the whole
price but it is an assurance for large production series which need good durability for the
Decentered piece
Although it can be a cause of harm of the mould, having the piece decompensated is not
that bad if only a few pieces are going to be produced and of this reduced sizes. A direct
Expansible Injection Mould Design
When a mould is decompensated, usually tends to get damaged by its use, having
ng basically. To solve that one what is needed is to balance the piece by
centralizing the it to the entrance, but as it has been explained before, it is needed a lateral
entrance for the flux to develop correctly through the piece so a corridor is added f
nozzle to the side of the piece.
In that case, what is done is add the called 3rd plate which have mechanized only the
corridor and which have to be moved to remove it at the same time that it is extracted
Figure 15 3rd plate operation scheme
This system adds some technical difficulties and extra pieces which can increase the whole
price but it is an assurance for large production series which need good durability for the
Although it can be a cause of harm of the mould, having the piece decompensated is not
that bad if only a few pieces are going to be produced and of this reduced sizes. A direct
Entrance
When a mould is decompensated, usually tends to get damaged by its use, having
ng basically. To solve that one what is needed is to balance the piece by
centralizing the it to the entrance, but as it has been explained before, it is needed a lateral
entrance for the flux to develop correctly through the piece so a corridor is added f
In that case, what is done is add the called 3rd plate which have mechanized only the
corridor and which have to be moved to remove it at the same time that it is extracted
3rd plate operation scheme
This system adds some technical difficulties and extra pieces which can increase the whole
price but it is an assurance for large production series which need good durability for the
Although it can be a cause of harm of the mould, having the piece decompensated is not
that bad if only a few pieces are going to be produced and of this reduced sizes. A direct
Entrance
Runner
Piece
When a mould is decompensated, usually tends to get damaged by its use, having
ng basically. To solve that one what is needed is to balance the piece by
centralizing the it to the entrance, but as it has been explained before, it is needed a lateral
entrance for the flux to develop correctly through the piece so a corridor is added f
In that case, what is done is add the called 3rd plate which have mechanized only the
corridor and which have to be moved to remove it at the same time that it is extracted
3rd plate operation scheme
This system adds some technical difficulties and extra pieces which can increase the whole
price but it is an assurance for large production series which need good durability for the
Although it can be a cause of harm of the mould, having the piece decompensated is not
that bad if only a few pieces are going to be produced and of this reduced sizes. A direct
Runner
Piece
When a mould is decompensated, usually tends to get damaged by its use, having
ng basically. To solve that one what is needed is to balance the piece by
centralizing the it to the entrance, but as it has been explained before, it is needed a lateral
entrance for the flux to develop correctly through the piece so a corridor is added f
In that case, what is done is add the called 3rd plate which have mechanized only the
corridor and which have to be moved to remove it at the same time that it is extracted
This system adds some technical difficulties and extra pieces which can increase the whole
price but it is an assurance for large production series which need good durability for the
Although it can be a cause of harm of the mould, having the piece decompensated is not
that bad if only a few pieces are going to be produced and of this reduced sizes. A direct
When a mould is decompensated, usually tends to get damaged by its use, having
ng basically. To solve that one what is needed is to balance the piece by
centralizing the it to the entrance, but as it has been explained before, it is needed a lateral
entrance for the flux to develop correctly through the piece so a corridor is added from the
In that case, what is done is add the called 3rd plate which have mechanized only the
corridor and which have to be moved to remove it at the same time that it is extracted
This system adds some technical difficulties and extra pieces which can increase the whole
price but it is an assurance for large production series which need good durability for the
Although it can be a cause of harm of the mould, having the piece decompensated is not
that bad if only a few pieces are going to be produced and of this reduced sizes. A direct
Ejection direction
23
When a mould is decompensated, usually tends to get damaged by its use, having
ng basically. To solve that one what is needed is to balance the piece by
centralizing the it to the entrance, but as it has been explained before, it is needed a lateral
rom the
In that case, what is done is add the called 3rd plate which have mechanized only the
corridor and which have to be moved to remove it at the same time that it is extracted
This system adds some technical difficulties and extra pieces which can increase the whole
price but it is an assurance for large production series which need good durability for the
Although it can be a cause of harm of the mould, having the piece decompensated is not
that bad if only a few pieces are going to be produced and of this reduced sizes. A direct
Ejection direction
Expansible Injection Mould DesignBuch Cardona, Eloi
entrance simplifies the mould but also presents some problems with its size
that it has to be mounted into a machine with size limits.
However if needed, the entrance could be diagonally placed allowing to center a bit more
the piece to the mould. That would be enough but would also add some difficulties to the
extra
static part of the mould.
4.1.2.3
Nothing prevents a change of the position of th
housing zone. If the mould size is not too large this simple solution is optimum because it
permits to center the piece without complicating the system.
4.1.2.4
In this case the 3rd plate and the decentered n
usage. Both decentered solutions are optimum in simplicity and price. The difference is
very slight in every case. The 3rd plate option would have been the optimum in a case of a
larger piece or a multiple piec
decentrage of the nozzle, as seen in other moulds in CCP, is the best option.
Expansible Injection Mould DesignBuch Cardona, Eloi
entrance simplifies the mould but also presents some problems with its size
that it has to be mounted into a machine with size limits.
However if needed, the entrance could be diagonally placed allowing to center a bit more
the piece to the mould. That would be enough but would also add some difficulties to the
extraction of the piece increasing the pulling force needed for the piece to not stick on the
static part of the mould.
.1.2.3 Decentered nozzle
Nothing prevents a change of the position of th
housing zone. If the mould size is not too large this simple solution is optimum because it
permits to center the piece without complicating the system.
.1.2.4 Decision
In this case the 3rd plate and the decentered n
usage. Both decentered solutions are optimum in simplicity and price. The difference is
very slight in every case. The 3rd plate option would have been the optimum in a case of a
larger piece or a multiple piec
decentrage of the nozzle, as seen in other moulds in CCP, is the best option.
Expansible Injection Mould DesignBuch Cardona, Eloi
entrance simplifies the mould but also presents some problems with its size
that it has to be mounted into a machine with size limits.
However if needed, the entrance could be diagonally placed allowing to center a bit more
the piece to the mould. That would be enough but would also add some difficulties to the
ction of the piece increasing the pulling force needed for the piece to not stick on the
static part of the mould.
Decentered nozzle
Nothing prevents a change of the position of th
housing zone. If the mould size is not too large this simple solution is optimum because it
permits to center the piece without complicating the system.
Decision
In this case the 3rd plate and the decentered n
usage. Both decentered solutions are optimum in simplicity and price. The difference is
very slight in every case. The 3rd plate option would have been the optimum in a case of a
larger piece or a multiple piec
decentrage of the nozzle, as seen in other moulds in CCP, is the best option.
Expansible Injection Mould Design
entrance simplifies the mould but also presents some problems with its size
that it has to be mounted into a machine with size limits.
However if needed, the entrance could be diagonally placed allowing to center a bit more
the piece to the mould. That would be enough but would also add some difficulties to the
ction of the piece increasing the pulling force needed for the piece to not stick on the
Figure 16 Piece layout within the mould
Nothing prevents a change of the position of th
housing zone. If the mould size is not too large this simple solution is optimum because it
permits to center the piece without complicating the system.
In this case the 3rd plate and the decentered n
usage. Both decentered solutions are optimum in simplicity and price. The difference is
very slight in every case. The 3rd plate option would have been the optimum in a case of a
larger piece or a multiple piece production,
decentrage of the nozzle, as seen in other moulds in CCP, is the best option.
entrance simplifies the mould but also presents some problems with its size
that it has to be mounted into a machine with size limits.
However if needed, the entrance could be diagonally placed allowing to center a bit more
the piece to the mould. That would be enough but would also add some difficulties to the
ction of the piece increasing the pulling force needed for the piece to not stick on the
Piece layout within the mould
Nothing prevents a change of the position of the nozzle more than the machine mould
housing zone. If the mould size is not too large this simple solution is optimum because it
permits to center the piece without complicating the system.
In this case the 3rd plate and the decentered nozzle are the best solution in terms of mould
usage. Both decentered solutions are optimum in simplicity and price. The difference is
very slight in every case. The 3rd plate option would have been the optimum in a case of a
e production, the mould has reduced size so
decentrage of the nozzle, as seen in other moulds in CCP, is the best option.
entrance simplifies the mould but also presents some problems with its size
that it has to be mounted into a machine with size limits.
However if needed, the entrance could be diagonally placed allowing to center a bit more
the piece to the mould. That would be enough but would also add some difficulties to the
ction of the piece increasing the pulling force needed for the piece to not stick on the
Piece layout within the mould
e nozzle more than the machine mould
housing zone. If the mould size is not too large this simple solution is optimum because it
permits to center the piece without complicating the system.
ozzle are the best solution in terms of mould
usage. Both decentered solutions are optimum in simplicity and price. The difference is
very slight in every case. The 3rd plate option would have been the optimum in a case of a
the mould has reduced size so
decentrage of the nozzle, as seen in other moulds in CCP, is the best option.
entrance simplifies the mould but also presents some problems with its size
However if needed, the entrance could be diagonally placed allowing to center a bit more
the piece to the mould. That would be enough but would also add some difficulties to the
ction of the piece increasing the pulling force needed for the piece to not stick on the
Piece layout within the mould
e nozzle more than the machine mould
housing zone. If the mould size is not too large this simple solution is optimum because it
ozzle are the best solution in terms of mould
usage. Both decentered solutions are optimum in simplicity and price. The difference is
very slight in every case. The 3rd plate option would have been the optimum in a case of a
the mould has reduced size so
decentrage of the nozzle, as seen in other moulds in CCP, is the best option.
entrance simplifies the mould but also presents some problems with its size and the fact
However if needed, the entrance could be diagonally placed allowing to center a bit more
the piece to the mould. That would be enough but would also add some difficulties to the
ction of the piece increasing the pulling force needed for the piece to not stick on the
e nozzle more than the machine mould
housing zone. If the mould size is not too large this simple solution is optimum because it
ozzle are the best solution in terms of mould
usage. Both decentered solutions are optimum in simplicity and price. The difference is
very slight in every case. The 3rd plate option would have been the optimum in a case of a
the mould has reduced size so in this case the
decentrage of the nozzle, as seen in other moulds in CCP, is the best option.
24
and the fact
However if needed, the entrance could be diagonally placed allowing to center a bit more
the piece to the mould. That would be enough but would also add some difficulties to the
ction of the piece increasing the pulling force needed for the piece to not stick on the
e nozzle more than the machine mould
housing zone. If the mould size is not too large this simple solution is optimum because it
ozzle are the best solution in terms of mould
usage. Both decentered solutions are optimum in simplicity and price. The difference is
very slight in every case. The 3rd plate option would have been the optimum in a case of a
in this case the
Expansible Injection Mould DesignBuch Cardona, Eloi
4.1.3
The dynamic nature of the core pull difficults the refrigeration in the inner parts of the
piece. There are no different solutions to choose from so the solution found consists in
covering the perimeter and cooling indirectly the piece by cooling as much as possible the
core pull and surrounding pieces.
Nevertheless in other moulds of similar characteristics this system has been proven
enough by the fact that the piece is thin at least in the parts not supposed to be thrown
away (overflow channel). The uneven cooling can be a problem for
differences between the inner and outer parts of the piece
4.1.4
The traditional pin
taking in account that it is moving while the whole mould is clamped. To
are two possible solutions.
4.1.4.1
Expansible Injection Mould DesignBuch Cardona, Eloi
.1.3 Refrigeration
The dynamic nature of the core pull difficults the refrigeration in the inner parts of the
e. There are no different solutions to choose from so the solution found consists in
covering the perimeter and cooling indirectly the piece by cooling as much as possible the
core pull and surrounding pieces.
Nevertheless in other moulds of similar characteristics this system has been proven
enough by the fact that the piece is thin at least in the parts not supposed to be thrown
away (overflow channel). The uneven cooling can be a problem for
differences between the inner and outer parts of the piece
.1.4 Ejection
The traditional pin
taking in account that it is moving while the whole mould is clamped. To
are two possible solutions.
.1.4.1 Core pull ejector
Expansible Injection Mould DesignBuch Cardona, Eloi
efrigeration
The dynamic nature of the core pull difficults the refrigeration in the inner parts of the
e. There are no different solutions to choose from so the solution found consists in
covering the perimeter and cooling indirectly the piece by cooling as much as possible the
core pull and surrounding pieces.
Nevertheless in other moulds of similar characteristics this system has been proven
enough by the fact that the piece is thin at least in the parts not supposed to be thrown
away (overflow channel). The uneven cooling can be a problem for
differences between the inner and outer parts of the piece
jection
The traditional pin-ejection system has some problems to move along with the core pull
taking in account that it is moving while the whole mould is clamped. To
are two possible solutions.
Core pull ejector
Expansible Injection Mould Design
The dynamic nature of the core pull difficults the refrigeration in the inner parts of the
e. There are no different solutions to choose from so the solution found consists in
covering the perimeter and cooling indirectly the piece by cooling as much as possible the
core pull and surrounding pieces.
