MOLD DESIGN FUNDAMENTAL CALCULATION

Product

BATTERY COVER

Code of Project

MOT-009-NKD

Machine Clamping Force (Fc)

Formula

: Fc = P x A / 0.8
A
P
0.8
Fc

: Total Projection Area of product and runner (cm2)

: Average Pressure inside cavity (kgf/cm2)
: Safety Ratio
: Injection Machine Clamping Force (kgf)

140
260 >>see Table 1
0.8
50050
MINIMUM = 50 T

Table 1. Injection Pressure

Name of Plastic Resin
Poly Ethylene (PE)
Poly Propylene (PP)
Poly Styrene (PS)
Poly Carbonate (PC)
Acrylonitrile Butadine Styrene
(ABS)
Poly Amide (PA)
2

180~130
200~300
180~315
280~320

Injection Pressure
(kgf/cm2)
600~1400
600~1400
700~1700
800~1500

Pressure Inside Cav.

(kgf/cm2)
230~320
220~320
260~320
270~300

200~280

700~1500

330~440

230~300

800~1500

240~450

Resin Temp (C)

Injection Volume
Total Product Volume (cm3)
Ideal Injection Volume of Machine (cm3)

Gate Dimension
Table 2. Flow Coeficient
High Flow
Middle Flow
n=0.6
n=0.7
PS
POM
PP
PBT
PE
PA
AS
ABS

32
45.7

Low Flow
n=0.8
PA
PVC
PMMA

A. Side Gate Dimension

Formula

: h=nxt
w = n x A / 30
n
t
V
A
h

: Flow coeficient
: Product thickness (mm)
: Product volume (mm3)
: V/t
: Height of gate (mm)

0.6 >>see Table 2

2.2
16047
7294.091
1.32

w
4

: Width of gate (mm)

1.708109

Mold Base Dimension

A. Pressure Plate Thickness (B)

Formula

B=

5 x P x L x M^4

32 x E x L2 x Ymax1

P
L
n
M
E
Ymax1
L2
B

: Injection Pressure Inside Cavity (kgf/cm2)

: Article Size (mm)
: Number of Support Pillar Position
: Distance between Spacer Blocks (mm)
: Young Modulus of Elasticity (kgf/cm2)
: Deflection of Plate (mm)
: Mold Move Length (mm)
: Pressure Plate Thickness (mm)

280 >>see Table 1

170
4
264
2100000
0.01
250
22.24681

B. Wall Thickness (D)

Formula

P
A
L
E
B2
Ymax2
D1
Formula

P x A x L^4

32 x E x B2 x Ymax2

D1 =

: Injection Pressure Inside Cavity (kgf/cm2)

: Wall Depth (mm)
: Article Size (mm)
: Young Modulus of Elasticity (kgf/cm2)
: Mold Plate Thickness (mm)
: Deflection of Wall (mm)
: Wall thickness (mm)

280 >>see Table 1

15
170
2100000
60
0.05
25.91303

C x P x A^4

3 E x Ymax2

D2 =

P
A
L
L/A
C
E
Ymax2
D2

: Injection Pressure Inside Cavity (kgf/cm2)

: Wall Depth (mm)
: Article Size (mm)
: Depth Ratio
: Depth Coeficient
: Young Modulus of Elasticity (kgf/cm2)
: Deflection of Wall (mm)
: Wall Thickness (mm)

280 >>see Table 1

15
170
11.33333
0.1 >>see Table 3
2100000
0.05
2.381102

Table 3. Depth Coeficient

L/A
C
L/A
1.0
0.044
1.7
1.1
0.053
1.8
1.2
0.062
1.9
1.3
0.070
2.0
1.4
0.078
3.0
1.5
0.084
4.0
1.6
0.090
5.0
5

Spring Force for Ejector Plate (Fs1)

Formula

Fs1 =

Wxv
n

h1
h2
w
l
W
v
n
s
Fs1
k

: Thickness of Ejector Plate 1 (mm)

: Thickness of Ejector Plate 2 (mm)
: Width of Ejector Plate (mm)
: Length of Ejector Plate (mm)
: Weight of Ejector Plate (kgf)
: Safety factor
: Number of Spring
: Spring initial deflection
: Minimum Spring Force (kgf)
: Minimum Spring Constant (kgf/mm)

25
30
260
450
50.193
1.4
4
10
17.56755
1.756755

Spring Force for Slide Core (Fs2)

Formula

C
0.096
0.102
0.106
0.111
0.134
0.140
0.142

Fs2 =

Wxv
n

W
v
n
s1
Fs2
k

: Weight of Slide Core (kgf)

: Safety factor
: Number of Spring
: Spring Initial Deflection (mm)
: Minimum Spring Force (kgf)
: Minimum Spring Constant (kgf/mm)

2.842
2
1
5
5.684
1.1368

Finger Pin Diameter (Da)

Formula

Da =
k
s2

k x s2 x cos x L
(Tb/v) x
: Spring constant (kgf/mm)
: Spring final deflection (mm)

1.1368
15


L
Tb
v
Da

: Finger pin angle

: Free length of finger pin (mm)
: Bending stress of finger pin material (kgf/mm2)
: Safety factor
: Finger pin diameter (mm)

Core Pulling Distance

S = H x Tan +2~3

H=

6.74

H = Lenght required for slider(mm)

S=

13.1385

= Dip Angle Pin

15
80
120
4
#VALUE!

Length Angular pin

L = S/COS

-8.872064

MINIMUM = 50 TON

ADP-PLT-1
SUP-PLT
MLD-STA
MLD-MOV
SPC-BLC
EJC-PLT-1
EJC-PLT-2
ADP-PLT-2

Panjang (mm)
1000
1000
1000
1000
1000
1000
1000
1000

Lebar (mm)

Tebal (mm)
600
450
450
450
150
246
246
600

45
79.8
140
170
100
30
35
45

Volume (mm)
27000000
35910000
63000000
76500000
15000000
7380000
8610000
27000000

Berat (kg)
Berat (Ton)
210.6
0.2106
280.098
0.280098
491.4
0.4914
596.7
0.5967
117
0.117
57.564
0.057564
67.158
0.067158
210.6
0.2106
2.03112