Tool Design 3 PDF

INSTITUT T E K N :) LOG BAN 0 U N G
BANDUNG NSTITUTF UF TECHNOLOGY
PROYEK POLYTEt<".NIK MEKANIK SWISS

SWISS PROJECT ON POL
---------------------------
VT E HN I C
C FOR MECHANICS
JlN.IR.H.JUANDA (KPL.KANA'fAKAN' TROMOl POS 70 PHONE 8208' 6ANOUNG INDONESIA
94 - 1
tool design
A PROJECT OF THE SWISS TECHNICAL COOPERATION
AND SWISSCONTACT. THE SWISS FOUNDATION
SWISSCONTACT FOR TECHNICAL ASSISTANCE. Z(JAICH

INSTITUT TEKNOLOGI BAN 0 U N G
RANDUNG INSTITUTE OF TECHNOLOGY
PROYEK POLYTEKNIK MEKANIK SWISS

SWISS PROJECT ON POLYTECHNIC FOR MECHANICS
JLN IA H JU"NOA (I(PL.I<"N ....
V...I(AN) TROMOL PO::; TO PHONE 112061 BANOUNG INOONES,'"
94 - 2
Compiled by H.R. Luchsinger
CONTENT
Page
Inj2ction moulding 3
Cavity and punch 4
Runrie r s 9
14
Patting lines 25
Ej ecti on 29
Ejector Return mechanism 45
UndO"r:::uts 50
Mou1:~~g of internal threaded compon~nts 63
Mo'J~:::cco l i ng 71
Thre~ plate moulds 80
Tool location 89
Mould Ventilation 94
In case of difficulties ... 94
And f i nal1y ... 97
Steel qualities required for injection moulds 98
Thennop 1as tics 99
Raw - rnat e r i a l sources of thennoplastics 107
~10u1d Layou t 1 oa
Gener~l Calculations 109
Gates 11 U
Mould Ventilation 111
r·1ould Cool inq 112
Ejector Systems llJ
Taper Formtool Location 114
Edition April 1982

This book is by no rnea n s to be copied and to b e s o ld without w r i t t en
p,ermisSion from Polyteknik r1ekanik Swiss-ITI3
t{
POUTEKNIK MEKANIK TOOL DESIGN 3 I 94 - 3
SWISS· ITB
3. INJECTION MOULDING ( General .)
If we observe some typical parts produced by injection

moulding we shall find certain common points in almost
all parts.
(a) More or less uniform wall thickness

(b) A point or small area indicating that an extension
of the part has been cut or broken (Gate/Runner)
(c) Some small round or rectangular marks (absent in
some cases) generally in the same plane or paral-
lel planes. (Ejectors)
(dl A thin hair line around the moulding (Par~ing line)
(e) Tlie material of these parts is popularly known 'as
"Plastics" (Technically in general as 'I'rie
rrnopLaa-:
tics, in few cases also Duroplastics and Elasto-
mers) .
"Alloys" (in general Aluminium and Zinc alloys)
This observations we shall discuss side by side when we

stu~~- about Injection Moulds (for thermoplastics only,
fros ~ow on often simply called 'plastic').
An injection mould is a tool for producing plastics

components in unison with an injection moulding machine.
Here we shall discuss in very brief about ~he basic
construction of an injection mould and its function in
connection with a moulding machine.
Form No. 4.00.3

rULII1:I\N.,\ MtKANIK IUUL Ut~lGN J , 94 - 4
SWISS - ITB
As it is clear form the name of the tool that it ~on-

sists basically of a solid block with a cavity of the
required shape and a provision to inject molten plas-
tic into it. This block is further made in basically
two parts with a provision of opening to allow the
removal of moulded component and then closing, thus
being ready for moulding the next component and so on.
Figure 3-001 shows a systemic diagram of a mould, a

moulding machine and their combined function for pro-
du~ing plastics components.
Now once the basic construction and function of an in-
je~~ion mould is understood we can study the diffcren~
rna.i,n
parts of a mould and their function (figure 3··002)
Before we move to that, a short explanation about

Shrinkage. The plastic is injected as heated and some-
how ,fluid material. While cooling down, its volume
decreases. This we call shrinkage (it shrinks'. The
sr-~=':_lkage
is expressed in percentage. Say, the shrink-
a~e of a certain type of Thermoplastic is 1% and we
want the length of the component to be 100 mm, the
length of the cavity has to be 101 mm. Usually we have
to deal with shrinkage-values of between 0.5 to 1.5%.
The Shrinkage is the reason why we find on tool drawings
often odd dimensions, very seldom they finish as 30.00
but rather as 30.18 (0.6% shrinkage assumed) etc.
3.1. Cavity and punch
A cavity in a mould is~the hollow space (female part)

to accommodate the molten plastics injected under
pressure into it. It determines the outer shape of the
component and is located mostly on the injection side
(fixed side). For very simple components we couid 00
away with a cavity_only. Say we want to mould a round
cylinder dia 30, .thickness 5.
POllTEXNIK MEKA"'IK TOOL DESIGN 3 94 - 5
SWISS - ITB
Injection Moulding Process 3 - 001
Moving pla_!:._ten Plastic granules in hopper

In ection piston
Pressure from hydraulic pump

side ready to move towards the
Injection Zylinder
is pressed
towards the
Mould
-iIIII!!S
Pressure from hydro pump stops

before the Injection Zylinder
moves back &nd the scrp-w starts
to rotate.
cooling down/afterwards Screw starts to
next part ).
Injection Zylinder
is mouving back-·---- ....
wards material
brake s '\~i%~~E~~~=========3-
due to
oil is reservoir
C~oling ~ime is over/Injection side moves back/completes dosing operation/

Cl..aupingside opens the mould/Part is ejected/Mould closes again-and is ready for
the next shot.
Form. No.4 .003

I UU L Ut ::> 1 l:i I~ j 94 - 6
POllTEKNIK MEKANIK
POLITEKNIK SWISS, ITB Main parts of an Injection roou
Ld :) - 002
SWISS ~
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,
In ptets o( Ill'In)KtlOft .,,,14
( 6' £~ettof back pllt4 (11) Loc.tinq ring 116) .... h bock
) c&vity pl.te (Laver'
, Cav\ty pl.te tUpptr' ( 1) tttetO' hoI 'er pi.t. ,12) 1.!Ktor pl"'9 (I') Ejector
, $'lC,_e:: ~).I:c UoO\IIiiIri ( It, t ...