Figure 17
Nevertheless in other moulds of similar characteristics this system has been proven
enough by the fact that the piece is thin at least in the parts not supposed to be thrown
away (overflow channel). The uneven cooling can be a problem for
differences between the inner and outer parts of the piece
ejection system has some problems to move along with the core pull
taking in account that it is moving while the whole mould is clamped. To
The dynamic nature of the core pull difficults the refrigeration in the inner parts of the
e. There are no different solutions to choose from so the solution found consists in
covering the perimeter and cooling indirectly the piece by cooling as much as possible the
Perimeter refrigeration
Nevertheless in other moulds of similar characteristics this system has been proven
enough by the fact that the piece is thin at least in the parts not supposed to be thrown
away (overflow channel). The uneven cooling can be a problem for
differences between the inner and outer parts of the piece
ejection system has some problems to move along with the core pull
taking in account that it is moving while the whole mould is clamped. To
The dynamic nature of the core pull difficults the refrigeration in the inner parts of the
e. There are no different solutions to choose from so the solution found consists in
covering the perimeter and cooling indirectly the piece by cooling as much as possible the
r refrigeration
Nevertheless in other moulds of similar characteristics this system has been proven
enough by the fact that the piece is thin at least in the parts not supposed to be thrown
away (overflow channel). The uneven cooling can be a problem for
differences between the inner and outer parts of the piece
ejection system has some problems to move along with the core pull
taking in account that it is moving while the whole mould is clamped. To
The dynamic nature of the core pull difficults the refrigeration in the inner parts of the
e. There are no different solutions to choose from so the solution found consists in
covering the perimeter and cooling indirectly the piece by cooling as much as possible the
Nevertheless in other moulds of similar characteristics this system has been proven
enough by the fact that the piece is thin at least in the parts not supposed to be thrown
away (overflow channel). The uneven cooling can be a problem for the characteristics
ejection system has some problems to move along with the core pull
taking in account that it is moving while the whole mould is clamped. To
The dynamic nature of the core pull difficults the refrigeration in the inner parts of the
e. There are no different solutions to choose from so the solution found consists in
covering the perimeter and cooling indirectly the piece by cooling as much as possible the
Nevertheless in other moulds of similar characteristics this system has been proven
enough by the fact that the piece is thin at least in the parts not supposed to be thrown
the characteristics
ejection system has some problems to move along with the core pull
taking in account that it is moving while the whole mould is clamped. To solve that there
25
The dynamic nature of the core pull difficults the refrigeration in the inner parts of the
e. There are no different solutions to choose from so the solution found consists in
covering the perimeter and cooling indirectly the piece by cooling as much as possible the
Nevertheless in other moulds of similar characteristics this system has been proven
enough by the fact that the piece is thin at least in the parts not supposed to be thrown
the characteristics
ejection system has some problems to move along with the core pull
solve that there
Expansible Injection Mould DesignBuch Cardona, Eloi
The first thing it has to be assured is that the piece remains on the moving side of the
mould by letting so
not let the piece stay once solidified
the piece to fall off.
Then what elevates the cell pull is the same wedge actuated by the piston that wou
a third position. This is one of the easiest solutions but has some difficulties when trying to
add a third position to the piston.
4.1.4.2
This solution consists in binding the ejector plate with the base plate making it move alo
with the ejection movement. By itself only passes through but modifying the piece on its
perimeter and adding some pieces fixed on the base plate interfering with the
modification the result is an effective ejection.
The piece would also need to enter
stack on the nozzle side. This needs to be in a disposable part otherwise it will be an extra
part to be taken out.
Expansible Injection Mould DesignBuch Cardona, Eloi
The first thing it has to be assured is that the piece remains on the moving side of the
mould by letting so
let the piece stay once solidified
the piece to fall off.
Then what elevates the cell pull is the same wedge actuated by the piston that wou
a third position. This is one of the easiest solutions but has some difficulties when trying to
add a third position to the piston.
.1.4.2 Plate ejection
This solution consists in binding the ejector plate with the base plate making it move alo
with the ejection movement. By itself only passes through but modifying the piece on its
perimeter and adding some pieces fixed on the base plate interfering with the
modification the result is an effective ejection.
The piece would also need to enter
stack on the nozzle side. This needs to be in a disposable part otherwise it will be an extra
part to be taken out.
Expansible Injection Mould DesignBuch Cardona, Eloi
The first thing it has to be assured is that the piece remains on the moving side of the
mould by letting some material pass to an entrance
let the piece stay once solidified
the piece to fall off.
Then what elevates the cell pull is the same wedge actuated by the piston that wou
a third position. This is one of the easiest solutions but has some difficulties when trying to
add a third position to the piston.
Plate ejection
This solution consists in binding the ejector plate with the base plate making it move alo
with the ejection movement. By itself only passes through but modifying the piece on its
perimeter and adding some pieces fixed on the base plate interfering with the
modification the result is an effective ejection.
The piece would also need to enter
stack on the nozzle side. This needs to be in a disposable part otherwise it will be an extra
part to be taken out.
Expansible Injection Mould Design
The first thing it has to be assured is that the piece remains on the moving side of the
me material pass to an entrance
let the piece stay once solidified. When ejecting the cavity no longer exists and permits
Figure 18
Then what elevates the cell pull is the same wedge actuated by the piston that wou
a third position. This is one of the easiest solutions but has some difficulties when trying to
add a third position to the piston.
This solution consists in binding the ejector plate with the base plate making it move alo
with the ejection movement. By itself only passes through but modifying the piece on its
perimeter and adding some pieces fixed on the base plate interfering with the
modification the result is an effective ejection.
The piece would also need to enter to the pull cell cavity in order to assure it does not
stack on the nozzle side. This needs to be in a disposable part otherwise it will be an extra
The first thing it has to be assured is that the piece remains on the moving side of the
me material pass to an entrance
When ejecting the cavity no longer exists and permits
18 Cell pull extra cavity
Then what elevates the cell pull is the same wedge actuated by the piston that wou
a third position. This is one of the easiest solutions but has some difficulties when trying to
This solution consists in binding the ejector plate with the base plate making it move alo
with the ejection movement. By itself only passes through but modifying the piece on its
perimeter and adding some pieces fixed on the base plate interfering with the
modification the result is an effective ejection.
to the pull cell cavity in order to assure it does not
stack on the nozzle side. This needs to be in a disposable part otherwise it will be an extra
Material entrance
The first thing it has to be assured is that the piece remains on the moving side of the
me material pass to an entrance to the cell pull
When ejecting the cavity no longer exists and permits
Cell pull extra cavity
Then what elevates the cell pull is the same wedge actuated by the piston that wou
a third position. This is one of the easiest solutions but has some difficulties when trying to
This solution consists in binding the ejector plate with the base plate making it move alo
with the ejection movement. By itself only passes through but modifying the piece on its
perimeter and adding some pieces fixed on the base plate interfering with the
to the pull cell cavity in order to assure it does not
stack on the nozzle side. This needs to be in a disposable part otherwise it will be an extra
entrance
The first thing it has to be assured is that the piece remains on the moving side of the
to the cell pull while melt that would
When ejecting the cavity no longer exists and permits
Then what elevates the cell pull is the same wedge actuated by the piston that wou
a third position. This is one of the easiest solutions but has some difficulties when trying to
This solution consists in binding the ejector plate with the base plate making it move alo
with the ejection movement. By itself only passes through but modifying the piece on its
perimeter and adding some pieces fixed on the base plate interfering with the
to the pull cell cavity in order to assure it does not
stack on the nozzle side. This needs to be in a disposable part otherwise it will be an extra
The first thing it has to be assured is that the piece remains on the moving side of the
while melt that would
When ejecting the cavity no longer exists and permits
Then what elevates the cell pull is the same wedge actuated by the piston that would need
a third position. This is one of the easiest solutions but has some difficulties when trying to
This solution consists in binding the ejector plate with the base plate making it move alo
with the ejection movement. By itself only passes through but modifying the piece on its
perimeter and adding some pieces fixed on the base plate interfering with the
to the pull cell cavity in order to assure it does not
stack on the nozzle side. This needs to be in a disposable part otherwise it will be an extra
26
The first thing it has to be assured is that the piece remains on the moving side of the
while melt that would
When ejecting the cavity no longer exists and permits
ld need
a third position. This is one of the easiest solutions but has some difficulties when trying to
This solution consists in binding the ejector plate with the base plate making it move along
with the ejection movement. By itself only passes through but modifying the piece on its
perimeter and adding some pieces fixed on the base plate interfering with the
to the pull cell cavity in order to assure it does not
stack on the nozzle side. This needs to be in a disposable part otherwise it will be an extra
Expansible Injection Mould DesignBuch Cardona, Eloi
4.1.4.3
The problems with the piston dealing with more than two positions a
think that a more expensive one with its control system is needed. In the other hand the
plate ejection would increase a bit the after treatment for each piece by having to remove
the extra parts. This time the budget determines the decisi
with the plate ejection.
4.1.5
Pros
•
•
•
Cons
•
•
•
•
*To reduce a bit more the total cost it would be possible to put a pneumatic piston instead
of an hydraulic one by setting a low wedge angle making the piston need to support less
force directly from the
4.2
4.2.1
Expansible Injection Mould DesignBuch Cardona, Eloi
.1.4.3 Decision
The problems with the piston dealing with more than two positions a
think that a more expensive one with its control system is needed. In the other hand the
plate ejection would increase a bit the after treatment for each piece by having to remove
the extra parts. This time the budget determines the decisi
with the plate ejection.
.1.5 Compilation
• Piece centered
• Ordinary machine needed
• Versatility in remodeling the piece
Cons
• Difficulties to refrigerate evenly
• Additional piece later treatment
• Additional thermal treatmen
• Expensive piston addition*
*To reduce a bit more the total cost it would be possible to put a pneumatic piston instead
of an hydraulic one by setting a low wedge angle making the piston need to support less
force directly from the
Precise opening system
.2.1 Mould operation
Expansible Injection Mould DesignBuch Cardona, Eloi
ecision
The problems with the piston dealing with more than two positions a
think that a more expensive one with its control system is needed. In the other hand the
plate ejection would increase a bit the after treatment for each piece by having to remove
the extra parts. This time the budget determines the decisi
with the plate ejection.
ompilation
Piece centered
Ordinary machine needed
Versatility in remodeling the piece
Difficulties to refrigerate evenly
Additional piece later treatment
Additional thermal treatmen
Expensive piston addition*
*To reduce a bit more the total cost it would be possible to put a pneumatic piston instead
of an hydraulic one by setting a low wedge angle making the piston need to support less
force directly from the pressure on the mould.
Precise opening system
ould operation
Expansible Injection Mould Design
The problems with the piston dealing with more than two positions a
think that a more expensive one with its control system is needed. In the other hand the
plate ejection would increase a bit the after treatment for each piece by having to remove
the extra parts. This time the budget determines the decisi
Ordinary machine needed
Versatility in remodeling the piece
Difficulties to refrigerate evenly
Additional piece later treatment
Additional thermal treatment for the friction parts
Expensive piston addition*
*To reduce a bit more the total cost it would be possible to put a pneumatic piston instead
of an hydraulic one by setting a low wedge angle making the piston need to support less
pressure on the mould.
Precise opening system
ould operation
The problems with the piston dealing with more than two positions a
think that a more expensive one with its control system is needed. In the other hand the
plate ejection would increase a bit the after treatment for each piece by having to remove
the extra parts. This time the budget determines the decisi
Versatility in remodeling the piece
Difficulties to refrigerate evenly
Additional piece later treatment
t for the friction parts
*To reduce a bit more the total cost it would be possible to put a pneumatic piston instead
of an hydraulic one by setting a low wedge angle making the piston need to support less
pressure on the mould.
The problems with the piston dealing with more than two positions a
think that a more expensive one with its control system is needed. In the other hand the
plate ejection would increase a bit the after treatment for each piece by having to remove
the extra parts. This time the budget determines the decision which is to eject the piece
t for the friction parts
*To reduce a bit more the total cost it would be possible to put a pneumatic piston instead
of an hydraulic one by setting a low wedge angle making the piston need to support less
The problems with the piston dealing with more than two positions are big enough to
think that a more expensive one with its control system is needed. In the other hand the
plate ejection would increase a bit the after treatment for each piece by having to remove
on which is to eject the piece
*To reduce a bit more the total cost it would be possible to put a pneumatic piston instead
of an hydraulic one by setting a low wedge angle making the piston need to support less
re big enough to
think that a more expensive one with its control system is needed. In the other hand the
plate ejection would increase a bit the after treatment for each piece by having to remove
on which is to eject the piece
*To reduce a bit more the total cost it would be possible to put a pneumatic piston instead
of an hydraulic one by setting a low wedge angle making the piston need to support less
27
re big enough to
think that a more expensive one with its control system is needed. In the other hand the
plate ejection would increase a bit the after treatment for each piece by having to remove
on which is to eject the piece
*To reduce a bit more the total cost it would be possible to put a pneumatic piston instead
of an hydraulic one by setting a low wedge angle making the piston need to support less
Expansible Injection Mould DesignBuch Cardona, Eloi
This system consists in precisely opening the mould by using the injection machine
software, increasing the cavity in one direction while a spring system maintains the piece
closed m
The springs are always compressed and act until their limiter screw allows them making
possible to eject the piece.
They work against the clamping
machine. Pressure inside the piece is lost in a greater way than the cell pull system so it is
important to properly design, mechanize and thermally treat the parts involved to
minimize its effect an
4.2.2
In terms of piece position conclusions are the same as the previous type of mould but with
extra reasons in favor of the piece centering. Springs are not externally commanded and
they are an extra mould
4.2.3
In this case the refrigeration system actuates equally both in the perimeter and in the
inner piece through a refrigeration circuit beneath the protuberance that delimits the
bottom of the piece.
Expansible Injection Mould DesignBuch Cardona, Eloi
This system consists in precisely opening the mould by using the injection machine
software, increasing the cavity in one direction while a spring system maintains the piece
closed making it expand towards the desired direction
The springs are always compressed and act until their limiter screw allows them making
possible to eject the piece.
They work against the clamping
machine. Pressure inside the piece is lost in a greater way than the cell pull system so it is
important to properly design, mechanize and thermally treat the parts involved to
minimize its effect an
.2.2 Piece position
In terms of piece position conclusions are the same as the previous type of mould but with
extra reasons in favor of the piece centering. Springs are not externally commanded and
they are an extra mould
.2.3 Refrigeration system
In this case the refrigeration system actuates equally both in the perimeter and in the
inner piece through a refrigeration circuit beneath the protuberance that delimits the
bottom of the piece.
Expansible Injection Mould DesignBuch Cardona, Eloi
This system consists in precisely opening the mould by using the injection machine
software, increasing the cavity in one direction while a spring system maintains the piece
aking it expand towards the desired direction
The springs are always compressed and act until their limiter screw allows them making
possible to eject the piece.
They work against the clamping
machine. Pressure inside the piece is lost in a greater way than the cell pull system so it is
important to properly design, mechanize and thermally treat the parts involved to
minimize its effect and prevent flaws on the piece.
iece position
In terms of piece position conclusions are the same as the previous type of mould but with
extra reasons in favor of the piece centering. Springs are not externally commanded and
they are an extra mould harm if not evenly placed.
efrigeration system
In this case the refrigeration system actuates equally both in the perimeter and in the
inner piece through a refrigeration circuit beneath the protuberance that delimits the
bottom of the piece. By doing this a better even cooling is achieved.
