ME3263E/TME3263

DESIGN FOR MANUFACTURING & ASSEMBLY

A/P Lee Kim Seng

Deputy Head (Outreach) Mech
Mechanical Engg Dept.
National Univ. of S’pore
Room: EA 04-17
Tel: 6516 2574
mpeleeks@nus.edu.sg

Homepage:
http://courses.nus.edu.sg/
course/mpeleeks/personal
/index.htm
 ME3263E
DESIGN FOR MANUFACTURING & ASSEMBLY
http://courses.nus.edu.sg/course/mpeleeks/personal/Injection%20Mould%20e_Learning/E-Training.html/index.html

http://courses.nus.edu.sg/course/mpeleeks/personal/ME3263%20eBook/index.html
TYPICAL APPLICATIONS

Plastic Injection
Moulding

A/P Lee Kim Seng

Features of Injection Molded Plastic Part

A/P Lee Kim Seng

Examples Injection Molded Plastic Part
 Injection Molding

Injection molding technology is a method of

processing predominantly used for thermoplastic
polymers.
It consists of heating thermoplastic material until
it melts, then forcing this into melted plastic into
a steel mold, where it cools and solidifies.
The increasing sophisticated use of injection
molding is one of the principal tools in the battle
to produce elegant product structures with
reduced part counts.

A/P Lee Kim Seng

 Injection Molding

In order to exploit the versatility of injection

molding technology for economical
manufacture, it is necessary to understand
the basic mechanisms of the process and
related aspects of the molding equipment
and materials used.

A/P Lee Kim Seng

A TYPICAL INJECTION MOULDING SYSTEM
Clamping Mould Injection Unit Dryer
unit
Controller

Chiller

Chiller : Heat Exchanger

Pump

Outlet Inlet
Manifold Manifold
Mould
 Plastic molding processes
Clamping Mould Injection Unit Dryer
unit
Controller

Chiller

Injection molding

Blow molding

Insert molding

Rotational molding

Vacuum forming
Other types of plastic molding processes
Clamping Mould Injection Unit Dryer
unit
Controller

Chiller

Stretch blow molding

Gas injection molding

Plastic dip coating

Expanded PS molding

Extrusion Blow Molding

A TYPICAL INJECTION MOULDING SYSTEM
A TYPICAL INJECTION MOULDING SYSTEM
 Basic Phases in Injection Moulding
1. Mould closes. Screw moves forward 2. Filling Completes. Screw continues moving
for injection. forward for packing.

3. Screw in full forward position. Packing

completes. 4. Cooling and Plasticising.

5. Cooling completes. Mould opens for Moulding Sequence

part ejection.  Mould Closes
 1st Stage Filling
 2nd Stage Packing
 Cooling and Plasticising
 Mold Opens
 Part Ejected.
 Injection Moulding Cycle

1. 1st Stage Filling

2. 2nd Stage Packing
A. Remaining Cushion
3. Cooling
B. Holding Pressure Volume
4. Mould Opens
C. Injection Volume
5. Part Ejected
D. Decompression
6. Mould Closes
 Injection Molding Operations
 Fountain Effect Flow
 Hot resin flow from the middle of the flow channel to the walls and
cools
 Pressure Curves
 (1) Hydraulic Pressure
 (2) Injection Pressure (Pressure in front of screw)
 (3) Pressure in Gate
 (4) Pressure near Gate
 (5) Pressure far from Gate

(5) (4) (3) (2) (1)

 Basic characteristics of a Cavity Pressure Curve

 Start Injection
 Melt reaches sensor position
4
 Cavity is volumetrically filled (Switch
5 Over)
 Peak Cavity Pressure 4~5 The volume
change due to cooling of the melt is
compensated by additional melt pressed
3 into the cavity.
6  Freezing point at the gate.
1 2
 Atmospheric pressure.
Optimised Process Conditions

Optimised
Process
Conditions
 CAD CAM

Product Mould Design Mould

Design Manufacturing

Material CAE IPC

A SINGLE CAVITY MOULD TWO CAVITIES MOULD

Mould Base
INJECTION MOULDS
Mold Layout
 Continuing a mold
Designing a mold for design for an
a new project existing project

Data Preparation Data

•Load Part Preparation
•IMOLD CSYS •Load Assembly
•Scale Factor
•Containing Box

Proceeding on
with where you
Filling Module have left off
•Layout
•Gate Design
•Runner Design

Mold Base Parting

•Choose Type •Parting Line

•Enter size •Insert Creation

Hot Runner Design

•Manifold Selection
•Manifold Design
•Nozzle Design
•Gate Design

Ejector Design
•Design Ejection
Slider Design •Edit Ejection

Lifter Design Standard

Library

IMOLD Electrode
Cooling Design
Design
 Runner System
 Several types of runners
 single part runner
 multiple part runner
• symmetrical runner
• non-symetrical runner
 runner-less designs with hot
manifolds
 Sprue Guidelines
 The sprue must not freeze before any other cross section. This is
necessary to permit sufficient transmission of holding pressure.
 The sprue must de-mold easily and reliably.

Dco ≥ tmax + 1.5 mm

Ds ≥ Dn + 1.0 mm
α ≥ 1º - 2º
tan α = Dco - Ds / 2L
Sprue
 Runner Guidelines
 Common runners
 Full-round runner
 Trapezoidal runner
 Modified trapezoidal runner (a combination of
round and trapezoidal runner)
 Half-round runner
 Rectangular runner
Gate System

Submarine Tunnel Gate Fan Gate

Gate

Pinpoint Gate Side Gate Sprue Gate

Different type of gates available

Gates & Runners

Standard
gate
position

Standard
gate
position

Standard gate
position
Standard gate positions

A/P Lee Kim Seng

Gates & Runners

A/P Lee Kim Seng

 Where would you put the
Gating for the part shown ?
 Hot Runner System
 The ideal injection molding system delivers molded parts of uniform density, and free from all
runners, flash, and gate stubs.
 To achieve this, a hot runner system, in contrast to a cold runner system, is employed. The
material in the hot runners is maintained in a molten state and is not ejected with the molded
part. Hot runner systems are also referred to as hot-manifold systems, or runnerless molding.

FIGURE 1. Hot runner system types: (a) the insulated hot runner, (b) the internally
heated hot-runner system, and (c) the externally heated hot-runner system
Cam Operated Sliders

Finger Cam Pin

A/P Lee Kim Seng

Hydraulic Operated Sliders

A/P Lee Kim Seng

Slider

Ejector
Pin

A/P Lee Kim Seng

Type #1 Type #2

Type #3 Type #4

Type #5
Ejector Pin

A/P Lee Kim Seng

Lifter

A/P Lee Kim Seng

E_Learning

Ref:
Application of Multimedia and
Internet Technology in
e_Learning of Industrial
Design.
Dr Shum SP, Simon
IMCC 2002, Xiamen China

http://us.share.geocities.com/chanwingkin1981/project.swf

A/P Lee Kim Seng

Multi Colours Moulding
Thank You

A/P Lee Kim Seng