.a<ff ;", ·oll··. '\ 1; C'Jld. plil.r 118) $,"1' pin
( " Cavity snle't (Punch) (14) Cuh". but" (19' Rtl.Jinlnq .prlng
, Ct.-psn9 pl.te (Lowe,'
Sprue bu.h tiS) Loebtu" bulh (20) ty. bolt
, Cl.apl~ pl.te (Upper' :101
POllTEKHIK ME KANI!( TOOL DESIGN 3 I 94 - 7
SWISS - ITS
In this case we would locate the cavity (with a hollow

shape of dia around 30 and thickness around 5, consi-
dering the shrinkage) exceptio~ally on the moving side.
To be sure to remove the sprue together with the com-
ponent it is required to keep them (with the help of
sprue puller, see later) on the moving side. So they
can easily be ejected after opening.
This was now a particular simple case, involving a ca-
vity only for giving the shape of the component.
Most of the time components are designed in a way to
have in addition to the outer shape also hollow spaces
(e.g holes etc.). This is quite well pussibl&with
n~ulding technology and even one of the main attraction
=..;.c'- 2.:::vantagesin it. We take again our cylinder dia
We want a centre-hole of dia 15.
During injecting we have now to keep the space free.
w~ wj.ll do it with the help of a pin around dia 15
(-::::::::llsidering
the shrinkage) This ~in dia 15 will act
a.::o
.::.
~urp or punch as we call the male f o rrn part.
.:'" i s
T:-:. j~ he ve rye 1ass ical cas e .
Mcst of the time cavity and punch are used to focm a
component. The basic layout of the mould in this
"normal" cases will be as follows: the cavity 1.S lo-
cated on the injection (fixed) side, the punch (pin in
ou~ example) is fixed on the ejector side (moving part)
Please compare again 3-001 : pas 17 is the cavity, pas
9 is the punch, designed as sp~cial insect. In order
to save costly tool steel the artual form parts only
are made out of it and located in cheaper mild steel
plates. To guarantee sure removaJ. of the component we
will make the cavity tapered, (1/2 to 1-1/2 degrees,
according to the depth of it) of COULse in opening
d .ir r- r. r. i. o n .
We want t~e component to sit on the runch after opening
of the mould.
~-- ..,_ if nn"l

POLITEKNIK ME KANIK TOOL DESIGN 3 94 - 8
SWISS - ITS
I
Therefore we make sure that the
/
part is rEmoved £ror.1
the cavity. Since the punch is fixed on the ejecto~
side (moving p~rt) easy removal is assured.
The punch is aJso tapered and well polished in opening
direction. Sqmetimes it is necessary to cr2ate ~n
additional undercut on the punch in order to maKe sure
to hold the component on the ejector side. A very
special type bf punch (or core) is acting not ir the
opening c t Lo n of
d i.r-e the mould, mostly In 90 ~lec:,rees
to it. This 'In mould maker-circles is popularly
i<::r..cw"TI
as slider or Sliding core and will in det3.il be
discussed later. If we are talking about 2; 3, 4-cavity
n~u~~s etc. obviously also as many punches are involved
a s -....;e
have cavities. "Cavity-punch" will be treated as
one unit in respect of application. But they are S~-
parated by the parting line.
3.1.1. N--.:...±er
of cav ities :
c s r t a i n cases
I::-_ it is necessa.cy to have morc t.ha n o r. e
c=.-,-::..ty
in a mould. This method is adopted when 2 small
size moulded component is required in big quantity & in
a shorter period of time. However some times a ~uJLi-
cavity mould is also designed to produce diffprent com-
ponents in each ca.vity, mostly required for a ccmrnon
a s s ernbl.y . This is a p p Li c e b Le only when equal n um b e r rs
of each component are required and also in the same
colour and mat.erial. This we call "Group mould".
3.1.2. Arrangement of cavities
The layout of cavities in multicavity tools require

considerable care to a c h ieve be s t re su 1 t s _ F'o11,:)\"i
ng
consideration must be borne in mind.
(i) Best possible disposition of caviti0s to ac~icvc

minimum overall tool size.
(ii) Correct .layout of cavities to obtain o a La ric.e

d
clamping (figure 3-003)_
POLITEKNIK MEKANIK TOOL DESIGN 3 I 94 - 9
SWISS· ITB ~-------------------,-------------------------------~
(iii) Due to the excessive length of runner, a high

pressure drop will result from the rapidly
cooling moulding material as it travels along
the runner. This will give rise to high pres-
suxe at the start of the runner.
The cavities near the centre of the tool will
thus fill first, whereas those at the and of
the runner will fill last, at lower, cavity
pressure or if the conditions are adverse, will
not fill completely due to early cOoling of the
plastic. Therefore the runners are to be kept
as short as possible.
'iv) Attainment of balanced clamping is imp6rtant

for correct operation of the tool and machine
with minimum wear and tear from flashing. The
mould opening force arising from cavity pressure
should be acting opposite to the clamping force
centre line to maintain the balance. Obviously,
if the opening force is one sided to the clamp
(i.e. out of balance) I a mechanical moment will
be set up which could cause the tool to open on
that side and lead to flashing.
3.2. Runners:
In figure 3-004 we see some possible layouts for

runners arrangements for multicavity tools.
Generally the main runner starting from the sprue is
called primary runner and the further branches are
known as secondary runners. The runner is expected
to offer to the hot plastic a quick flow path. The
ideal section is round. The dimensions vary according
to the required volume of plastic.
If the section is too narrow compared to the flow path
and the volume of the cavities the plastic will cool
down too quick and we risk that the cavities will not
to be filled completely or not i~ satisfactory quality
.i.n
view of uniformity.
FOrlll No. 4.003

POllTEKNIK MEKANIK TOOL DESlGN J .1 94 - 10
SWISS· ITB ~--------------------------------------~.
In case the section is comparatively too big the

cycle time is extended unnecessarily because of
longer cooling time.
This would also call for a bigger size of the sprue
hole, again extending the cycle time.
It is recommended not to polish the runners at all,
it is advisable to leave them in a slightly ro~gh
condition (e.g. medium-filing, medium to rough spark
erosion). With this measure we promote the (requi~ed)
tendency to .have cooled down the outer po~tion of the
fluid plastic to proce~d in a fairly regular spaed
towards the gate. Due to the linsulation""21so the
~a~perature of the plastic will be maintained.
~~e end of the runner is the gate.
3.2.1. INSULATED Runner
In this type of mould the sprue bush has a -["(~(".;h;:,mbl2r

i:-:::o
which the injection nozzle (copper) r i ts .
':'::-.==e
is a gap be tween the chambe r wa 11 an d nc :71e
~~~ch is filled with the plastic material ~nd chen
acts as an insula·tion between the cold sprue bush
and hot nozzle. The moulding should be produced at
a rate not less that 3-4 shots per min becausE' the
centre of the "plastic insulation" is not aJlow-ed to
ccol down. Moulds with this system are wo rk Ln c au t.o>
matic, not easy to set, adjust and run.
Power cuts affect the efficiency of production because
of possibly intermediate cleaning and resetting of
the mould due to cooling down of the runner-system.
3 .2 .2 . HOT Runn8r
In this case the injection nozzle temperature lS
rnaintained electr ica 11 y to avo id coa t ing of .nater ial .

The nozzle touches more or,less the mould aud :\ pin
point gate is created.
POLITEKNIK MEKANIK TOOL DESIGN 3 I 94· ~ 11
SWISS· ITB
Also this system permits fully automatic working,

but it is quite delicate to set and to maintain.
Insulated and Hot-Runners are rather sophisticated
methods and reserved for advanced moulding technics.
We shall not diacuss these systp.ms in detail as we
try to understand first the basic moulding techno-
logy.
Form No. 4.003

.r : , - ..l L
t'ULlI tKNIK MtKANl1'(. IVVL L..J4-.Jlull
SWISS - ITB Layout of cavities 3 - 003

~------------------------~~------------~------------------------------"-------.--------
Unbalanced Rectified
\
c
c
......_____.._+._; .
I
=+
x
Ideal solution for this part in

respect of balance
c mUlticavity mould
c c
c
.i->: c
x Offset
pressure
from centre of clamping
IOD~l
POLITEKN IK .M"E KANiK TOOL DESIGN 3 94 - 13
SWISS - ITB
Runners 3 - 004
ArranG~~er.ts of Runners
Good but very costly
Better solution and difficult to
IT'anu::acture
/ /
/
bett.0.r so l o c i o n Centre still liquid

poor 15° as long as packing
to be? avo i d o d
la = 1,25b/r 0,2 iJ ~ough surface

(not polished)
Runner Sections Section of filled Runner

during injection operation
Fo rm . No .4 .003
POLlTfKNIK MEKANlk
SWISS· ITB
3.3. Gates :
The small passage (or passages) which is leading

direct into the cavity is called gate. The section
of the best suitable gate is very important.
The drawings 3-005 to 3-014 present a few popu~ar
and recommended types, including short descri~tions,
While studying gates two main points have to be ob-
served, size ~nd location of it.
About determining the size we recommend basically
one thing, we better start with the really minimum
size. It var~es of course according to the size
(volume) and also the shape of component.
~~e final size of the gate will be adjusted according
~he test results on the moulding machine. In View
of location we have to observe one major factor we
should not a~low the injection to take place in a
large hollow space but whenever possible against a
~~~ch (or core) .
•
:-:-_is
measure··helps to improve the quality (uniformity)
=~ the comporient. Two other things have to be men-
tioned in connection of the gate-size. If we make it
too small we risk that the cavity will not be filled
or the plastic will be burnt due to excessive fric-
tion while passing the gate.
If we make it too big degating will be more time
consuming and the actual gate mark will be very
prominent.
TOOL OEStGN 3' 94 - 15
IpOlITEKNIK ~ ....
E..KANIK
~_ SWISS· I TB Typical 4 - cavity layout 3 - 005
3 2 1
\
6
Ejected components still linked by runners ( q~tes
A TYPICAL FOUR - CAVITY MOULD