Expansible Injection Mould Design
This system consists in precisely opening the mould by using the injection machine
software, increasing the cavity in one direction while a spring system maintains the piece
aking it expand towards the desired direction
Figure 19 Spring system operation
The springs are always compressed and act until their limiter screw allows them making
They work against the clamping force so it is important to work under the limits of the
machine. Pressure inside the piece is lost in a greater way than the cell pull system so it is
important to properly design, mechanize and thermally treat the parts involved to
d prevent flaws on the piece.
In terms of piece position conclusions are the same as the previous type of mould but with
extra reasons in favor of the piece centering. Springs are not externally commanded and
harm if not evenly placed.
efrigeration system
In this case the refrigeration system actuates equally both in the perimeter and in the
inner piece through a refrigeration circuit beneath the protuberance that delimits the
doing this a better even cooling is achieved.
This system consists in precisely opening the mould by using the injection machine
software, increasing the cavity in one direction while a spring system maintains the piece
aking it expand towards the desired direction
Spring system operation
The springs are always compressed and act until their limiter screw allows them making
force so it is important to work under the limits of the
machine. Pressure inside the piece is lost in a greater way than the cell pull system so it is
important to properly design, mechanize and thermally treat the parts involved to
d prevent flaws on the piece.
In terms of piece position conclusions are the same as the previous type of mould but with
extra reasons in favor of the piece centering. Springs are not externally commanded and
harm if not evenly placed.
In this case the refrigeration system actuates equally both in the perimeter and in the
inner piece through a refrigeration circuit beneath the protuberance that delimits the
doing this a better even cooling is achieved.
This system consists in precisely opening the mould by using the injection machine
software, increasing the cavity in one direction while a spring system maintains the piece
aking it expand towards the desired direction
Spring system operation
The springs are always compressed and act until their limiter screw allows them making
force so it is important to work under the limits of the
machine. Pressure inside the piece is lost in a greater way than the cell pull system so it is
important to properly design, mechanize and thermally treat the parts involved to
In terms of piece position conclusions are the same as the previous type of mould but with
extra reasons in favor of the piece centering. Springs are not externally commanded and
In this case the refrigeration system actuates equally both in the perimeter and in the
inner piece through a refrigeration circuit beneath the protuberance that delimits the
doing this a better even cooling is achieved.
This system consists in precisely opening the mould by using the injection machine
software, increasing the cavity in one direction while a spring system maintains the piece
The springs are always compressed and act until their limiter screw allows them making
force so it is important to work under the limits of the
machine. Pressure inside the piece is lost in a greater way than the cell pull system so it is
important to properly design, mechanize and thermally treat the parts involved to
In terms of piece position conclusions are the same as the previous type of mould but with
extra reasons in favor of the piece centering. Springs are not externally commanded and
In this case the refrigeration system actuates equally both in the perimeter and in the
inner piece through a refrigeration circuit beneath the protuberance that delimits the
doing this a better even cooling is achieved.
This system consists in precisely opening the mould by using the injection machine
software, increasing the cavity in one direction while a spring system maintains the piece
The springs are always compressed and act until their limiter screw allows them making
force so it is important to work under the limits of the
machine. Pressure inside the piece is lost in a greater way than the cell pull system so it is
important to properly design, mechanize and thermally treat the parts involved to
In terms of piece position conclusions are the same as the previous type of mould but with
extra reasons in favor of the piece centering. Springs are not externally commanded and
In this case the refrigeration system actuates equally both in the perimeter and in the
inner piece through a refrigeration circuit beneath the protuberance that delimits the
28
This system consists in precisely opening the mould by using the injection machine
software, increasing the cavity in one direction while a spring system maintains the piece
The springs are always compressed and act until their limiter screw allows them making
force so it is important to work under the limits of the
machine. Pressure inside the piece is lost in a greater way than the cell pull system so it is
important to properly design, mechanize and thermally treat the parts involved to
In terms of piece position conclusions are the same as the previous type of mould but with
extra reasons in favor of the piece centering. Springs are not externally commanded and
In this case the refrigeration system actuates equally both in the perimeter and in the
inner piece through a refrigeration circuit beneath the protuberance that delimits the
Expansible Injection Mould DesignBuch Cardona, Eloi
Because of the piece position the
momentarily the solid plate to reenter in a more fa
4.2.4
The ejection pretty much resembles to the traditional non
consist in a pin system ending on the surface of the piece bottom that move along with the
ejection plate that move once the mould
Expansible Injection Mould DesignBuch Cardona, Eloi
Because of the piece position the
momentarily the solid plate to reenter in a more fa
.2.4 Piece ejection
The ejection pretty much resembles to the traditional non
consist in a pin system ending on the surface of the piece bottom that move along with the
ejection plate that move once the mould
Expansible Injection Mould DesignBuch Cardona, Eloi
Figure
Because of the piece position the
momentarily the solid plate to reenter in a more fa
jection
The ejection pretty much resembles to the traditional non
consist in a pin system ending on the surface of the piece bottom that move along with the
ejection plate that move once the mould
Expansible Injection Mould Design
Figure 20 Inner piece refrigeration system
Because of the piece position the perimeter
momentarily the solid plate to reenter in a more fa
The ejection pretty much resembles to the traditional non
consist in a pin system ending on the surface of the piece bottom that move along with the
ejection plate that move once the mould
Figure
Inner piece refrigeration system
perimeter circuit cannot be continue and has to exit
momentarily the solid plate to reenter in a more favorable position.
The ejection pretty much resembles to the traditional non
consist in a pin system ending on the surface of the piece bottom that move along with the
ejection plate that move once the mould opening is complete.
Figure 21 Pin layout
Inner piece refrigeration system
circuit cannot be continue and has to exit
vorable position.
The ejection pretty much resembles to the traditional non-foamed mould pieces which
consist in a pin system ending on the surface of the piece bottom that move along with the
opening is complete.
Pin layout
Inner piece refrigeration system
circuit cannot be continue and has to exit
vorable position.
foamed mould pieces which
consist in a pin system ending on the surface of the piece bottom that move along with the
circuit cannot be continue and has to exit
foamed mould pieces which
consist in a pin system ending on the surface of the piece bottom that move along with the
29
circuit cannot be continue and has to exit
foamed mould pieces which
consist in a pin system ending on the surface of the piece bottom that move along with the
Expansible Injection Mould DesignBuch Cardona, Eloi
Pins are placed in the ends of the piece and in predicted trouble points such as the
entrance and the overflow channel which have an extra amount of material as well.
To prevent flaws a
4mm Ø). Also
that lets melt plastic enter and prevents the piece from stacking on the wrong side when
solidifi
It is important for that to use a pin in a non wanted part of the piece that was going to be
taken out such as the overflow channel or the entrance.
4.2.5
Pros
•
•
•
Cons
•
•
•
Expansible Injection Mould DesignBuch Cardona, Eloi
Pins are placed in the ends of the piece and in predicted trouble points such as the
entrance and the overflow channel which have an extra amount of material as well.
To prevent flaws a
4mm Ø). Also, like
that lets melt plastic enter and prevents the piece from stacking on the wrong side when
solidified. When the pin is released also is the said entrance that falls along with the piece.
It is important for that to use a pin in a non wanted part of the piece that was going to be
taken out such as the overflow channel or the entrance.
.2.5 Compilation
• Piece centered
• Even refrigeration
• Cheaper than other options
Cons
• High pressure drop when first opening the mould
• Limited piece versatility
• Difficulty in equally setting all the springs
Expansible Injection Mould DesignBuch Cardona, Eloi
Pins are placed in the ends of the piece and in predicted trouble points such as the
entrance and the overflow channel which have an extra amount of material as well.
To prevent flaws and marks in the piece it is important for them to be wide enough (i.e.
like in the previous mould, the ejection system needs to have an entrance
that lets melt plastic enter and prevents the piece from stacking on the wrong side when
ed. When the pin is released also is the said entrance that falls along with the piece.
It is important for that to use a pin in a non wanted part of the piece that was going to be
taken out such as the overflow channel or the entrance.
ompilation
Piece centered
Even refrigeration
Cheaper than other options
High pressure drop when first opening the mould
Limited piece versatility
Difficulty in equally setting all the springs
Expansible Injection Mould Design
Pins are placed in the ends of the piece and in predicted trouble points such as the
entrance and the overflow channel which have an extra amount of material as well.
nd marks in the piece it is important for them to be wide enough (i.e.
in the previous mould, the ejection system needs to have an entrance
that lets melt plastic enter and prevents the piece from stacking on the wrong side when
ed. When the pin is released also is the said entrance that falls along with the piece.
It is important for that to use a pin in a non wanted part of the piece that was going to be
taken out such as the overflow channel or the entrance.
Cheaper than other options
High pressure drop when first opening the mould
Limited piece versatility
Difficulty in equally setting all the springs
Pins are placed in the ends of the piece and in predicted trouble points such as the
entrance and the overflow channel which have an extra amount of material as well.
nd marks in the piece it is important for them to be wide enough (i.e.
in the previous mould, the ejection system needs to have an entrance
that lets melt plastic enter and prevents the piece from stacking on the wrong side when
ed. When the pin is released also is the said entrance that falls along with the piece.
It is important for that to use a pin in a non wanted part of the piece that was going to be
taken out such as the overflow channel or the entrance.
High pressure drop when first opening the mould
Difficulty in equally setting all the springs
Pins are placed in the ends of the piece and in predicted trouble points such as the
entrance and the overflow channel which have an extra amount of material as well.
nd marks in the piece it is important for them to be wide enough (i.e.
in the previous mould, the ejection system needs to have an entrance
that lets melt plastic enter and prevents the piece from stacking on the wrong side when
ed. When the pin is released also is the said entrance that falls along with the piece.
It is important for that to use a pin in a non wanted part of the piece that was going to be
taken out such as the overflow channel or the entrance.
High pressure drop when first opening the mould
Pins are placed in the ends of the piece and in predicted trouble points such as the
entrance and the overflow channel which have an extra amount of material as well.
nd marks in the piece it is important for them to be wide enough (i.e.
in the previous mould, the ejection system needs to have an entrance
that lets melt plastic enter and prevents the piece from stacking on the wrong side when
ed. When the pin is released also is the said entrance that falls along with the piece.
It is important for that to use a pin in a non wanted part of the piece that was going to be
Pins are placed in the ends of the piece and in predicted trouble points such as the
entrance and the overflow channel which have an extra amount of material as well.
nd marks in the piece it is important for them to be wide enough (i.e.
in the previous mould, the ejection system needs to have an entrance
that lets melt plastic enter and prevents the piece from stacking on the wrong side when
ed. When the pin is released also is the said entrance that falls along with the piece.
It is important for that to use a pin in a non wanted part of the piece that was going to be
30
Pins are placed in the ends of the piece and in predicted trouble points such as the
nd marks in the piece it is important for them to be wide enough (i.e.
in the previous mould, the ejection system needs to have an entrance
that lets melt plastic enter and prevents the piece from stacking on the wrong side when
ed. When the pin is released also is the said entrance that falls along with the piece.
It is important for that to use a pin in a non wanted part of the piece that was going to be
Expansible Injection Mould DesignBuch Cardona, Eloi
4.3
Both designs are equally valid for the
In the core cell mould the main advantage is its versatility however its elevated cost and
difficult refrigeration reduces its value whereas the controlled opening system has fast
and good quality ending
So there are no better or worse moulds in absolute terms and that implies to make a
decision.
In that case it is decided to put the economic and final quality piece factors as preferred
and, in consequence, choose to de
differ a lot in a possible future decision to produce the cell pull one.
Expansible Injection Mould DesignBuch Cardona, Eloi
Final decision
Both designs are equally valid for the
In the core cell mould the main advantage is its versatility however its elevated cost and
difficult refrigeration reduces its value whereas the controlled opening system has fast
and good quality ending
So there are no better or worse moulds in absolute terms and that implies to make a
decision.
In that case it is decided to put the economic and final quality piece factors as preferred
and, in consequence, choose to de
differ a lot in a possible future decision to produce the cell pull one.
Expansible Injection Mould DesignBuch Cardona, Eloi
Final decision
Both designs are equally valid for the
In the core cell mould the main advantage is its versatility however its elevated cost and
difficult refrigeration reduces its value whereas the controlled opening system has fast
and good quality ending pieces in exchange for versatility.
So there are no better or worse moulds in absolute terms and that implies to make a
In that case it is decided to put the economic and final quality piece factors as preferred
and, in consequence, choose to de
differ a lot in a possible future decision to produce the cell pull one.
Expansible Injection Mould Design
Both designs are equally valid for the project main purpose but with obvious differences.
In the core cell mould the main advantage is its versatility however its elevated cost and
difficult refrigeration reduces its value whereas the controlled opening system has fast
pieces in exchange for versatility.
So there are no better or worse moulds in absolute terms and that implies to make a
In that case it is decided to put the economic and final quality piece factors as preferred
and, in consequence, choose to develop the precise opening mould system which will not
differ a lot in a possible future decision to produce the cell pull one.
project main purpose but with obvious differences.
In the core cell mould the main advantage is its versatility however its elevated cost and
difficult refrigeration reduces its value whereas the controlled opening system has fast
pieces in exchange for versatility.
So there are no better or worse moulds in absolute terms and that implies to make a
In that case it is decided to put the economic and final quality piece factors as preferred
velop the precise opening mould system which will not
differ a lot in a possible future decision to produce the cell pull one.
project main purpose but with obvious differences.
In the core cell mould the main advantage is its versatility however its elevated cost and
difficult refrigeration reduces its value whereas the controlled opening system has fast
pieces in exchange for versatility.
So there are no better or worse moulds in absolute terms and that implies to make a
In that case it is decided to put the economic and final quality piece factors as preferred
velop the precise opening mould system which will not
differ a lot in a possible future decision to produce the cell pull one.
project main purpose but with obvious differences.
In the core cell mould the main advantage is its versatility however its elevated cost and
difficult refrigeration reduces its value whereas the controlled opening system has fast
So there are no better or worse moulds in absolute terms and that implies to make a
In that case it is decided to put the economic and final quality piece factors as preferred
velop the precise opening mould system which will not
differ a lot in a possible future decision to produce the cell pull one.
project main purpose but with obvious differences.
In the core cell mould the main advantage is its versatility however its elevated cost and
difficult refrigeration reduces its value whereas the controlled opening system has fast
So there are no better or worse moulds in absolute terms and that implies to make a
In that case it is decided to put the economic and final quality piece factors as preferred
velop the precise opening mould system which will not
31
project main purpose but with obvious differences.