2 1 'i !)
1 Cavity
2 Runner
3 Gate
4 Sprue
5 Sprue bush
6 Sprue puller
7 Ejecto:::-
Form.No.4.003
PUlIlEKNIK
SWISS
MtKANIK
_ ITS
....---------------------------_ .. -----
Gates 3 - 006
.Sprue Gate (depending u po r: if u i~~ very

long angle l1as b<c' ren'Iced
accordingly;
Jo ining mark will -y---.....~~""--"-.;:--'>.,~ttlf-~-t+.r--

be 'visible on
cor;r;:onent
Sprue pull-2= if (Li,:,=, -::-.:'s c.t is

necessary arid =:~-:.,. t_ r a t, sec t ion
as ~,-:_::
acceptable -.::::.ly o i~,: -=,'-::; 1e·:. Cl t 1CI st.
a nc -__
-_:.:::::::t?~·;";L ...: 110
s h r ; :-_>-_::-_ :::'2:_- Y _;, s no u 1(.1
General
Simpliest and oldest method: material lS centrally ~0 the ca-
vity d i r ec r Ly through sprue bush (bush-diameter v i s ..': . a~J f:i.rHo
line). :: :--,8 mark is permitted (exc(~;,:. the c ornpu Ls t r. :;':'::\:.0 ma rk.)
the sprue ~~ll be provided in the cavi~y-plate.
Applications
For componen ts with thi ck walls if at '=.he same tim,,:: c:.::::: ~.-.r: lCV .i n
dimensions is required~ Also for inje:cting less f~~:_~ ~0terial
sprue gate is recommended. Commonly used on house-:- __-_= ar'::.icl,-"s
of rather bigger size. (e.g. Buckets e:.c.)
In case it is difficult to fill the mQ~ld sprue gat~
too.
Advantage
Minimwn pressure loss occurs due t o d i r oc t; .i n j e c t jc . !:.z::.'Cjul 2'1. r
wall thickness can be obtained.
Disadvantage
\dditional labour for removing the s p r u-> is noe d c d .
3prue mark will always be visible. r-;c~ suitable f or :-_ulti-c2vity-
tools.
Remark
It is essential to polish t.he spcue-holc as best a:c: ,': '~:3 il Lv i. n
POllTEKNIK MEKANIK TOOL DESIGN 3 94 - 17
SWISS - ITB Gates 3 - 007
Edcre Gate
m a x . d- 7.= ~
: ~ ~
!g ,. ~. t
General
A very pC~'llar type of gate and mostly used in mUlticavity tools.
It is located always along the parting line and feeds the compo-
nent at an end.
Advantage
Easy removal of the runner since the section is comparatively
small. Rather minor gate-marks.
Disadvantage
High injection pressure required 5inc~ the material flow is poor
due to the small section of the gate. Chances of air traps
("edge feeding") Sometimes welding line does appear.
Remarks
~he ideal section (ideal dimensions: as small as possible for easy
~~moval from the runner but not to small, otherwise chances of
over heating due to fast flow of the plastic) is usu~lly deter-
mined by trial and adjusted according to results.
Form _No _4 _00 l

t'ULII tl\Nl1\ Mt:I\AN.I\
....
------------------------ .
--,.~-----__1
SWISS-ITB Gates 3 - 008
Diaohragm Gate
General
Diaphragm gates are preferably used for moulding gears and also
hollow cylinders.
The feedi~~ is centrally located and therefore used in s;ngle
cavity mc~:::_=-s.The gate is all along the periphery and 'jarantees
uniform fi:::_lingof the ~avity.
Ad·...
rantage
Uniformity in diameter and strength is assured by using this gate.

Due to the uniform filling no weld~ng line will appear. In view
of accuracy very good results can be obtained.
Disadvantages
Extra labour is required for degating, mostly on machines.

Core can be located on one side only, therefore length of hollow
components to be moulded must be restricted if uccuracy is
expected.
POlITEKNtK MEKANlK TOOL DESIGN 3 94 - 19
:King Gate Sprue
Ring runner
-------- Sprue puller
?:'Olliid component
Primary runner
Ge :-leral
Ri~g gate is mostly applied for moulding long hollow cylinders

even in multicavity moulds. The cavities are fed by a sprue
gate which leads via primary runner to the ring runner.
Between ri~~ runner and actual cavity the section of the gate is
reduced, ~~=~efore the ring-runner is filled first and only after
the cavity w~ll be injected uniformly.
Advantaqe
The rare is allowed to be located on both e~ds. Injection takes

place all around the cavity at the same time and provides uniform
wall thick~~ss and strength, of course also in connection with
the double side located core.
Disadvantaqe
Extra labour required for degae~ng, mostly on machines.

~ ~ L_
PULllEKNIK. MtK.ANIf\
Flash Gate
Cross runner
(same effect as r i nq
runner on ring gate)
·:unner
Actual gate
""
._____-------Xt !
F·-· +-
Ge:1.eral
The characteristic of the flash gate is very similar to the ring-

gate. The cross-runner is filled first since the section of the
actual ga~e is smalle~. So again uniform injection all along the
gate is as s'.::.red.It is mainly used for moulding flat and long
parts, preferably in mUlti-cavity moulds.
Advantage
As we start to inject from one end the material flow is in one

direction c n Ly and no .welding line will appear and a homcgene
structure and good mechanic~l strength will be obtained.
Twisting of the component can be avoided.
Disadvantage
Extra labour is often required for degating. In case of single

cavity mould unbalance<;i clamping force is not to avoid.
POLITEKNIK MEKAN!K TOOL DESIGN 3 94 - 21
SWISS· ITB
Gates 3 - 011
Subm~rine ( Self shearing) Gate
Conical,
, inclined
Sprue puller
?ci~t
Very popular gate in mUlticavity tools. T~e actual gate is not

situated i~ the parting line b~t appears as pin point somewhere
(sidewise inside the ca~ity. Either while opening the mould or
durina e~~=~ing (depending on design) the point (gate) is sheared
I off "autc=~~ic". This gate is mainly a~plied for injecting

"elastic" material since during degating the inclined, conical
I part itself is not allowed

expected ~o be pulled out
to break in the parting
(after being cut) together with sprue
line but is
.1 and runner. In case of injecting brittle material deforming has

to take pl~ce while sprue and gate land obviously also the
I component) are still relatively hoc (and therefore more elastic).
Advantaqe
Automatic production possible. Due to automatic degating no

extra labour costs.
Disadvant1ge
~elatively high injection pressure required since the material
I .low is rather poor due to the sm~ll gate-section. See also
I edge-gate. Submarine-and edge gate, both are located sidewise
I and anyway similar.
I
I.
I-
I
L ~ ~
,) Form. No.4 .003
POllTEKNIK MEKANIK
SWISS·ITB Gates
Su~marine Gates
I I
/ V
-t-'h~-t-t-t-+-t1t-H-b4V+-f-+-j-
! v / --f_t-~L~++_--l-+--tJ~j-=t--~-+-
J_L. --_--'
I / / / v __
- --D 1,t := l
2 .6rttIIH-:/fV+¥/H-++/j;v~V+-H-+-+--Wj__IIJ[:b~
4rttiiIIlVv~v~~b/~~~~~lJJJ=CH-~
/'
/
v
8 tillllt1t/7t-t
7vTfV~+/+v+/'-tv++~:::1f--i::t_+-~D~-~2 ~rrJLTI-4=rtFt-,
1. 6 n=t7/t/7iv-:,N-rtvvTH+-H-++-H-+W-L1JIJ_ ..I~·--;_j·~~
1.4
rr~/7-/lttvfi-rrtt4~~~~llIJ~
If
/ ,/
, i t-I-
i
I •.
f=Filft11P'/1V?:_t~=t~~tj~+jf::+=~~=t~_=tj=±=Ef~El=El=ff'~-
1.2
1,0 v - rH+ti
0.1 0.2 0.3 O.L. 0,5 0,6 07 0 ,80,9 1,0 1,1 ,I---l-+
l,t 1.3 1 t. 1,5
POLITEXNIK MEKANIK rOOL CESIGN 3 .j- 94
_._
.. 23
SWISS - ITB Gat.es 3 - 013

I I I T I I I I I I I r 1 I I +rr I , I i1
I ! I I I I I I I I I I Submarin:' Gates' L->-_ D=~'
l. , 6 4---+--+- i
-I--
/
'I
--
l..2-~
I
L 0-= x: ~~7L<./
~./ /
-r-i I
-+-+-l-
I
rr --t--+-I-I+--~~--/:~~:
~ -l-----~,..,..::.:s<:..., / /. g / I!
2.3 .-,==- ~~y 1\1\ -+-+---+--~J,·-+--Vh.t· -+--!V--I-1~.j--+--I---I
:.:h
't--+-'y
,/.£:
.~
I
-4--+--+--+--+--+--7 .
7 VI
-'-._-.--+--~I---I
J 4~ i () E V vI f-+-+-+--I
~: ~ $0 ~"/~ t--+--+-+,-+-+--I-/vl--l- I ~~c--_1=t-~--I----1I--+---1
'"E:
.
E:
rr
...;
QJ
~,~ +-1--+------1
2.8
2.6
t=r
.c i / [Ir---+-1-+--+-,-' j--f--+-v/-+-V-l-J+-V/-+/-I-/i-VI ~~~I-i l~'-!-_:_-t--1-1
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~_ / II V
~ 2.2~ ! I i +--+--:r---:--+-+--+t/'-+-I-J/L...-t---h~/-+--+·'- - - -_. ---+--+--+--1
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1,2 / / V /
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VV / /
IV-fr-/-Y-+/--1-~-+--+-+-1 -+---4.---l--+.--l--l--+.-- _.-I-- "-+-+---+-4.
"/./ / '-1'-[-
0.8 -t--t--t--t--t--t--t-+-+/-I,/7'-/+.vr+-/-y,,-+-t--t--t--I--+--t--+---l--t--I---t- L -.f--+-+- .._+--+---1~
1),6
/~'/ V V
0.1.
0.2
0.1
0.1 0.2 C"J O,L. 0,5 0,6 07 0,8 0.9 1.0 1.1 1,2 1,3 '..'. ',5
Height h at 02/03/04/05
I U U t., U L, ._) I II II
POLITEKNIK MEKANIK
SWISS _ ITB ~-----_--------------------~--------------------~ 3 - 014
wtes
~----------------------~------~--------------------------------------------
Pin Point Gate
General
The gate .'~~:~>..'0rs as very small luilc: ~;ituaL(:'cJ 1l1()~;! lv ,:('11L,),11 Ly tr :
the c a v i.t.: It is successtullv ,lpplic'd In cluLC)[1l.1i

].,: ilic)\lld:;
(autoTllati:.: ::.egating) in C3~:;e iI1~;u L,:1t('cl l-unn<'rs Ot: "]J/)\ )'\111il") "
are provi:::ed. Also in so o a Ll od 3--pli}tc-mould~~ t.t ii.ts Lyp ()t
gate is used_ For large componcnt:.s mu Lt. i, pin point. q,lt:,:,:~ c a n lx:
applied_
Advantage
Automatic degating and therefore no c:<tra cost.s, in c,:'se cf

insulated and hot runner no wast~zl(JC of cunner mat_Ec"'I-i_,ll.
Disadvantaoe
In most of the cases a marc complicated mould is requir?d and

also the moulding machine is c:--::)cctcd to be well d c v e Lore d .
The setting of the mould and ma c hi n o is more d o Li c a t e .ir: \.Tic,..;
_f shot. interval and temperature I except. in 3-plat.e-rnould::;.
3-plate moulds are on t.ha ot.her hand anyway relatively
complicated mainly the perfect EuncLion (2 parting }lne~)_
So the initial costs .ar e c c r c a i n Ly ri i q h o r ,
POLITEKNIK MEKAN:K
TOOL DESIGN 3 94 - 25
SWISS - rTB Parting Lines 3 - 015
SymbOl for parting line
Diffic~~~ ~~ection Easy Ejection
Difficult Ejection Stepped Parting Line

but unavoidable.
Profiled Parting Line

r- l.I_ A nn"'\
POllTEKNIK MEKANIK
TOOL DES I GN -3-------T;~--'-)r->·
t-----------------------.~--.J...-'---(- )
SWISS - ITB Parting Line exer c i se 3 - en fj
I------__JL-r--____.:..=..:..::....=~·.:-:::.=:..::~----------------
-,
1. 2. oJ.
1.4--------t---------~---------------------
. 5. 6.
i--------t---------__l--- -------
---------
7. 8.
-----,,------- ---- - -- -------

9. 10. 11.
,----------t----------__l----------------------4-
13.
~'b-~
LlJ....---+---..A~i~~:r~l
~r__-----+---~-----J'!
IL- -+ . ._:J
'------ __J,_ . ,_... .__ , _._ .._. ._, ~.J
TOOL DE:',IGN 3 94 - 27
POLITEKNIK MEKANIK
SWISS - ITB Par:ting Li.nes J - 017
K.3.dio knob Bowl
a = Cavity
b ~=~~ _difficult
C.3.vity _
to
machine
~a~~_y machinable (but p3~tingline visiole)
Component (a) (b)
Undercut occurs . rr
Unde u t av o i.d ed
POllTEKNIK MEKANIK
SWISS - ITS Sprue Puller 3 - 018
The sprue puller has to make sure that the sprue dces not remain
inside the sprue bush after opening of the mould it is r.ecommended
to locate it opposite to the sprue bush.
The parts be ejected the usual way. Here we see a few
t=:::;ssibilities.
2.
. __ .
-
__ ._.- __ -
3. 4.
_. __ ..
5.
1/2/3 = recommended
Spruepuller types
(Sprue ejected by Ejectorpin)
4 complicated way of sprue-

pulling.
--. __ ._
Core hase to be fixed
Clamping plat.e.
in the
_._.-
(Sprue ejected by Ejectof~leeve)
5 recommended spruepuller. type

for Stripperplate ej~ction.
ro rm . No .4 .003
POllTEKNIK MEKANIK TOOL DESIGN 3
SWISS· HB
3. 5. EJECTION
N6rmally the component shrinks and grips on to the core