In the core cell mould the main advantage is its versatility however its elevated cost and
difficult refrigeration reduces its value whereas the controlled opening system has fast
So there are no better or worse moulds in absolute terms and that implies to make a
In that case it is decided to put the economic and final quality piece factors as preferred
velop the precise opening mould system which will not
Expansible Injection Mould DesignBuch Cardona, Eloi
5.Final mould
Once fully
parts are t
their own naming and price for them. Note that if taken other brand product some shapes
and sizes may change and with that the solution needed.
Pieces can be ordered by the followi
Structural:
•
•
•
•
•
•
•
•
Plate 5
Plate 4
Plate 3
Plate 2
Expansible Injection Mould DesignBuch Cardona, Eloi
Final mould
Once fully-defined the mould, it is time to evaluate its production needs. The following
parts are taken complete or partially almost exclusively from HASCO catalog which have
their own naming and price for them. Note that if taken other brand product some shapes
and sizes may change and with that the solution needed.
Pieces can be ordered by the followi
Structural:
• K12- Plate 1
• K20- Plate 2
• K20- Plate 3
• K30- Plate 4
• K60- Plate 5
• K70- Plate 6
• K40- Plate 8
• K12- Plate 7
Plate 5
Plate 3
Plate 2
Plate 1
Expansible Injection Mould DesignBuch Cardona, Eloi
Final mould
defined the mould, it is time to evaluate its production needs. The following
aken complete or partially almost exclusively from HASCO catalog which have
their own naming and price for them. Note that if taken other brand product some shapes
and sizes may change and with that the solution needed.
Pieces can be ordered by the followi
Plate 1
Plate 2
Plate 3
Plate 4
Plate 5
Plate 6
Plate 8
Plate 7
Plate 1
Expansible Injection Mould Design
Final mould development
defined the mould, it is time to evaluate its production needs. The following
aken complete or partially almost exclusively from HASCO catalog which have
their own naming and price for them. Note that if taken other brand product some shapes
and sizes may change and with that the solution needed.
Pieces can be ordered by the following topics
Figure
development
defined the mould, it is time to evaluate its production needs. The following
aken complete or partially almost exclusively from HASCO catalog which have
their own naming and price for them. Note that if taken other brand product some shapes
and sizes may change and with that the solution needed.
topics:
Figure 22 Mould exterior
development
defined the mould, it is time to evaluate its production needs. The following
aken complete or partially almost exclusively from HASCO catalog which have
their own naming and price for them. Note that if taken other brand product some shapes
and sizes may change and with that the solution needed.
Mould exterior
development
defined the mould, it is time to evaluate its production needs. The following
aken complete or partially almost exclusively from HASCO catalog which have
their own naming and price for them. Note that if taken other brand product some shapes
Plate 6
defined the mould, it is time to evaluate its production needs. The following
aken complete or partially almost exclusively from HASCO catalog which have
their own naming and price for them. Note that if taken other brand product some shapes
32
defined the mould, it is time to evaluate its production needs. The following
aken complete or partially almost exclusively from HASCO catalog which have
their own naming and price for them. Note that if taken other brand product some shapes
Plate 7
Plate 8
Expansible Injection Mould DesignBuch Cardona, Eloi
Refrigeration:
•
•
Ejection:
•
•
Placers
•
•
•
•
•
•
•
•
•
•
•
Then
treatment and mechanization if needed.
Expansible Injection Mould DesignBuch Cardona, Eloi
Refrigeration:
• Z87 refrigeration male nozzle
• Z94 threaded plug
Ejection:
• Z40 ejector
• Z60 spring
Placers and guidance
• Z1000 centering disk
• Z38 limiter screw
• Z31 allen screw with cylindrical head
• Z33 countersunk screw
• Z691 spring washer with detent
• Z00 column guide
• Z10 bushing guide
• Z20 centering bush
• Z55 stop washer
• Z70 transport
• Z51 nozzle
Then it is time to
treatment and mechanization if needed.
Expansible Injection Mould DesignBuch Cardona, Eloi
Z87 refrigeration male nozzle
Z94 threaded plug
0 ejector
Z60 spring
and guidance:
Z1000 centering disk
Z38 limiter screw
allen screw with cylindrical head
countersunk screw
spring washer with detent
00 column guide
Z10 bushing guide
centering bush
stop washer
Z70 transport flange
Z51 nozzle
it is time to proceed to an exhaustive de
treatment and mechanization if needed.
Expansible Injection Mould Design
Z87 refrigeration male nozzle
Z1000 centering disk
allen screw with cylindrical head
countersunk screw
spring washer with detent
flange
proceed to an exhaustive de
treatment and mechanization if needed.
allen screw with cylindrical head
spring washer with detent
proceed to an exhaustive definition of each piece as well as thermal
treatment and mechanization if needed.
finition of each piece as well as thermal finition of each piece as well as thermal finition of each piece as well as thermal
33
finition of each piece as well as thermal
Expansible Injection Mould DesignBuch Cardona, Eloi
5.1.
5.1.1.
�
�
�
�
�
�
�
�
Expansible Injection Mould DesignBuch Cardona, Eloi
5.1.Piece description
5.1.1.Static part
� Name: Plate 1� Code and size
� Price: 173.03� Mechanization
-Decentered nozzle drilling
-Centering disk housing milling and position screws
-Transport flange drilling
� Thermal treatment
� Material
� Quantity
� Use and position
directly by the injection machine
Expansible Injection Mould DesignBuch Cardona, Eloi
Piece description
Static part
: Plate 1 Code and size: K12-
: 173.03€ Mechanization: Yes
Decentered nozzle drilling
Centering disk housing milling and position screws
Transport flange drilling
Thermal treatment
Material: DIN 1.1730Quantity: 1 Use and position: First platdirectly by the injection machine
Expansible Injection Mould Design
Piece description
Figure 23
-246x296x2
: Yes
Decentered nozzle drilling
Centering disk housing milling and position screws
Transport flange drilling
Thermal treatment: Quench and: DIN 1.1730
: First plate of the mould, subjects Plate 2 and is being subjected directly by the injection machine
23 Plate 1: Nozzle support
246x296x27
Decentered nozzle drilling
Centering disk housing milling and position screws
Transport flange drilling
Quench and Temper
e of the mould, subjects Plate 2 and is being subjected directly by the injection machine
Plate 1: Nozzle support
Centering disk housing milling and position screws
e of the mould, subjects Plate 2 and is being subjected
Centering disk housing milling and position screws thread
e of the mould, subjects Plate 2 and is being subjected
thread drilling
e of the mould, subjects Plate 2 and is being subjected
34
e of the mould, subjects Plate 2 and is being subjected
Expansible Injection Mould DesignBuch Cardona, Eloi
�
�
�
�
�
�
�
�
Expansible Injection Mould DesignBuch Cardona, Eloi
� Name: Plate 2� Code and size
� Price: 114.23� Mechanization
-Decentered nozzl
� Thermal treatment
� Material
� Quantity
� Use and position
piece produced. Is bound together with Plate 1 and holds the Z00 column guidesthat guides the mould
Expansible Injection Mould DesignBuch Cardona, Eloi
: Plate 2 Code and size: K20-
: 114.23€ Mechanization: Yes
Decentered nozzl
Thermal treatment
Material: DIN 1.1730Quantity: 1 Use and position: Is subjected by Plate 1 and consists in the upper limit for the piece produced. Is bound together with Plate 1 and holds the Z00 column guidesthat guides the mould
Expansible Injection Mould Design
Figure 24 Plate 2: Upper piece delimiter
-246x296x36
: Yes
Decentered nozzle small diameter drilling
Thermal treatment: Quench and : DIN 1.1730
: Is subjected by Plate 1 and consists in the upper limit for the piece produced. Is bound together with Plate 1 and holds the Z00 column guidesthat guides the mould
Plate 2: Upper piece delimiter
246x296x36
e small diameter drilling
Quench and Temper
: Is subjected by Plate 1 and consists in the upper limit for the piece produced. Is bound together with Plate 1 and holds the Z00 column guides
Plate 2: Upper piece delimiter
e small diameter drilling
: Is subjected by Plate 1 and consists in the upper limit for the piece produced. Is bound together with Plate 1 and holds the Z00 column guides
Plate 2: Upper piece delimiter
: Is subjected by Plate 1 and consists in the upper limit for the piece produced. Is bound together with Plate 1 and holds the Z00 column guides
: Is subjected by Plate 1 and consists in the upper limit for the piece produced. Is bound together with Plate 1 and holds the Z00 column guides
35
: Is subjected by Plate 1 and consists in the upper limit for the piece produced. Is bound together with Plate 1 and holds the Z00 column guides
Expansible Injection Mould DesignBuch Cardona, Eloi
5.1.2.
�
�
�
�
�
�
�
�
Expansible Injection Mould DesignBuch Cardona, Eloi
5.1.2.Mobile part
� Name: Plate 3� Code and size
� Price: 114.23� Mechanization
-Piece shape milled trough the piece
-Z60 spring and Z38 limiter screw housings drilling
-Refrigeration drilling
� Thermal treatment
� Material
� Quantity
� Use and position
steady part until the 2 mm expansion reached due to the Z60 spring action making the piece retain its general shape. Guided by Z00 column guides and Z10 bushing guide.
Expansible Injection Mould DesignBuch Cardona, Eloi
Mobile part
: Plate 3 Code and size: K20-
: 114.23€ Mechanization: Yes
Piece shape milled trough the piece
Z60 spring and Z38 limiter screw housings drilling
Refrigeration drilling
Thermal treatment
Material: DIN 1.1730Quantity: 1 Use and position: Limited by the Platesteady part until the 2 mm expansion reached due to the Z60 spring action making the piece retain its general shape. Guided by Z00 column guides and Z10 bushing
Expansible Injection Mould Design
Figure 25 Plate 3: Piece shape retainer
-246x296x36
: Yes
Piece shape milled trough the piece
Z60 spring and Z38 limiter screw housings drilling
Refrigeration drilling
Thermal treatment: Quench and : DIN 1.1730
: Limited by the Platesteady part until the 2 mm expansion reached due to the Z60 spring action making the piece retain its general shape. Guided by Z00 column guides and Z10 bushing
Plate 3: Piece shape retainer
246x296x36
Piece shape milled trough the piece
Z60 spring and Z38 limiter screw housings drilling
Quench and Temper
: Limited by the Plate 4 and the Z38 limiter screw. Stays in the steady part until the 2 mm expansion reached due to the Z60 spring action making the piece retain its general shape. Guided by Z00 column guides and Z10 bushing
Plate 3: Piece shape retainer
Piece shape milled trough the piece
Z60 spring and Z38 limiter screw housings drilling
4 and the Z38 limiter screw. Stays in the steady part until the 2 mm expansion reached due to the Z60 spring action making the piece retain its general shape. Guided by Z00 column guides and Z10 bushing
Plate 3: Piece shape retainer
Z60 spring and Z38 limiter screw housings drilling
4 and the Z38 limiter screw. Stays in the steady part until the 2 mm expansion reached due to the Z60 spring action making the piece retain its general shape. Guided by Z00 column guides and Z10 bushing
4 and the Z38 limiter screw. Stays in the steady part until the 2 mm expansion reached due to the Z60 spring action making the piece retain its general shape. Guided by Z00 column guides and Z10 bushing
36
4 and the Z38 limiter screw. Stays in the steady part until the 2 mm expansion reached due to the Z60 spring action making the piece retain its general shape. Guided by Z00 column guides and Z10 bushing
Expansible Injection Mould DesignBuch Cardona, Eloi
�
�
�
�
�
�
�
�
�
Expansible Injection Mould DesignBuch Cardona, Eloi
� Name: Plate 4� Code and size
� Base material block size
� Price: 250.00� Mechanization
-Piece shape milling until desired height
-Guide drilling
-Z38 limiter
-Z40 Pin
-Z60 spring housing drilling
-Refrigeration drilling
� Thermal treatment
� Material
� Quantity
� Use and position
Act as the piece bottom limiter that moves when precisely opening the mouldSpring-limiter screws are bound in that plate.
Expansible Injection Mould DesignBuch Cardona, Eloi
Figure
: Plate 4 Code and size: Hole position based on K30Base material block size
: 250.00€ Mechanization: Yes
Piece shape milling until desired height
Guide drilling
Z38 limiter and Z31 allen screw
Z40 Pin and
Z60 spring housing drilling
Refrigeration drilling
Thermal treatment
Material: DIN 1.1730Quantity: 1 Use and position: Bounded with Plate 8 x2 in the mobile partAct as the piece bottom limiter that moves when precisely opening the mould
limiter screws are bound in that plate.
Expansible Injection Mould Design
Figure 26 Plate 4
: Hole position based on K30Base material block size: 246x296x70
: Yes
Piece shape milling until desired height
Guide drilling
and Z31 allen screw
and drilling
Z60 spring housing drilling
Refrigeration drilling
Thermal treatment: Quench and : DIN 1.1730
Bounded with Plate 8 x2 in the mobile partAct as the piece bottom limiter that moves when precisely opening the mould
limiter screws are bound in that plate.
Plate 4: Piece bottom expander
: Hole position based on K30-: 246x296x70
Piece shape milling until desired height
and Z31 allen screw thread
Z60 spring housing drilling
Quench and Temper
Bounded with Plate 8 x2 in the mobile partAct as the piece bottom limiter that moves when precisely opening the mould
limiter screws are bound in that plate.
: Piece bottom expander
-246x296x36
Piece shape milling until desired height
thread drilling
Bounded with Plate 8 x2 in the mobile partAct as the piece bottom limiter that moves when precisely opening the mould
limiter screws are bound in that plate.
: Piece bottom expander
246x296x36
drilling
Bounded with Plate 8 x2 in the mobile part with the Z31 screwsAct as the piece bottom limiter that moves when precisely opening the mould
with the Z31 screwsAct as the piece bottom limiter that moves when precisely opening the mould.
37
with the Z31 screws. .
Expansible Injection Mould DesignBuch Cardona, Eloi
�
�
�
�
�
�
�
�
�
�
�
�
�
�
�
Expansible Injection Mould DesignBuch Cardona, Eloi
� Name: Plate 5� Code and size
� Price: 63.90� Mechanization
-Z40 ejectors housing drilling
� Thermal treatment
� Material
� Quantity
� Use and position
holds the Z40 ejector pins that will take out the pie
� Name: Plate 6� Code and size
� Price: 80.47� Mechanization
-Machine ejection screw thread drilling
� Thermal treatment
� Material
� Quantity
Expansible Injection Mould DesignBuch Cardona, Eloi
: Plate 5 Code and size: K60-
63.90€ Mechanization: Yes
Z40 ejectors housing drilling
Thermal treatment
Material: DIN 1.1730Quantity: 1 Use and position: Bound with Plate 6holds the Z40 ejector pins that will take out the pie
: Plate 6 Code and size: K70-
80.47€ Mechanization: Yes
Machine ejection screw thread drilling
Thermal treatment
Material: DIN 1.1730Quantity: 1
Expansible Injection Mould Design
Figure 27 Plate 5:
-246x296x12
: Yes
Z40 ejectors housing drilling
Thermal treatment: Quench and: DIN 1.1730
Bound with Plate 6holds the Z40 ejector pins that will take out the pie
Figure 28 Plate 6: Ejector pins retainer
-246x296x17
: Yes
Machine ejection screw thread drilling
Thermal treatment: Quench and : DIN 1.1730
Plate 5: Ejection
x12
Z40 ejectors housing drilling
Quench and Temper
Bound with Plate 6 and controlled directly by the machine it holds the Z40 ejector pins that will take out the pie
Plate 6: Ejector pins retainer
246x296x17
Machine ejection screw thread drilling
Quench and Temper
Ejection pins housing
and controlled directly by the machine it holds the Z40 ejector pins that will take out the piece. It is guided by those ejectors.
Plate 6: Ejector pins retainer
Machine ejection screw thread drilling
ins housing
and controlled directly by the machine it ce. It is guided by those ejectors.
Plate 6: Ejector pins retainer
and controlled directly by the machine it ce. It is guided by those ejectors.
38
and controlled directly by the machine it ce. It is guided by those ejectors.
Expansible Injection Mould DesignBuch Cardona, Eloi
�
�
�
�
�
�
�
�
�
Expansible Injection Mould DesignBuch Cardona, Eloi
� Use and position
screws. It receives directly the threaded rod from the machine related to the ejection.
� Name: Plate 1� Code and size
� Price: 173.03� Mechanization
-Decentered nozzle drilling
-Centering disk housing milling and position screws drilling
-Transport flange drilling
� Thermal treatment
� Material
� Quantity
� Use and position
and positioned by Z20 centering bushes. It gives space for the ejection system to move and retains the plates on the mobile part.
Expansible Injection Mould DesignBuch Cardona, Eloi
Use and position: Bound with Plate 5 with Z31 screws and centered with Z33 screws. It receives directly the threaded rod from the machine related to the
: Plate 1 Code and size: K12-
: 173.03€ Mechanization: Yes
Decentered nozzle drilling
Centering disk housing milling and position screws drilling
Transport flange drilling
Thermal treatment
Material: DIN 1.1730Quantity: 2 Use and position: Bound between Plaand positioned by Z20 centering bushes. It gives space for the ejection system to move and retains the plates on the mobile part.
Expansible Injection Mould Design
Bound with Plate 5 with Z31 screws and centered with Z33 screws. It receives directly the threaded rod from the machine related to the
Figure 29 Plate 8: Structur
-246x296x17
: Yes
Decentered nozzle drilling
Centering disk housing milling and position screws drilling
Transport flange drilling
Thermal treatment: Quench and : DIN 1.1730
Bound between Plaand positioned by Z20 centering bushes. It gives space for the ejection system to move and retains the plates on the mobile part.
Bound with Plate 5 with Z31 screws and centered with Z33 screws. It receives directly the threaded rod from the machine related to the
Plate 8: Structur
246x296x17
Decentered nozzle drilling
Centering disk housing milling and position screws drilling
Transport flange drilling
Quench and Temper
Bound between Plates 4 and 7 with Z31 screwsand positioned by Z20 centering bushes. It gives space for the ejection system to move and retains the plates on the mobile part.
Bound with Plate 5 with Z31 screws and centered with Z33 screws. It receives directly the threaded rod from the machine related to the
Plate 8: Structural limiter
Centering disk housing milling and position screws drilling
tes 4 and 7 with Z31 screwsand positioned by Z20 centering bushes. It gives space for the ejection system to move and retains the plates on the mobile part.
Bound with Plate 5 with Z31 screws and centered with Z33 screws. It receives directly the threaded rod from the machine related to the
Centering disk housing milling and position screws drilling
tes 4 and 7 with Z31 screws and positioned by Z20 centering bushes. It gives space for the ejection system to
Bound with Plate 5 with Z31 screws and centered with Z33 screws. It receives directly the threaded rod from the machine related to the
Centering disk housing milling and position screws drilling
passing throughand positioned by Z20 centering bushes. It gives space for the ejection system to
39
Bound with Plate 5 with Z31 screws and centered with Z33
passing through and positioned by Z20 centering bushes. It gives space for the ejection system to
Expansible Injection Mould DesignBuch Cardona, Eloi
�
�
�
�
�
�
�
�
5.1.3.
Name
Centering
disk
Allen screw
Spring
washer with
detent
Allen screw
Stop washer
Expansible Injection Mould DesignBuch Cardona, Eloi
� Name: Plate 7� Code and size
� Price: 173.03� Mechanization
-Decentered
-Transport flange drilling
� Thermal treatment
� Material
� Quantity
� Use and position
mould mobile
5.1.3.Other elements
Name Code/Size
Centering K100
125x8
Allen screw Z31
12x120
Spring
washer with
detent
Z691
12x5
Allen screw Z31
12x30
Stop washer Z55
Expansible Injection Mould DesignBuch Cardona, Eloi
: Plate 7 ode and size: K12-
: 173.03€ Mechanization: Yes
Decentered
Transport flange drilling
Thermal treatment
Material: DIN 1.1730Quantity: 1 Use and position: Last plate bound to the mobile part of the machine. Sustamould mobile part and retains the Z20 centering bush
Other elements
Code/Size Price/u
K100 -
125x8 25.25
Z31 -
12x120 2.11
Z691 -
12x5 0.13
Z31 -
12x30 0.52
Z55 - 18x3 0.62
Expansible Injection Mould Design
Figure 30 Plate 7: Mobile part support
-246x296x2
: Yes
Decentered machine ejection rod position
Transport flange drilling
Thermal treatment: Quench and : DIN 1.1730
Last plate bound to the mobile part of the machine. Sustapart and retains the Z20 centering bush
Price/u(€) Qty.
25.25 1
2.11 4
0.13 8
0.52 4
0.62 4
Plate 7: Mobile part support
246x296x27
machine ejection rod position
Transport flange drilling
Quench and Temper
Last plate bound to the mobile part of the machine. Sustapart and retains the Z20 centering bush
ty. Material
1 1.1730
4 12.9
8 DIN
17221
4 12.9
4 1.0711
Plate 7: Mobile part support
machine ejection rod position drilling
Last plate bound to the mobile part of the machine. Sustapart and retains the Z20 centering bush
Material Therm. T.
-
-
-
-
-
Plate 7: Mobile part support
drilling
Last plate bound to the mobile part of the machine. Sustapart and retains the Z20 centering bush.
Mechanization
-
-
-
-
-
Last plate bound to the mobile part of the machine. Sustains the
nization Use
Nozzle
holder
Bound
permanently
Impede
screw going
back
Bound
permanently
Limit
40
ins the
Nozzle
Bound
permanently
Impede
screw going
Bound
permanently
Expansible Injection Mould DesignBuch Cardona, Eloi
Spring
washer with
retent
Countersunk
screw
Allen screw
Centering
bush
Bushing
guide
Column guide
Refrigeration
male nozzle
Threaded
plug
Ejector
Spring
Transport
flange
Limiter screw
Nozzle
Expansible Injection Mould DesignBuch Cardona, Eloi
Spring
washer with
retent
Z691
12x2
Countersunk
screw Z33
Allen screw Z31
Centering
Z20
30x100
ing
Z10
24
Column guide Z00
24x55
Refrigeration
male nozzle Z87
Threaded Z94
Ejector Z40
4x100
Spring Z60
25x
Transport
flange Z70
Limiter screw Z38
16x30
Nozzle Z51
18x27
Expansible Injection Mould DesignBuch Cardona, Eloi
Z691 -
12x2 0.13
Z33 - 4x8 0.25
Z31 - 8x16 0.22
Z20 -
30x100 6.44
Z10 - 36 -
12.62
Z00 - 36 -
24x55 17.10
Z87 0.76
Z94 0.30
Z40 -
4x100 2.83
Z60 -
25x30 18.50
Z70 209.73
Z38 -
16x30 5.69
Z51 -
18x27 36.46
Expansible Injection Mould Design
0.13 4
0.25 4
0.22 4
6.44 4
12.62 4
17.10 4
0.76 8
0.30 7
2.83 7
18.50 4
209.73 1
5.69 4
36.46 1
4 DIN
17221
4 8.8
4 12.9
4 1.0401
4 1.0401
4 1.0401
8 2.0401
7 2.0401
7 1.2516
4 2098
1
4 12.9
1 1.2826
-
-
-
Nitriding
Nitriding
Nitriding
-
-
Nitriding
-
-
Nitriding
-
-
-
-
-
-
-
-
-
2 cut 7mm, 1
piece retainer
mechanization
-
-
-
Cut in Plate 1
+2 distance
ejection
movement
Impede
screw going
back
Bound
permanently
Bound
permanently
Decrease
friction
Decrease
friction
Guide every
plate
Connect
mould to
refrigeration
Plug
refrigeration
holes
2 cut 7mm, 1
piece retainer
mechanization
Retain and
eject piece
Maintains
Plate 3 at
place
Maintain
mould
and
transport
Limit spring
stroke
Cut in Plate 1
+2 distance
Connect
machine end
with mould
41
ejection
movement
Impede
screw going
Bound
permanently
Bound
permanently
Decrease
friction
Decrease
friction
Guide every
Connect
mould to
refrigeration
refrigeration
Retain and
eject piece
Maintains
Plate 3 at
Maintain
closed
transport
Limit spring
Connect
machine end
with mould
Expansible Injection Mould DesignBuch Cardona, Eloi
6.Mechanization
Although most pieces are directly taken from cat
with them is not enough. Pieces such as guides and screws don't need changes but plates
do. Standardized plates have only the guidance and thread holes and lets the design up to
you. For that, mould plates need to be me
The mechanization processes needed are:
different roughnesses helps achieving both low time and good finishing for the piece
quality pieces as well as for its health.
In the mould there is a non standardized piece
completely, first rou
rough and finally grinding it.
Expansible Injection Mould DesignBuch Cardona, Eloi
Mechanization
Although most pieces are directly taken from cat
with them is not enough. Pieces such as guides and screws don't need changes but plates
do. Standardized plates have only the guidance and thread holes and lets the design up to
you. For that, mould plates need to be me
The mechanization processes needed are:
-Milling. The main way to achieve the shapes wanted in the piece. Cutting off in
different roughnesses helps achieving both low time and good finishing for the piece
-Drilling. Way to obtain the round sha
-Grinding
quality pieces as well as for its health.
the mould there is a non standardized piece
completely, first rou
rough and finally grinding it.
Expansible Injection Mould DesignBuch Cardona, Eloi
Mechanization
Although most pieces are directly taken from cat
with them is not enough. Pieces such as guides and screws don't need changes but plates
do. Standardized plates have only the guidance and thread holes and lets the design up to
you. For that, mould plates need to be me
The mechanization processes needed are:
Milling. The main way to achieve the shapes wanted in the piece. Cutting off in
different roughnesses helps achieving both low time and good finishing for the piece
Drilling. Way to obtain the round sha
Grinding. It is important for a mould to fit perfectly to produce regular and good
quality pieces as well as for its health.
the mould there is a non standardized piece
completely, first roughing until there is little thickness left to take out, then a finishing
rough and finally grinding it.
Expansible Injection Mould Design
Mechanization
Although most pieces are directly taken from cat
with them is not enough. Pieces such as guides and screws don't need changes but plates
do. Standardized plates have only the guidance and thread holes and lets the design up to
you. For that, mould plates need to be me
The mechanization processes needed are:
Milling. The main way to achieve the shapes wanted in the piece. Cutting off in
different roughnesses helps achieving both low time and good finishing for the piece
Drilling. Way to obtain the round sha
. It is important for a mould to fit perfectly to produce regular and good
quality pieces as well as for its health.
the mould there is a non standardized piece
ghing until there is little thickness left to take out, then a finishing
rough and finally grinding it.
Mechanization
Although most pieces are directly taken from cat
with them is not enough. Pieces such as guides and screws don't need changes but plates
do. Standardized plates have only the guidance and thread holes and lets the design up to
you. For that, mould plates need to be mechanized.
The mechanization processes needed are:
Milling. The main way to achieve the shapes wanted in the piece. Cutting off in
different roughnesses helps achieving both low time and good finishing for the piece
Drilling. Way to obtain the round shapes through the pieces
. It is important for a mould to fit perfectly to produce regular and good
the mould there is a non standardized piece (Plate 4
ghing until there is little thickness left to take out, then a finishing
Although most pieces are directly taken from catalogs with standardized models, only
with them is not enough. Pieces such as guides and screws don't need changes but plates
do. Standardized plates have only the guidance and thread holes and lets the design up to
.