(Punch), which is generally on the movable half of the
tool. After the tool opens it is necessary to remove
the component from the core which demands a consi-
derable care. This removal of the component is known
as ejection/which is quite a system by itself and needs
efficent designing. Here we sha~l study a few methods
of ejection. Excsption in a few cases, which we are
going to discuss later (e.g. Air ejection, ejection
~~~m injection side etc.) asually the ejector system in
~te ~ould itself is basically similar.
I~ is c~mposed out of ejector plug, ejector back

plate, ejector-plate-, an" suitable type of ejector
(s), push bctcks and at least 2 guiding pins.
(b) Th2 system is located on the moving side/since the
standard ejector equipment on the machine is pro-
vided opposite to the inj8ction-side. To (a) and
(b) see figure 3-019.
3. ~ _1. Eiector system - machine side
Most of the now operating injp.ction-moulding machines

(except handmoulding) offer the facility of centre
e= cct i.on either (a) : In the opening movement the
mo u l.d (ejector plug respoc r i vo j y ) is pushed aginst a
stationary press-centre, mostly a rod,which is adjus-
ta~le and therefore dete~nines the ejector-stroke.
Since the mould continuous to open the ejector plug
(which is fixed to the ejector system) moves in
direction injection and pushes the components
from the core (5). This system allows to work automatic
(see figure 3-020). In Q few modern machines the cen-
tral ejector rod is operated hydraulic and linked with
the ejector plug.
This hydraulic solution offers the possibility of an
exact timing of the ejection, independent (in view of
the working cycle of the mould) and even delayed, also
convenient for automatic work (see figure 3-021).
1:'__ ",_ A 1"\"''1

,------------...,..---------------------'_'--------.
POLITEKNIK MEKANIK TOOL DESIGN 3 94 - 30
SWISS - ITB
Ejection 3 - 019
1 = Cavity plate (lower)

2 = Cavity plate (upper)
3 = Support plate (lower)
4 = Clamping plate (lower)
5 = ::amping plate (upper)
6 = ~jector back plate
7 = ~JE~tor holder plate
8 = ::;;:·.!(:'2r c r Riser
9 = ':a::.i.t::: ':'.:-.se:-::. (lower)
10 = Cavity i.--:sert: (upper)
ow
II
112
13 = ;::j~cr ,?lug
14 = Guide pillar
15 = Guide t.;,..:s~
[ L = max.
Lj r
:::"ie::-.:::-
+ r--
stroke I
Lx
(
18 6 15 8 7- 3 1. 9 16 17- 1'+ 10 2 ·r')' 5 12
, c . ;;,.; .,' ,003

POLITEKNIK MEKANiK
SWISS· ITB
Ejectorsystem machine side a) 3 - 020
11ou1_d c Lo s e d
Tie bar/
Fixed
Mc~_~~
___ ___cc=latten---' /
~10111d open
--- . ---- ------. ---_-_. - .---
----- . -----~ - -------_- - -----

POllTEKNIK MEKANIK TOOL DESIGN 3 9L\ - 32
SWISS - ITB Ejectorsystem machine side 'b) 3 - 021
Mould closed
. --. -- --. -- --_. --- . --- . ---
1--lould o pe n
._--._--
~--------------------------------------'
POllTEKPdK ME KANIK TOOL DESIGN 3 I 94 - 33
SWISS-ITB
Types of ejectors
3.5.2 ~in Ejectors (See Figure 3-022)
These are the simplest, cheapest and most common

types of ejectors. Generally cylindrical pins are
often available in the market in different sizes
and with one end peeled into a head (cylindrical or
60" tapered).
Th~ pins can also be stepped or ground flat on one

side.
The ske~ch shows the application of each type. The
ejector leaves its impression on the mouldin~ (ob-
se~vation). It should be located as not to damage
~~e component, moreover the impressions are not to
~~sturb its function.
3.5 .3 B~ade Ejector (Figure 3-023 A)
~his figure shows a typical applicaticn.

:~~ the component has long and thin ribbs, which
~=~en cause trouble- while ejecting, it is mostly
3~visable to split the cavity ~nserts (also easier
for manufacturing and ventilation of the mould) and
use blade ejectors to assist a proper removing of
the component.
3.5.4 ~~eeve Ejector (3-023 B)
This type of ejector is u~ed ~o eject circular com-

ponent, '-litha thin wall sticking on a core. The
core itself is attached to the back plate (ejection
side) . The ejector i1 for of ~ sleeve is around
this core pin and ejects the component all around
the edge.
Notes
Form No. 4.003

TOOL DE~IGN 3 94 - 34
POLITEKNIK MEKANIK
SWISS - ITB Ejector Pin
L Cylindrical head, cylindrical shaft ~~oste comun,,~

2. Conical head (60°), cylindrical shaft
3. Cylindrical head, stepped shaft ·X
,--,
2 c;-.
i
I L
1-----:-. __.j
' __ m_c_,:-:imum Ejec:t:Jr--1
st:roke
Ejector 0 d
1 - J
3 - 5
5 - 8
8 12 (25 - 2) x d
POlITEKNIK MEKANIK TOOL DESIGN 3 94 - 35
SWISS - ITS
Blade and Sleeve Ejector 3 - 023
(B)
I'
rI
!i
Form.No.4.003
POllTEKNIK MEKANIK
ro.u DLS I eN ] J--;~;~-
SWISS - ITB ~--------------------------------------------
3. 5. 5. Stripper plate (see figure 3 - 024)
The stripper plate is an accurately adjusted plGte

around the ~ore, being the parting line. During
ejection the. plate moves along the core pushing
and removing the component_ It is an expensive
solution because accurate adjustment is required
(r is k 0 f f 1a-she s) _
No ejector marks are visible.
Disc Ejector (sec fi0ure 3 - 025)
~his mechanism is used basically for mould~ng

r.cuse hold utensils or big enough cornpo ne n cs
.c i.r-c u La r ) .
by a centrally
It consists
located
of a round
rod.
. disc
opera~ed
-
The.disc"ejects a
comporatively delicated moulding at the base
wit ho u c damaging it ("lS the oo n t eo t surf2cc is
~:::.rge)
. Even the c i rc u Lar rna rk produced \)~.'
thl"
~isc,blends with the rou~d shape of ~he compoGcnt.
== is cheap to manufacture and more and effective
~hen ejecting deep components with thin walls.
So far we have discussec. a feh of the so-called

conventional methods of ejection by pushing thR
component from the movlng slde of the mould.
Notes
L- ~ . '_. _
POllTEKNI~ MEKANIK
SWISS - ITB 3 - 024
Stripper plate Ejector
I
r .
plate in
I
I
I
j. Form. No.4. 003
POLITEKNIK MEKANIK r-_..,.,....,. TOO L 0 E S I G .r·j 3
.----1' 94 - 3()
._.L __ ____:_::___J
!
SWISS - ITS
Disc Ejector 3 - 025
Cavit,y plate Lowe r
Supp'ort plate
Mould closed
C~~~~=ted ~~ the Ejector-

sys,=.=:,; i:: -c:-:~ lower part
c:: '.::-:e mc'...:.-'..c
C:tvity Insert Cavity In:::;,:,rt= Sprue; Insert

----_._-------
lower (punch) upper--rD i e-)--
Slot ~cting as an
air inlet to prevellt
a vacuum
Mould open, disc eicctor in operatiun

POllTEKNI K ME KANIK TOOL OE~IGN 3 I 94 - 39
SWISS - ITB
We shall study several "special" ejection systems.

In this group ejection takes place without the me-
chanism of the moulding machine hut somehow com-
pulsory while opening the mould or by other external
influences.
3.5.7. Air Ejection
The figure 3 - 026 A shows a typical arrangement of

this ejection system. Compressed air ente=s through
the punch plate and pushes the ejector towards the
injection side. The air is of course not flowing
continuously but is regulated by a switch allowing
=~~ short blast after each mould opening.
The ejector return is usually op8rated by spring
force. It is a relatively cheap method and used
preferably for box-type components. It avoids the
c~~ation of vacuums and, therefore, checks distor-
t~=n to some extent.
3. S. (3. ~lection from injection side (Figure 3 - 026 B)
While designing a mould it is mostly preferred to

have the component sticking to the moving half of
the mould. But in certain situations (e.g. when no
=~ector or gate marks are allowed at the external
faces) the component sticks to the injection side.
From this fixed side it can be ejected by a
stripper plate or other mechani~m operated by the
moving half of the mould (through chain & bars).
3.5.9. Chain Ejection
When it is not possible to do CE:ntre ejection due to
j the machine design or the construction of the tool,
I this method can be used. Chains are always fixed
! on the sides of the tool.

I
Provision to adjust the
I,
chain slackness equally on either side is very
important.
Unevan length of chains causes tilting of ejection
system.
j Form No. 4.003

POLITEKNIK MEKANIK
TOOL DESIGN 3 I 94 - 40
SWISS - IT B
(A)
/
;/' /
I
!------------.:___------------~
I
I
(8)
step 1 opening, stroke"S

step 2 ,-,;:_~ippiI)CJ
from S!'l-UC-
.:..:-.sert
.. " -,-,'.
r:
--~--.--
I....--~---------------------.--.--"
---------------------_ __
.. ._---- . ... _---_ ... _-_._----
POUTEKHIK MEKANIK TOOL DESIGN 3 I 94 - 41
SWISS· ITB
The function is obvious: during the first opening

phase only the mould half moves un~il the chain is
tightened. Then the chain will stop the ejector
from travell~ng with the mould. The relative move
of the ejector becomes therefore opposite to the
mould moving dir2ction and the component is ejected.
(see figure 3 - 027).
3.S.10. Rod Ejection
It is used under similar c;:ircurnst'1nces

as the chain
e~ection. Figure 3 - 028 shows the application.
Af~er the mould has opened for the stroke "S", the
___ is forced to operate the ejection system which
l3 designed as usual. On both chain and rod ejection
the ejectors are forced to wards the injection side
by a system built into the mould and operated
"automatic" while the tool opens.
3. S.ll. __::u31 EJ,:::ction
>ihenev(:::r
the injection moulding machine is not pro-
vided with ejection-facilities the component will
be removed manually. Figure ~ - 029 shows a few
different systems. If this type of ejection is
2?plied, the required rorce should not be big and
che time intervals are not expected to be regular.
Notes:
Form Nc. 4.003

POllTEKNIK ME KANIK TOOL DESIGN 3 94 - 43
SWISS - ITB ROO Ejection 3 - 028
5 max. Mould
o...,ening (not
udjustable)
L :nax. Ejector
s cz ok e (Lx + Ly)
1--1ould closed.
I
l
I Mould open St:ripping operation finish
I
J Form.No.4.003
POLITEKNIK MEKANIK TOOL DESIGN 3
SWISS - ITS l·L~i_nuztlEjection
".:-, /
1//
/
/
\vedqc SL 1 r!(:
Lt
r---~====='------------~I
/'
I
Rotary Cam
L rna x , Ejec~oL st roke (Lx + Ly)

--_----_._---_ .. _----
POLITEKNIK ME KAN!I<. I TOOL OES~GN 3 I 94 - 45
SWISS - ITS
1
3.6. Ejector Return Mechanism
After the component has been ejected/the mould is

ready to be closed again for the next shot. It is
now very important to ma~e sure/that the ejectors
are brouqht back before the mould is completely
closed, if,order not to damage the cavity.
Different methons are kn~wn for that purpose. The
simplest and certainly most popular one is with
the help of push backs.
3.6.1. Pushbacks
They are very similar to pin ejectors and also

::=.c::tached
in the same way to the ejector plane. In
closed position of the mould/when the ejector
plate is back,these pins are flush with the mould
face (parting line).
Since they are located in the ejector plate)
~bviously they are moving along with it. So the
Jther way around works naturally also as soon
as the mould face presses against the pins/the
ejector system is "pushed back :". This type of
ejector return 1S popular and cheap. Often, on
the spots where these push backs are touching the
mould face (parting line), hardened inserts are
installed to prevent damage to the soft fixed
plate (see figure 3 - 030).
3.6.2. Ejector - return serings
The above mentioned push backs are not suitable to

be applied in split tools (detaiIs about split
moulds see later) . Since the sll.ders start to
close before the ejectors are backlit is cleCl~
that they would be sheared off by the moving
splits. The splits (sliders) are usually operated
by finger cams or inclined pillars. In cases
like this, we recommend to install compression
springs.
Form No. 4.003

SWISS· ITS
Figure 3-031 A + B shows two basic designs. As soon

as the mould starts to close)the compressed spri~gs
are able to push back the ejector plate.
An imediate return of the ejector plate is alsu
needed to ensure a correct fallout of the moulded
part (double ejection possible for automatic run, in
connection with a hydraulic machine ejector)
.:; . 6 • 3 Ej ector return C,am (s) (se ldom in use)
The system is not complicated. Two free hanging pi-

'ro::.ing
cams are attached to the punch plate 0 r a llJ
c-::.:Ler pia te sitting direct on the spacer s on' t.Le
;:-:-_2~I .i!lgside.
-_ -':.:12 pi ct u re only one C2m lS v i a i b Lo .
order to ba lance tbe e j (O'c

tor pia te whi 1e 1t10V .i nq I
a second one has to be attached on the opposite side.
These pivoting cams are moved with the help of t~o
=':":::;er
cams, attached on the fixed plate (injection
While closing the mouldJthe pivoting caw lS
~=~5sed against the fixed cam on one side and the

-==:tended ejector plate on the other side. Therefore
the ejector plate is forced to move back.
(See figure 3-032)
Notes
['0.;::,;:, ~,:o. 4.003

POLITEKNIK MEKANIK
SWISS _ ITB Ejector RetUD1 "Push back" 3 - 030
Locatin
late
.£crue
plate
Cav ; t v insert
uc::e:-
(only used when

Cavity plate is
not prehardened)
EJE::cto!."
Push buck
.,5 a Push ::"':::: .-._--..- .........:....-...-1
Cavity plate
Support plate
1_-SUdC'"
... .._
-~ l-c;
..... 1 ....
ser
_
Guide bush
Ejector
plate
....___
E;ector
Stop pin
_Clamping plate plug

lowQ
Remarks : I In general, the Push backs nowadays are mostly used

in collaboration with return springs, they only act
as a "security" in case of broken return springs
3-031).
, (see also figure
J Form. No.4 .003

POLITEKNIK
SWISS
MEKANIK
- I TB
1-- l_O_O_L_D__E_S_I_G_N
Ejector
__
Return Springs
3_~---_--_-T 9"
_ - 011
- 4r -j
-- I
(ll.)
_'___r--~-
l...L _
I
II
([3\
1-
(
...,---.---
;
-+----f----
l. _1 _
SWISS' ITS 3 - 032
Ejector Pet.urn Cams
Mould open, Ejector in operation
,/
MO\'ing cam
U
(p i vo t.e d ) -.
Fixed
>lould closed Cam
J:jector plug
[RemarkS:
~ince all of the new Injection

~=uld~ng machine offer the
~ossi~ility of direct connec-
tion between Ejection system
of machine and Ejector plug
of the mould, the return .system
I by Return Cams is hardly seen

anyrno r e .
I
1
1 Form. No • 4 • 00 3
POllTEKNIK ME KAHIK TOOL DESIGN 3 I 94 - 50
SWISS· ITS
3.7. Undercuts
So far we have discussed about moulds for components

without undercuts, means the component can be ejected
straight after opening without any other arrangement
prior to the ejectors are operated. This does not
apply to components with undercuts. One example of
an undercut is the thread. If we want to mould an
outer thread the cavity will not be built in one
piece. If the cavity is in one piece, moulding of
course can be done, but it is not possible to eject
t~e moulded bolt the usual way, because the outer
diameter would not allow it. This is a typical part
~~~ch will be done in a split mould. La.ter we shall
discuss other ways of how to eject especially inside
threaded components. But for the time being we
discuss splits only. The splits are popul.arly known
as sliders and are operated either by inclined
?illars or del~yed action finger cams (also called
:::'::::;dlegs}
.
;~out slider. arrangements etc. see figure 3-033 and
3-034.
There are many ways of moving a slider but we con-
centrate on ·the most common ones.
3.7.1 =nclined Pillars and Cams
This design of split moulds is often required. The