Milling. The main way to achieve the shapes wanted in the piece. Cutting off in
different roughnesses helps achieving both low time and good finishing for the piece
pes through the pieces
. It is important for a mould to fit perfectly to produce regular and good
(Plate 4) which have to be mechanized
ghing until there is little thickness left to take out, then a finishing
alogs with standardized models, only
with them is not enough. Pieces such as guides and screws don't need changes but plates
do. Standardized plates have only the guidance and thread holes and lets the design up to
Milling. The main way to achieve the shapes wanted in the piece. Cutting off in
different roughnesses helps achieving both low time and good finishing for the piece
pes through the pieces
. It is important for a mould to fit perfectly to produce regular and good
which have to be mechanized
ghing until there is little thickness left to take out, then a finishing
alogs with standardized models, only
with them is not enough. Pieces such as guides and screws don't need changes but plates
do. Standardized plates have only the guidance and thread holes and lets the design up to
Milling. The main way to achieve the shapes wanted in the piece. Cutting off in
different roughnesses helps achieving both low time and good finishing for the piece
. It is important for a mould to fit perfectly to produce regular and good
which have to be mechanized
ghing until there is little thickness left to take out, then a finishing
42
alogs with standardized models, only
with them is not enough. Pieces such as guides and screws don't need changes but plates
do. Standardized plates have only the guidance and thread holes and lets the design up to
Milling. The main way to achieve the shapes wanted in the piece. Cutting off in
. It is important for a mould to fit perfectly to produce regular and good
which have to be mechanized
ghing until there is little thickness left to take out, then a finishing
Expansible Injection Mould DesignBuch Cardona, Eloi
7.Thermal
For the thermal treatment there are basically two types to be taken in account:
tension the first treatment provoked. The result is a harder steel than the one in the
beginning with
them last without degrading excessively by i
(Rockwell hardness). Higher values are needed in pieces that slide to minimize friction
degradation such as Plate 3 and 4, but being careful not to harden it too much to prevent
brittle behaviors of the pieces.
first layers of material in the surface preventing them from the harm of friction. That is
why is done at the parts that move guided such as ejection pins or column gui
Depending on where normalized pieces bought those thermal treatments may be already
done but depending on the situation a different treatment would be needed anyway
mould singularities such as our example that need different Rc in some pieces
Expansible Injection Mould DesignBuch Cardona, Eloi
Thermal
For the thermal treatment there are basically two types to be taken in account:
-Quench and temperate. It consists in hardening
tension the first treatment provoked. The result is a harder steel than the one in the
beginning with
them last without degrading excessively by i
(Rockwell hardness). Higher values are needed in pieces that slide to minimize friction
degradation such as Plate 3 and 4, but being careful not to harden it too much to prevent
brittle behaviors of the pieces.
-Nitriding.
first layers of material in the surface preventing them from the harm of friction. That is
why is done at the parts that move guided such as ejection pins or column gui
Depending on where normalized pieces bought those thermal treatments may be already
done but depending on the situation a different treatment would be needed anyway
mould singularities such as our example that need different Rc in some pieces
Expansible Injection Mould DesignBuch Cardona, Eloi
Thermal t
For the thermal treatment there are basically two types to be taken in account:
Quench and temperate. It consists in hardening
tension the first treatment provoked. The result is a harder steel than the one in the
good ductile properties. Is done basically in the structural pieces to make
them last without degrading excessively by i
(Rockwell hardness). Higher values are needed in pieces that slide to minimize friction
degradation such as Plate 3 and 4, but being careful not to harden it too much to prevent
brittle behaviors of the pieces.
Nitriding. It consists in a superficial treatment that deposits nitrides in the very
first layers of material in the surface preventing them from the harm of friction. That is
why is done at the parts that move guided such as ejection pins or column gui
Depending on where normalized pieces bought those thermal treatments may be already
done but depending on the situation a different treatment would be needed anyway
mould singularities such as our example that need different Rc in some pieces
Expansible Injection Mould Design
treatment
For the thermal treatment there are basically two types to be taken in account:
Quench and temperate. It consists in hardening
tension the first treatment provoked. The result is a harder steel than the one in the
good ductile properties. Is done basically in the structural pieces to make
them last without degrading excessively by i
(Rockwell hardness). Higher values are needed in pieces that slide to minimize friction
degradation such as Plate 3 and 4, but being careful not to harden it too much to prevent
brittle behaviors of the pieces.
It consists in a superficial treatment that deposits nitrides in the very
first layers of material in the surface preventing them from the harm of friction. That is
why is done at the parts that move guided such as ejection pins or column gui
Depending on where normalized pieces bought those thermal treatments may be already
done but depending on the situation a different treatment would be needed anyway
mould singularities such as our example that need different Rc in some pieces
reatment
For the thermal treatment there are basically two types to be taken in account:
Quench and temperate. It consists in hardening
tension the first treatment provoked. The result is a harder steel than the one in the
good ductile properties. Is done basically in the structural pieces to make
them last without degrading excessively by its use.
(Rockwell hardness). Higher values are needed in pieces that slide to minimize friction
degradation such as Plate 3 and 4, but being careful not to harden it too much to prevent
It consists in a superficial treatment that deposits nitrides in the very
first layers of material in the surface preventing them from the harm of friction. That is
why is done at the parts that move guided such as ejection pins or column gui
Depending on where normalized pieces bought those thermal treatments may be already
done but depending on the situation a different treatment would be needed anyway
mould singularities such as our example that need different Rc in some pieces
For the thermal treatment there are basically two types to be taken in account:
Quench and temperate. It consists in hardening the piece and then releasing the
tension the first treatment provoked. The result is a harder steel than the one in the
good ductile properties. Is done basically in the structural pieces to make
ts use. The final hardness is measured by Rc
(Rockwell hardness). Higher values are needed in pieces that slide to minimize friction
degradation such as Plate 3 and 4, but being careful not to harden it too much to prevent
It consists in a superficial treatment that deposits nitrides in the very
first layers of material in the surface preventing them from the harm of friction. That is
why is done at the parts that move guided such as ejection pins or column gui
Depending on where normalized pieces bought those thermal treatments may be already
done but depending on the situation a different treatment would be needed anyway
mould singularities such as our example that need different Rc in some pieces
For the thermal treatment there are basically two types to be taken in account:
the piece and then releasing the
tension the first treatment provoked. The result is a harder steel than the one in the
good ductile properties. Is done basically in the structural pieces to make
The final hardness is measured by Rc
(Rockwell hardness). Higher values are needed in pieces that slide to minimize friction
degradation such as Plate 3 and 4, but being careful not to harden it too much to prevent
It consists in a superficial treatment that deposits nitrides in the very
first layers of material in the surface preventing them from the harm of friction. That is
why is done at the parts that move guided such as ejection pins or column gui
Depending on where normalized pieces bought those thermal treatments may be already
done but depending on the situation a different treatment would be needed anyway
mould singularities such as our example that need different Rc in some pieces
For the thermal treatment there are basically two types to be taken in account:
the piece and then releasing the
tension the first treatment provoked. The result is a harder steel than the one in the
good ductile properties. Is done basically in the structural pieces to make
The final hardness is measured by Rc
(Rockwell hardness). Higher values are needed in pieces that slide to minimize friction
degradation such as Plate 3 and 4, but being careful not to harden it too much to prevent
It consists in a superficial treatment that deposits nitrides in the very
first layers of material in the surface preventing them from the harm of friction. That is
why is done at the parts that move guided such as ejection pins or column guiders.
Depending on where normalized pieces bought those thermal treatments may be already
done but depending on the situation a different treatment would be needed anyway due to
mould singularities such as our example that need different Rc in some pieces.
43
the piece and then releasing the
tension the first treatment provoked. The result is a harder steel than the one in the
good ductile properties. Is done basically in the structural pieces to make
The final hardness is measured by Rc
(Rockwell hardness). Higher values are needed in pieces that slide to minimize friction
degradation such as Plate 3 and 4, but being careful not to harden it too much to prevent
It consists in a superficial treatment that deposits nitrides in the very
first layers of material in the surface preventing them from the harm of friction. That is
Depending on where normalized pieces bought those thermal treatments may be already
due to
Expansible Injection Mould DesignBuch Cardona, Eloi
8.Budget
The final cost is totally approximated and may change significantly depending on the
mechanizing hours which have a huge weight in the final price
of the standardize items the hours can be reduced also.
Expansible Injection Mould DesignBuch Cardona, Eloi
Budget
final cost is totally approximated and may change significantly depending on the
chanizing hours which have a huge weight in the final price
of the standardize items the hours can be reduced also.
Expansible Injection Mould DesignBuch Cardona, Eloi
Budget resume
final cost is totally approximated and may change significantly depending on the
chanizing hours which have a huge weight in the final price
of the standardize items the hours can be reduced also.
Extra pieces
Standardized pieces
Thermal treatments
Mechanized and finishing
Other costs
+21% IVA
Total Mould Cost
Expansible Injection Mould Design
resume
final cost is totally approximated and may change significantly depending on the
chanizing hours which have a huge weight in the final price
of the standardize items the hours can be reduced also.
Extra pieces
Standardized pieces
Thermal treatments
Mechanized and finishing
Other costs
+21% IVA
Total Mould Cost
resume
final cost is totally approximated and may change significantly depending on the
chanizing hours which have a huge weight in the final price
of the standardize items the hours can be reduced also.
Standardized pieces
Thermal treatments
Mechanized and finishing
Total Mould Cost
final cost is totally approximated and may change significantly depending on the
chanizing hours which have a huge weight in the final price
of the standardize items the hours can be reduced also.
250
1.558
600
Mechanized and finishing 12.000
1.230
3.284
18.922
final cost is totally approximated and may change significantly depending on the
chanizing hours which have a huge weight in the final price. Depending on the quality
250€
1.558€
600€
12.000€
1.230€
3.284€
18.922€
final cost is totally approximated and may change significantly depending on the
. Depending on the quality
44
. Depending on the quality
Expansible Injection Mould DesignBuch Cardona, Eloi
9.Conclusions
As it has been seen, breathing mould is a simple idea mould with a not so simp
application. The spring system may not be technically the best for testing but surely it is
the cheapest an
personalized simplifying things such as refrigeration, but in the end the price increase
would had been huge.
This project stopped in the design state defining (or
a mould designer have to do before beginning to produce any piece. Next step would be
buying all the normalized items and beginning to thermally treat and mechanize the ones
which need that.
Finally just a reminder of what this technology r
products can be improved and that begins with big investing companies such as the
automotive ones doing what this project is aimed to, testing new technologies and
bringing them to the industry first making profit of it b
other companies.
Expansible Injection Mould DesignBuch Cardona, Eloi
Conclusions
As it has been seen, breathing mould is a simple idea mould with a not so simp
application. The spring system may not be technically the best for testing but surely it is
the cheapest an
personalized simplifying things such as refrigeration, but in the end the price increase
would had been huge.
This project stopped in the design state defining (or
a mould designer have to do before beginning to produce any piece. Next step would be
buying all the normalized items and beginning to thermally treat and mechanize the ones
which need that.
Finally just a reminder of what this technology r
products can be improved and that begins with big investing companies such as the
automotive ones doing what this project is aimed to, testing new technologies and
bringing them to the industry first making profit of it b
other companies.
Expansible Injection Mould DesignBuch Cardona, Eloi
Conclusions
As it has been seen, breathing mould is a simple idea mould with a not so simp
application. The spring system may not be technically the best for testing but surely it is
the cheapest and assures good quality pieces. The project could had been completely
personalized simplifying things such as refrigeration, but in the end the price increase
would had been huge.
This project stopped in the design state defining (or
a mould designer have to do before beginning to produce any piece. Next step would be
buying all the normalized items and beginning to thermally treat and mechanize the ones
which need that.
Finally just a reminder of what this technology r
products can be improved and that begins with big investing companies such as the
automotive ones doing what this project is aimed to, testing new technologies and
bringing them to the industry first making profit of it b
other companies.
Expansible Injection Mould Design
Conclusions
As it has been seen, breathing mould is a simple idea mould with a not so simp
application. The spring system may not be technically the best for testing but surely it is
d assures good quality pieces. The project could had been completely
personalized simplifying things such as refrigeration, but in the end the price increase
This project stopped in the design state defining (or
a mould designer have to do before beginning to produce any piece. Next step would be
buying all the normalized items and beginning to thermally treat and mechanize the ones
Finally just a reminder of what this technology r
products can be improved and that begins with big investing companies such as the
automotive ones doing what this project is aimed to, testing new technologies and
bringing them to the industry first making profit of it b
As it has been seen, breathing mould is a simple idea mould with a not so simp
application. The spring system may not be technically the best for testing but surely it is
d assures good quality pieces. The project could had been completely
personalized simplifying things such as refrigeration, but in the end the price increase
This project stopped in the design state defining (or
a mould designer have to do before beginning to produce any piece. Next step would be
buying all the normalized items and beginning to thermally treat and mechanize the ones
Finally just a reminder of what this technology r
products can be improved and that begins with big investing companies such as the
automotive ones doing what this project is aimed to, testing new technologies and
bringing them to the industry first making profit of it b
As it has been seen, breathing mould is a simple idea mould with a not so simp
application. The spring system may not be technically the best for testing but surely it is
d assures good quality pieces. The project could had been completely
personalized simplifying things such as refrigeration, but in the end the price increase
This project stopped in the design state defining (or approximately defining)
a mould designer have to do before beginning to produce any piece. Next step would be
buying all the normalized items and beginning to thermally treat and mechanize the ones
Finally just a reminder of what this technology represents, a whole new spectrum of
products can be improved and that begins with big investing companies such as the
automotive ones doing what this project is aimed to, testing new technologies and
bringing them to the industry first making profit of it but inevitably spreading it
As it has been seen, breathing mould is a simple idea mould with a not so simp
application. The spring system may not be technically the best for testing but surely it is
d assures good quality pieces. The project could had been completely
personalized simplifying things such as refrigeration, but in the end the price increase
approximately defining)
a mould designer have to do before beginning to produce any piece. Next step would be
buying all the normalized items and beginning to thermally treat and mechanize the ones
epresents, a whole new spectrum of
products can be improved and that begins with big investing companies such as the
automotive ones doing what this project is aimed to, testing new technologies and
ut inevitably spreading it
As it has been seen, breathing mould is a simple idea mould with a not so simp
application. The spring system may not be technically the best for testing but surely it is
d assures good quality pieces. The project could had been completely
personalized simplifying things such as refrigeration, but in the end the price increase
approximately defining) all the things
a mould designer have to do before beginning to produce any piece. Next step would be
buying all the normalized items and beginning to thermally treat and mechanize the ones
epresents, a whole new spectrum of
products can be improved and that begins with big investing companies such as the
automotive ones doing what this project is aimed to, testing new technologies and
ut inevitably spreading it to the
45
As it has been seen, breathing mould is a simple idea mould with a not so simple
application. The spring system may not be technically the best for testing but surely it is
d assures good quality pieces. The project could had been completely
personalized simplifying things such as refrigeration, but in the end the price increase
all the things
a mould designer have to do before beginning to produce any piece. Next step would be
buying all the normalized items and beginning to thermally treat and mechanize the ones
epresents, a whole new spectrum of
products can be improved and that begins with big investing companies such as the
automotive ones doing what this project is aimed to, testing new technologies and
to the
Expansible Injection Mould DesignBuch Cardona, Eloi
Acknowledgements
I would like to specially thank to my project tutor Miguel Sánchez for being
comprehensive of my mistakes and for guiding
plastics
Also, of course, my family
And to my recent English teacher Nicky who I hope never reads this project or else I will
be degraded to a lower course.
Finally I would like to thank to all the other peopl
more external way but enough to make me think twice and improve what I was doing.
Expansible Injection Mould DesignBuch Cardona, Eloi
Acknowledgements
I would like to specially thank to my project tutor Miguel Sánchez for being
comprehensive of my mistakes and for guiding
plastics which I was rece
Also, of course, my family
And to my recent English teacher Nicky who I hope never reads this project or else I will
be degraded to a lower course.
Finally I would like to thank to all the other peopl
more external way but enough to make me think twice and improve what I was doing.
Expansible Injection Mould DesignBuch Cardona, Eloi
Acknowledgements
I would like to specially thank to my project tutor Miguel Sánchez for being
comprehensive of my mistakes and for guiding
which I was recently presented with.
Also, of course, my family that gave me support every moment.
And to my recent English teacher Nicky who I hope never reads this project or else I will
be degraded to a lower course.
Finally I would like to thank to all the other peopl
more external way but enough to make me think twice and improve what I was doing.
Expansible Injection Mould Design
Acknowledgements
I would like to specially thank to my project tutor Miguel Sánchez for being
comprehensive of my mistakes and for guiding
ntly presented with.
that gave me support every moment.
And to my recent English teacher Nicky who I hope never reads this project or else I will
be degraded to a lower course.
Finally I would like to thank to all the other peopl
more external way but enough to make me think twice and improve what I was doing.
Acknowledgements
I would like to specially thank to my project tutor Miguel Sánchez for being
comprehensive of my mistakes and for guiding and helping
ntly presented with.
that gave me support every moment.
And to my recent English teacher Nicky who I hope never reads this project or else I will
Finally I would like to thank to all the other people in CCP and friends that helped me in a
more external way but enough to make me think twice and improve what I was doing.
I would like to specially thank to my project tutor Miguel Sánchez for being
and helping me
that gave me support every moment.
And to my recent English teacher Nicky who I hope never reads this project or else I will
e in CCP and friends that helped me in a
more external way but enough to make me think twice and improve what I was doing.
I would like to specially thank to my project tutor Miguel Sánchez for being
me entering this world
that gave me support every moment.
And to my recent English teacher Nicky who I hope never reads this project or else I will
e in CCP and friends that helped me in a
more external way but enough to make me think twice and improve what I was doing.
I would like to specially thank to my project tutor Miguel Sánchez for being
this world of
And to my recent English teacher Nicky who I hope never reads this project or else I will
e in CCP and friends that helped me in a
more external way but enough to make me think twice and improve what I was doing.
46
of
And to my recent English teacher Nicky who I hope never reads this project or else I will
e in CCP and friends that helped me in a
more external way but enough to make me think twice and improve what I was doing.
Expansible Injection Mould DesignBuch Cardona, Eloi
Bibliography
References
GÓMEZ, J.F. (2013) Caracterización y estudio comparativo de materiales celulares poliméricos obtenidos mediante moldeo por inyección con espumación física o química.Doctoral Thesis. SPÖRRER, N.J. (2007) Controlling Morphology of Injection Molded Structural FoamsMold Design and Processing
Norms
Notes
Catalogs
Websites
TREXEL INC.
[Online]Available from:
http://www.trexel.com/en/mucell
[Accessed on 10th May]
Expansible Injection Mould DesignBuch Cardona, Eloi
Bibliography
References
GÓMEZ, J.F. (2013) Caracterización y estudio comparativo de materiales celulares iméricos obtenidos mediante moldeo por inyección con espumación física o química.
Doctoral Thesis.
SPÖRRER, N.J. (2007) Controlling Morphology of Injection Molded Structural FoamsMold Design and Processing
Norms
• [1]UNE
• [2] UNE
Notes
• The injection moulding machine / Miguel Sánchez
Catalogs
• HASCO catalog
Websites
TREXEL INC. MuCel
[Online]Available from:
http://www.trexel.com/en/mucell
[Accessed on 10th May]
Expansible Injection Mould DesignBuch Cardona, Eloi
Bibliography
GÓMEZ, J.F. (2013) Caracterización y estudio comparativo de materiales celulares iméricos obtenidos mediante moldeo por inyección con espumación física o química.
SPÖRRER, N.J. (2007) Controlling Morphology of Injection Molded Structural FoamsMold Design and Processing
[1]UNE-EN ISO 178 Pl
[2] UNE-EN ISO 527
The injection moulding machine / Miguel Sánchez
HASCO catalog
MuCell Molding Technology
[Online]Available from:
http://www.trexel.com/en/mucell
[Accessed on 10th May]
Expansible Injection Mould Design
Bibliography
GÓMEZ, J.F. (2013) Caracterización y estudio comparativo de materiales celulares iméricos obtenidos mediante moldeo por inyección con espumación física o química.
SPÖRRER, N.J. (2007) Controlling Morphology of Injection Molded Structural FoamsMold Design and Processing Parameters
EN ISO 178 Plastics.
EN ISO 527-2 Pl
The injection moulding machine / Miguel Sánchez
HASCO catalog
l Molding Technology
http://www.trexel.com/en/mucell-injection
GÓMEZ, J.F. (2013) Caracterización y estudio comparativo de materiales celulares iméricos obtenidos mediante moldeo por inyección con espumación física o química.
SPÖRRER, N.J. (2007) Controlling Morphology of Injection Molded Structural FoamsParameters. JOURNAL OF CELLULAR PLASTICS
stics. Determination of flexural properties
2 Plastics. Determination of tensile properties
The injection moulding machine / Miguel Sánchez
l Molding Technology
injection-molding
GÓMEZ, J.F. (2013) Caracterización y estudio comparativo de materiales celulares iméricos obtenidos mediante moldeo por inyección con espumación física o química.
SPÖRRER, N.J. (2007) Controlling Morphology of Injection Molded Structural FoamsJOURNAL OF CELLULAR PLASTICS
Determination of flexural properties
Determination of tensile properties
The injection moulding machine / Miguel Sánchez
molding
GÓMEZ, J.F. (2013) Caracterización y estudio comparativo de materiales celulares iméricos obtenidos mediante moldeo por inyección con espumación física o química.
SPÖRRER, N.J. (2007) Controlling Morphology of Injection Molded Structural FoamsJOURNAL OF CELLULAR PLASTICS
Determination of flexural properties
Determination of tensile properties
The injection moulding machine / Miguel Sánchez-Soto
GÓMEZ, J.F. (2013) Caracterización y estudio comparativo de materiales celulares iméricos obtenidos mediante moldeo por inyección con espumación física o química.
SPÖRRER, N.J. (2007) Controlling Morphology of Injection Molded Structural Foams by JOURNAL OF CELLULAR PLASTICS Vol. 43
Determination of flexural properties
Determination of tensile properties
47
iméricos obtenidos mediante moldeo por inyección con espumación física o química.
by
Expansible Injection Mould DesignBuch Cardona, Eloi
Extra: Ecological footprint
In this chapter it is determined the environmental impact associated to this project in
particular.
The CC
regarding final projects done in their installations.
In the beginning of a new PFG student, he is given a questionnaire where he has to fill with
the different activities which h
environmental surface impact.
Objectives:
Elec
1 KwH = 0,264 KG
Quan
Plac
Desk
Vario
TOT
Expansible Injection Mould DesignBuch Cardona, Eloi
Extra: Ecological footprint
In this chapter it is determined the environmental impact associated to this project in
particular.
The CCP has a system of environmental management which controls several parameters
regarding final projects done in their installations.
In the beginning of a new PFG student, he is given a questionnaire where he has to fill with
the different activities which h
environmental surface impact.
Objectives:
• Determine the environmental impact of each PFG done in CCP
• S
the implantation of the
ctrical co
1 KwH = 0,264 KG
ntity of CO2
ce Co
k Co
ous Lig
TAL ESTIMA
Expansible Injection Mould DesignBuch Cardona, Eloi
Extra: Ecological footprint
In this chapter it is determined the environmental impact associated to this project in
P has a system of environmental management which controls several parameters
regarding final projects done in their installations.
In the beginning of a new PFG student, he is given a questionnaire where he has to fill with
the different activities which h
environmental surface impact.
Determine the environmental impact of each PFG done in CCP
Sensitize the students regarding environmental impact of their project and
the implantation of the
onsume
1 KwH = 0,264 KG of CO2
2 absorbed p
oncept
omputer
ghts
ATED
Expansible Injection Mould Design
Extra: Ecological footprint
In this chapter it is determined the environmental impact associated to this project in
P has a system of environmental management which controls several parameters
regarding final projects done in their installations.
In the beginning of a new PFG student, he is given a questionnaire where he has to fill with
the different activities which have their energetic consumption and the equivalent in
environmental surface impact.
Determine the environmental impact of each PFG done in CCP
the students regarding environmental impact of their project and
the implantation of the environmental management system.
per hectare a
Extra: Ecological footprint
In this chapter it is determined the environmental impact associated to this project in
P has a system of environmental management which controls several parameters
regarding final projects done in their installations.
In the beginning of a new PFG student, he is given a questionnaire where he has to fill with
ave their energetic consumption and the equivalent in
Determine the environmental impact of each PFG done in CCP
the students regarding environmental impact of their project and
environmental management system.
and year= 4,58 Tn
Time in h
40
100
Extra: Ecological footprint
In this chapter it is determined the environmental impact associated to this project in
P has a system of environmental management which controls several parameters
In the beginning of a new PFG student, he is given a questionnaire where he has to fill with
ave their energetic consumption and the equivalent in
Determine the environmental impact of each PFG done in CCP
the students regarding environmental impact of their project and
environmental management system.
= 4,58 Tn of CO
Power in
11
0.1
Extra: Ecological footprint
In this chapter it is determined the environmental impact associated to this project in
P has a system of environmental management which controls several parameters
In the beginning of a new PFG student, he is given a questionnaire where he has to fill with
ave their energetic consumption and the equivalent in
Determine the environmental impact of each PFG done in CCP
the students regarding environmental impact of their project and
environmental management system.
CO2
n Kw Kwh
440
10
Kwh
450
In this chapter it is determined the environmental impact associated to this project in
P has a system of environmental management which controls several parameters
In the beginning of a new PFG student, he is given a questionnaire where he has to fill with
ave their energetic consumption and the equivalent in
Determine the environmental impact of each PFG done in CCP
the students regarding environmental impact of their project and
environmental management system.
Kg CO2
118.8
48
In this chapter it is determined the environmental impact associated to this project in
P has a system of environmental management which controls several parameters
In the beginning of a new PFG student, he is given a questionnaire where he has to fill with
ave their energetic consumption and the equivalent in
the students regarding environmental impact of their project and
Kg CO2 Hecta
0.026
ares
Expansible Injection Mould DesignBuch Cardona, Eloi
Mob
1 l of
1l of
Tran
Walk
Train
TOTAL ESTIMA
Fina
Envi
Elect
Mob
TOTAL ESTIMA
Expansible Injection Mould DesignBuch Cardona, Eloi
bility
f gasoline = 0
gasoline = 4
nsport
king
n
TOTAL ESTIMATE
al values
ironmental
ctrical consu
bility
TOTAL ESTIMAT
Expansible Injection Mould DesignBuch Cardona, Eloi
0,88 kg CO2
40MJ
Km.
15
3200
ED
s
l Aspect kg CO2/Pro
ume 11
25
TED 14
Expansible Injection Mould Design
2
MJ/Km.
0,16
0,35
kg CO2/Project
18.8
5.06
43.86
MJ
2.4
1120
ject
Equivalent
l of gas
0,48
28
MJ
1122.4
Hectares
0.026
0.0055
0.0315
Equivalent in
soline Kg CO2
0,4224
24.
Kg CO2
4 25.
Kg CO2
0,4224
.64
Kg CO2
.06
49
Hectares
0.0055
2 13
11
67 5 4
8
9
10
22
20
19
18
16
17
21
2324
14
15
12
13
Mould assembly Est.sup.UNE 1037/Tol.gral.ISO 2778-K/Tol.geom.ISO 2778-m
Calificación:Fecha:Escala:
A1
Código plano:
Denominación plano:
Denominación proyecto:Escola d'Enginyeria de Terrassa - E E T Expansible Injection Mould
Design
a1 1 : 2 16/05/15
Buch Cardona, Eloi
396
76
105
23
246
64,2
84,
9
79,
1
102,6
19,
8
G
G
38 H7
18 H7
1x4
5º
3x4
5º
4,1
21,
1
27
15,5
20
14
30
15,8 13,2
M8
SECTION G-G
N6
20,
4
M8
15
1. ( )
Mechanization-Hole for the nozzle-Threads for subjecting-Housing stopper
N8 N6
Buch Cardona, Eloi
16/05/151 : 2p1
Expansible Injection Mould Design
Escola d'Enginyeria de Terrassa - E E TDenominación proyecto:
Denominación plano:
Código plano:
A3
Escala: Fecha: Calificación:
Est.sup.UNE 1037/Tol.gral.ISO 2778-K/Tol.geom.ISO 2778-mPlate 1SolidWorks Student Edition. For Academic Use Only.
296
246
85,5
121
,5
26
55
23
H
H
36
36
30
6,3
22,
1 18 M12
17,
6
SECTION H-H
2.
Mecanization-Hole for the nozzle
N8
Est.sup.UNE 1037/Tol.gral.ISO 2778-K/Tol.geom.ISO 2778-m
Calificación:Fecha:Escala:
A3
Código plano:
Denominación plano:
Denominación proyecto:
Escola d'Enginyeria de Terrassa - E E T Expansible Injection Mould Design
p2 1 : 2 16/05/15
Buch Cardona, Eloi
Plate 2SolidWorks Student Edition. For Academic Use Only.
130
72,
6
152
,6
70
226
70
106
70
166
60
192
,6
128
,6
125
80
70
8x4
5º
29
40
81,
5
81,5
I
I
N8 N6
N6
M10 2
5
30
16
10
8
36 10,2
29,
7
SECTION I-ISCALE 1 : 2
N6 N6
3. ( ) Refrigeration view
Mechanization-Piece shape through-Spring housing-Refrigeration drills
Plate 3 Est.sup.UNE 1037/Tol.gral.ISO 2778-K/Tol.geom.ISO 2778-m
Calificación:Fecha:Escala:
A2
Código plano:
Denominación plano:
Denominación proyecto:Escola d'Enginyeria de Terrassa - E E T Expansible Injection Mould
Design
p3 1 : 2 16/05/15
Buch Cardona, Eloi
SolidWorks Student Edition. For Academic Use Only.