inclined pillars or finger cams are fixed on t.he
injection side and opera.ting the slides (apposi.te
arrangement only in special cases).
The final closing is carried out by tapered faces
on both the cavity plate (injection side) and slide
(mav ing side).
The tapered faces (hardened inserts or wedge blocks)
are taking the pressure which is created while In-
jecting. Between inclined pillars and the inclined
holes in the slides clearance is needed.
POLITEKNIK 'MEKANIK TOOL DESIGN 3 94 - 51
SWISS· ITB Sliders Guiding System
Z t:etween 15° and 25u

W t:et'INeen 3° and 5° bigger than Z
max. sliding core travel I
CLearance "- 02
6 3 2 1
l 1. SLIDER GUIDE (hardened)
~~=--$$ I I
, /
I
2. S1·IVER
3. CAVITY INSERT LOWER

(hardened)
(hardened)
- - -,=:.=-.=-=--=-=-~._;=-::..-=--===---=--...:;-- LOWER ( M.S. )
4. CAVITY PLATE
) . PILLAR (hardened)
6. STOPPER
(Ball catcher)
7. COUNTER SCREW
Fa rrn . No .,1 .003

,.---------------,.---------------------------"...-------,
POlITEKN1K MEKANIK
TOOL DESI·GN 3 94 - 52
SWISS· ITS Sliders (DifferentLayout) 3 - 034
VIEWS ON MOVING PLATES ONLY
2 SLI DES ARRAl-1GEMENT 4 SLIDES ARRANGEMENT
-,.=---~~-::..-=--=--=---=, -, '-r-=--=-~~~~-=--=
I ." ~
.:;-
t
I '" I
@I---t--t-
I I
~-+--I-----""""""T.,,--'-__1r_-.-__,;:,..--.- - .L--f---i
iF·=·=--=---=",--=.-d -
I," I
\. _'-:.,..~-:--s...:-::--=- ~ ..J_
:1
If
II
II
II
'11
II
H---+---+Jl
BALANCED LAYOUT OF SLIDERS
3 SLIDES ARRANGEMENT
SLIDERS ARE OPERATED BY
1----~---~,: II 1. Inclined pillars

II
II
11 2. Delayed action f i.nq
cc carns
:1
JI
II 3. Hydraulic cylinders
"
)~ =_---=- =--=..,-;
Sliders can basically be fitted
in every direction (acc8~ding to
requirements> but are found mostly
at 90° (easy machini~g)_
REMARKS
UNBALANCED LAYOUT OF SLID~~ I
Taper pin or insert on par::ng ~

to counterbalance the thrust of 3rd
slider.
~----------------------------------------~----------------------.------------
--- -.'
---.-.~,:-.
POllTEKNIK: MEKA~1K TOOL DESIGN 3 I .94 - 53
SWISS· ITS
The angle of inclination between pillar and tapered

slider face has between 2 and about 5 degrees dif-
ference. The same is the case on dodleg applicat·on.
To state an example Pillar is inclined at 20 dc-
grees and the tapered slider face at 25. This is
done for 2 reasons.
1. We do not want the pillar and the tapered face
to press simultaneously on the slider, only the
tapered face sh6uld lock the mould.
2. Opening is facilitated, the slider does not rub
against the tapered face and the pillar can drive
out the slider undisturbed. In case the component
still remains after opening on the core it will be
ejected as usual. See figure 3-035.
In some cases the mould is desigped to avoid addi-
tional ejection. Figure 3-036/37 shows an example.
With the help of delayed action finger cams this is
made possible. To pullout first the upper center
core before the slider starts La move. The lower
center core has the function to prevent the compo-
nent from sticking on either side of the sliders.
After completely opening of the mould (sliders have
to be secured to stay in their opening position with
the help of ball catch or a security fixture)r
the part will be ejected.
Form No. 4.003

POLlTE"KNIK MEKANIK r- T_O_O_L
__ D_E_S
__I_G_N 3 ~4 - S4
SWISS - ITB
Slider with inclined pillar 3 - 035
~ould closed
Shoulder screw
Hasher
Compression sprino
(light duty)
Fixinq bracket
Slidinq core
,,'~dClC! o Lo c k
,---._--- --
Inclined pillar
Mould open
Ejector system
in
._--_
li.___--_._--._------
=
.....
<1.,:,~:_l:__"L.~; 1;
t: r ,1 , '~:.-
POllTEKNIK MEKANiK TOOL DESIGN 3 94 - 55
SWISS - tlB Delayed Action Finger cams 3 - 036
Mould closed
Finger Cam
, Center Core (upper)
1.
Center Core (lower)
Sliding Core
Wedge block or Heel

block
Mould starts to open"

stroke S is all ready
reached, until now
the sliders did not
move yet,'only th~
upper center core is
pulled completely
of the com2onent.
max. slider travell
Form. No. 4. .O(n

r------------------------L----
SWISS - ITB
Delayed Action Finger Cams 3 - 037
In L''.i. s stage
the s.i.lncr
travel. is fi-
ni.::;hed, the
sliding cores
are fixed in
their present
position with
the help of
the SeC'..lrlty
device (also
p':):::;:::;
ihle with
--4- -+--- =::::i3~1"- -yt--i th e ba 11
:.:a tel r)
3.
Mould is fully opened_