296
246
125
29
8x4
5º
81,
50
81,50
128
,61
70
40
A
A
N6
N6
25
75
26
23
55
75
25
52 119
126
3
3
74
37
100
1
50
181,50
18
51
100,04 122,55
112,55
30
14 4
30
10
20 36 5
7 70
SECTION A-AN
6
4. ( ) Refrigeration view
Mechanization complete-Mechanize inner protuberance-Drill guider holes-Drill screw threads-Drill ejectors path-Drill refrigeration-Drill spring housing
N8
Plate 4 Est.sup.UNE 1037/Tol.gral.ISO 2778-K/Tol.geom.ISO 2778-m
Calificación:Fecha:Escala:
A1
Código plano:
Denominación plano:
Denominación proyecto:Escola d'Enginyeria de Terrassa - E E T Expansible Injection Mould
Design
p4 1 : 2 16/05/15
Buch Cardona, Eloi
119
74
37
84,5
43,
5 6
,9
28,
9 52
33
14
296
158
126
I
I 1
2
6,8
4 H7
8 9
3
SECTION I-I
N6
5. ( )
Mechanization-Ejector pins housing
N6N8
Plate 5 Est.sup.UNE 1037/Tol.gral.ISO 2778-K/Tol.geom.ISO 2778-m
Calificación:Fecha:Escala:
A3
Código plano:
Denominación plano:
Denominación proyecto:Escola d'Enginyeria de Terrassa - E E T Expansible Injection Mould
Design
p5 1 : 2 16/05/15
Buch Cardona, Eloi
SolidWorks Student Edition. For Academic Use Only.
296
158
16
33
14
210,5
H
H
11 1
1
11 3,3
15 9
17
M14
9,3
SECTION H-H
6.
Mechanization-Expulsion rod thread
N8
Plate 6 Est.sup.UNE 1037/Tol.gral.ISO 2778-K/Tol.geom.ISO 2778-m
Calificación:Fecha:Escala:
A3
Código plano:
Denominación plano:
Denominación proyecto:Escola d'Enginyeria de Terrassa - E E T Expansible Injection Mould
Design
p6 1 : 2 16/05/15
Buch Cardona, Eloi
SolidWorks Student Edition. For Academic Use Only.
76
105
23
246
396
H
H
90 4
20
14
30
27
15,
5 135,5
SECTION H-H
7.
Mechanization-Space for theinstallationand acting of the ejection rod
N8
Plate 7 Est.sup.UNE 1037/Tol.gral.ISO 2778-K/Tol.geom.ISO 2778-m
Calificación:Fecha:Escala:
A3
Código plano:
Denominación plano:
Denominación proyecto:Escola d'Enginyeria de Terrassa - E E T Expansible Injection Mould
Design
p7 1 : 2 16/05/15
Buch Cardona, Eloi
SolidWorks Student Edition. For Academic Use Only.
Expansible Injection Mould Design
Expansible Injection Mould Design
Part 2 Budget
Autor: Eloi Buch Cardona
Director: Miguel Sánchez
2014-2015
Expansible Injection Mould Design
Autor: Eloi Buch Cardona
Director: Miguel Sánchez-Soto
Expansible Injection Mould Design
Buch Cardona, Eloi
Index
Standardized pieces...........................................................................3
Extra pieces.......................................................................................4
Mechanization..................................................................................5
Thermal treatments..........................................
Other costs.......................................................................................7
Final budget.....................................................................................8
Expansible Injection Mould Design
Standardized pieces...........................................................................3
a pieces.......................................................................................4
Mechanization..................................................................................5
Thermal treatments..................................................................
Other costs.......................................................................................7
Final budget.....................................................................................8
2
Standardized pieces...........................................................................3
a pieces.......................................................................................4
Mechanization..................................................................................5
.........6
Other costs.......................................................................................7
Final budget.....................................................................................8
Expansible Injection Mould Design
Buch Cardona, Eloi
Standardized pieces
Usually in moulds some standardized pieces are used such as guides, screws, retainers
and so, but other items like plates are often fully personalized to have a bigger
freedom to design their own mould. That also increases the price so in this case if
possible it has been taken the maximum standardized pieces by the fact that the
mould is not being designed t
the standard elements are enough for what is wanted.
Name
Centering disk
Allen screw
Spring washer with detent
Allen screw
Stop washer
Spring washer with retent
Countersunk screw
Allen screw
Centering bush
Bushing guide
Column guide
Refrigeration male nozzle
Threaded plug
Ejector
Spring
Transport flange
Limiter screw
Nozzle
Plate1
Plate2
Plate3
Plate5
Plate6
Plate7
Expansible Injection Mould Design
Standardized pieces
Usually in moulds some standardized pieces are used such as guides, screws, retainers
tems like plates are often fully personalized to have a bigger
freedom to design their own mould. That also increases the price so in this case if
possible it has been taken the maximum standardized pieces by the fact that the
being designed to produce many pieces and the lower quality
the standard elements are enough for what is wanted.
Code/Size Price/u(€) Qty,
K100 - 125x8 25,25 1
Z31 - 12x120 2,11 4
Spring washer with detent Z691 - 12x5 0,13 8
Z31 - 12x30 0,52 4
Z55 - 18x3 0,62 4
Spring washer with retent Z691 - 12x2 0,13 4
Z33 - 4x8 0,25 4
Z31 - 8x16 0,22 4
Z20 - 30x100 6,44 4
Z10 - 36 - 24 12,62 4
Z00 - 36 - 24x55 17,1 4
Refrigeration male nozzle Z87 0,76 8
Z94 0,3 7
Z40 - 4x100 2,83 7
Z60 - 25x30 18,5 4
Z70 209,73 1
Z38 - 16x30 5,69 4
Z51 - 18x27 36,46 1
K12-246x296x27 173,03 1
K20-246x296x36 114,23 1
K20-246x296x36 114,23 1
K70-246x296x17 80,47 1
K12-246x296x17 173,03 2
K12-246x296x27 173,03 1
TOTAL
3
Usually in moulds some standardized pieces are used such as guides, screws, retainers
tems like plates are often fully personalized to have a bigger
freedom to design their own mould. That also increases the price so in this case if
possible it has been taken the maximum standardized pieces by the fact that the
quality provided by
Price(€)
25
8
1
2
2
1
1
1
26
50
68
6
2
20
74
210
23
36
173
114
114
80
346
173
TOTAL 1.558€
Expansible Injection Mould Design
Buch Cardona, Eloi
Extra pieces
In this mould the only customized piece is the Plate4 which have a huge protuberance in the
middle and any standard item have enough d
piece would also had been possible to produce with a standardized plate with a thin housing
for a steel block that would be bounded by screws in the bottom of the plate.
A regular 1.1730 steel is used taking the other plates as similars. The price includes the exterior
sizing.
In this case the decision of taking standardized elements really reduces the final price although
some design changes have to be done in terms of piece position, refrigeration and spring
position for example.
Name Code/Size
Plate4 block 246x296x70
Expansible Injection Mould Design
Extra pieces
In this mould the only customized piece is the Plate4 which have a huge protuberance in the
middle and any standard item have enough dimensions to take it and then mechanizing it. The
piece would also had been possible to produce with a standardized plate with a thin housing
for a steel block that would be bounded by screws in the bottom of the plate.
A regular 1.1730 steel is used taking the other plates as similars. The price includes the exterior
In this case the decision of taking standardized elements really reduces the final price although
esign changes have to be done in terms of piece position, refrigeration and spring
Code/Size Price/u(€) Qty, Price(€)
246x296x70 250 1 250
4
In this mould the only customized piece is the Plate4 which have a huge protuberance in the
imensions to take it and then mechanizing it. The
piece would also had been possible to produce with a standardized plate with a thin housing
for a steel block that would be bounded by screws in the bottom of the plate.
A regular 1.1730 steel is used taking the other plates as similars. The price includes the exterior
In this case the decision of taking standardized elements really reduces the final price although
esign changes have to be done in terms of piece position, refrigeration and spring
Expansible Injection Mould Design
Buch Cardona, Eloi
Mechanization
Although most pieces are directly taken from catalogs with standardized models, only with
them is not enough. Pieces such as guides and
Standardized plates have only the guidance and thread holes and lets the design up to you. For
that, mould plates need to be mechanized.
The mechanization processes needed are:
-Milling. The main way to achieve th
different roughnesses helps achieving both low time and good finishing for the piece
-Drilling. Way to obtain the round shapes through the pieces
-Grinding. It is important for a mould to fit perfectly to prod
quality pieces as well as for its health.
The non standardized piece (Plate 4
until there is little thickness left to take out, then a finishing rough and finally grinding it.
The approximate number of hours working in Plate 4 are
The approximate number of hours working in the standardized elements including plates are
200h.
Workshop cost per hour is 40
The amount in hours is appro
as tolerances. Pieces entering
changes that increase the fina
Expansible Injection Mould Design
Mechanization
Although most pieces are directly taken from catalogs with standardized models, only with
them is not enough. Pieces such as guides and screws don't need changes but plates do.
Standardized plates have only the guidance and thread holes and lets the design up to you. For
that, mould plates need to be mechanized.
The mechanization processes needed are:
Milling. The main way to achieve the shapes wanted in the piece. Cutting off in
different roughnesses helps achieving both low time and good finishing for the piece
Drilling. Way to obtain the round shapes through the pieces
Grinding. It is important for a mould to fit perfectly to produce regular and good
quality pieces as well as for its health.
(Plate 4) which have to be mechanized completely, first roughing
until there is little thickness left to take out, then a finishing rough and finally grinding it.
approximate number of hours working in Plate 4 are 100h.
The approximate number of hours working in the standardized elements including plates are
40€
oximate and depend on the final finishing wanted
g or being entered need special care and that req
al hour amount.
TOTAL COST OF MECHAN
5
Although most pieces are directly taken from catalogs with standardized models, only with
screws don't need changes but plates do.
Standardized plates have only the guidance and thread holes and lets the design up to you. For
e shapes wanted in the piece. Cutting off in
different roughnesses helps achieving both low time and good finishing for the piece
uce regular and good
) which have to be mechanized completely, first roughing
until there is little thickness left to take out, then a finishing rough and finally grinding it.
The approximate number of hours working in the standardized elements including plates are
d in pieces as well
quires several tool
NIZATION: 12000€
Expansible Injection Mould Design
Buch Cardona, Eloi
Thermal treatments
For the thermal treatment there are basically two
-Quench and temperate. It consists in hardening the piece and then releasing the
tension the first treatment provoked. The result is a harder steel than the one in the beginning
with good ductile properties. Is done basical
without degrading excessively by its use. The final hardness is measured by Rc (Rockwell
hardness). Higher values are needed in pieces that slide to minimize friction degradation such
as Plate 3 and 4, but being careful not to harden it too much to prevent brittle behaviors of the
pieces.
-Nitriding. It consists in a superficial treatment that deposits nitrides in the very first
layers of material in the surface preventing them from the harm of friction. That i
at the parts that move guided such as ejection pins or column guiders.
Depending on where normalized pieces bought those thermal treatments may be already
done but depending on the situation a different treatment would be needed anyway
mould singularities.
Nitriding the mobile parts have an approximate cost of 200
Quenching and tempering all the plates have an approximate cost of 400
Expansible Injection Mould Design
Thermal treatments
For the thermal treatment there are basically two types to be taken in account:
Quench and temperate. It consists in hardening the piece and then releasing the
tension the first treatment provoked. The result is a harder steel than the one in the beginning
with good ductile properties. Is done basically in the structural pieces to make them last
without degrading excessively by its use. The final hardness is measured by Rc (Rockwell
hardness). Higher values are needed in pieces that slide to minimize friction degradation such
g careful not to harden it too much to prevent brittle behaviors of the
Nitriding. It consists in a superficial treatment that deposits nitrides in the very first
layers of material in the surface preventing them from the harm of friction. That i
at the parts that move guided such as ejection pins or column guiders.
Depending on where normalized pieces bought those thermal treatments may be already
done but depending on the situation a different treatment would be needed anyway
Nitriding the mobile parts have an approximate cost of 200€.
Quenching and tempering all the plates have an approximate cost of 400€
TOTAL COST OF THERMAL TREATMENTS: 600
6
types to be taken in account:
Quench and temperate. It consists in hardening the piece and then releasing the
tension the first treatment provoked. The result is a harder steel than the one in the beginning
ly in the structural pieces to make them last
without degrading excessively by its use. The final hardness is measured by Rc (Rockwell
hardness). Higher values are needed in pieces that slide to minimize friction degradation such
g careful not to harden it too much to prevent brittle behaviors of the
Nitriding. It consists in a superficial treatment that deposits nitrides in the very first
layers of material in the surface preventing them from the harm of friction. That is why is done
Depending on where normalized pieces bought those thermal treatments may be already
done but depending on the situation a different treatment would be needed anyway due to
TOTAL COST OF THERMAL TREATMENTS: 600€
Expansible Injection Mould Design
Buch Cardona, Eloi
Other costs
In extra costs there are design
In design, combining the mod
related to the production pre
With the technical office base
Transporting and mounting th
Expansible Injection Mould Design
n and mounting.
del design, 3D CAD development, CAD-CAM evalu
evious work, the amount of hours dedicated are 3
e pay of 30€ per hour it makes a total of 1050€
he mould is set at 6h at a price of 30€ makes a to
TOTAL COST OF DESIGN AN
7
uation and work
35h.
otal of 180€
ND MOUNT: 1230€
Expansible Injection Mould Design
Buch Cardona, Eloi
Final Budget
Extra pieces
Standardized pieces
Thermal treatments
Mechanized and finishing
Other
+21% IVA
Total Mould Cost
The final cost is totally ap
mechanizing hours which hav
standardize items the hours c
Expansible Injection Mould Design
Final Budget
Extra pieces 250€
Standardized pieces 1.558€
Thermal treatments 600€
Mechanized and finishing 12.000€
costs 1.230€
+21% IVA 3.284€
Total Mould Cost 18.922€
pproximated and may change significantly de
ve a huge weight in the final price. Depending on
can be reduced also.
8
epending on the
n the quality of the