The part is getting
ejected.
POLITEKNIK MEKAMIK TOOL DlSIGN 3 J 94 - 57
SWISS - ITS
3.7.2 Follow Split Mould
A typical component-shape which will be done in a

follow split mould you see in Figure 3-038/39.
While the mould is closed the spring (a) is compressed
arid the hook(c} is fully engaged in the split (b) which
is tapered on one side and guided by a groove.
When the mould starts to open, the hook (c) fixed on
the moving side, pulls out the split (b) which is
forced to slide along the taper and inclined groove.
The spring (a) pushes the split (b).
The actual undercut-form part (b) meves now side-wise
relative to the opening direction of the mould,due to
the taper and the inclined groove.
By the timejundercut is fully dis-engaged/the hook is
unlocked and the mould opens fully, carrying the com-
ponent still on the core. The spt-ing (a) moves to
the split (b) a bit further out, to ensure enough clear-
ance. The component will be ejected as usual, this
time with the help of the stripper ring (d).
Another possibility you will find in Figure 3-040

where the moving of the splits is only done by the
ejector plate. This component is likely to need an
operator for setting the "built-in" coml?onent and for
ejecti~g (by hand).
Figure 3-041 offers a solution, i~ case when the under-
cut is found inside the component. It works basically
again with the help of a ~aper, this time the core is
split in 3 parts (2 moving, I fixed).
While the ejection operation takes place, the split
cores are forced out by the rods which are located
in inclined holes and fixed into the 3plits.
1
There are two possiblities shown in this picture,
I side A} the rod is provided

to make sure that the split
with a compression
is returning.
spring,
The roll is
1 used to decrease the friction on the ejector plate.
I Side B/the end of the rod is cut to a key, which

sliding in a T-slot, on top of the ejector plate.
is
Form No. 4.003

POLITEKNIK M£KANIK TOOL DESIGN 3 94 - 58
SWISS.· ITB Fo llON Split MJuld 3 - 038
MOULD CLOSED PLASTIC

I~JECTED
Centering Unit
·0
POtlTEKN1K MEKA~IK TOOL DESIGN ~ 94 - 59
SWISS - !TU
Follaw Spli~ Mould 3 - 039
r-------------~---L---------------
MOULD FULLY
OPENED
COMPONENT ECECTED
I--
I
I-~---L
I! --- 1--
I ! --
i I
L _j
)
\
P'OllTEKNIK MEKANIK
SWISS - ITB Split mould for built-in components 3 - 040
1 Cavity insert
2 = Split with key and slot
for travel stopper
3 Key way (T-slot)
4 = Stopper
~l-
5 Ejector plate with 5
prisma for locating
of built-in component
6 Adjustment pin
7 Magnet.
After ejecting, the component has to be taKen out. of

the mould by hand (sct.ting is also done by harrd).
..._------------------.---"~ ..-..•. , -.- ".
POll TE KN I K ME KP.N r K TOOL OES I GN 3 94 - 61
5W 155 - ITB Internal undercuts 3-{)41
Mould closed
Guide bush
core
Fixation
Mould 'open core

'POLITEKNIK MEKA'NIK TOOL DESIGN 3 94 - 62
SWISS· ITB
portable Split Mould 3 - 042
3.7.3, Sometimes the requir~d

number of components
is too small to jus-, Locating pin
tify to make a com~
plicated split mould,
which could work auto-
matic. So we will propose
a so called "porta.!:?lesplit
mould". The isometric
drawing shows an example.
The splits will be removed
by hand and knocked apart.
Simple guiding pins
and holes are
required.
Handle
Locating
Sli tter
Locatin hole
pin
Com nent
"1--.___.;;;,;;"-'- _ ,,---,-----
FOI,"fh .. : J.
SWISS ~ ITS
3 .8 . Moulding of internal threaded components
The moulding t w i, th Lr. t.e

of a c~:)!nponen rna L thread is
done as usual. The problem starts when the component
has to be ejected. InteJ:'nalthreads are considered as
special type of undercuts. Unlike to an outer thread,
internal ones usually canno~ be deformed by splits.
The only way to deform them/is to unscrew first the
threaded core. Whether this unscrewing is done before
or after or while the mould opens/depending on the
design. We have different possibilities and a few we
shall discuss now, supported with drawings. For the
simpL"_est method I manual ejection, no pictu~~ is needed.
3.8.1 Manual ejection :
After injection, t'he mould is opened and the threaded

core removed from the tool entirely, only then the
component is unscrewed. This is of course a solution
which will be applied only on experimental tools, if
small numbers of-components are required or on hand-
moulding installations. That way the daily output
will be limited.
3.8.2 Unscrewing with rack and Pinion, see figure 3-043
This is a fairly good solution, COmbining automatic

degating (submarine gate) and automatic unscrewing of
the components from the core. The first opening step
of the mould serves for·degating and removing the
components from the cavities. Due to the design of
the rack during this initial stageJthe p1nion will
not yet be driven. After that first step <indicated
as "delayed"), the rack is prevented from moving
further away by the stop (before it is sliding through).
The mould continues to open and now the pinion is
driven and driving a second (vertical) rack which
rotates the cores.
Form No. 4.003

POllTEKNfK MEKANIK TOOL DESIGN 94 - 64
SWISS· ITB
In order not to damage the still warm com);?Gneni.:

it
is necessary to fit cores with lead threads. Of
course, these lead threads will have exactly the
same pitch as the components thread. Due to these
lead threads,the cores are pulled out of the compo-
nent. It is important to note that the components
are prevented from turning during this unscrewing
operation.
This is done on the punch side (moving side). We
install two small pins which are projected (not shown
in figure 3-043) and ultimately enter the wall of the
component from the front. The results in ~he compo-
nent are two holes. We can also have slots or pro-
jected points in the component, whatever is accept-
able. It is certainly a good solution to provide a
core with a lead thread. But it will be noted that
the core is moving axial.
The other possibility which In some cases can be
applied is with stationary core and actu31 cavity on
the moving side. Figure 3-044/3-045/3-046 and show
a combined example that way and moreover three other
means of rotating the cores.
Notes
POLITEKNIK MEkANtK TOOL DESIGN 3 94 - 65
SWISS - ~TB
Ejection 0 f Tl-:readed Parts 3 - 043
PINION
AREA WHERE TO pTJT TURN ING
STOP FOR WORKPIECE
--------'
DELAYED
RACK
BACK PLATE
CAVITY INSERT
LOCATING
SPRUE BUSH
BUSH
WORXPIECE
PINION
EAD THREAD \ \ SPACER

T... CORE
VERTICAL RACK (axial moves during
ejection)
Form _No• 4 .003

----- -- -- - -,
---- -- ---------
r-----------------------~--------------------------------------,----~--------
SWISS - ITB
Chain drive (Figure 3-044) Gear train (Fi~~Ec 3-045)

and Motor drive CC) (Figure 3-046)
This system of non-axial moving cores ~ight be applied

if the component shows straight knurled engravings
(e.g. bottle caps). The mould will open, the component
still sit inside the cavities on the mavins side, in-
cluding the sprue and runners. Now the handle or the
motor is operated and the axial stationary cores are
rotating and pushing the components ouc from t~e cavi-
ties. The sprue and runners might be ejected the usual
way.
Picture 3-044 shows a chain-driven system to ::::-ntate
the
cores, picture 3-045 a gear driven, both cf them
operated by a handle. 3-046 is also gear driven but
operated with the heip of an electric mater. Of course
these 3 different drives might also be applied for
axial moving cores and the rack/pinion method of axial
stationary cores.
To close this chapter you see in Figure 3-047 a quite
sophisticated, expensive, but very elegant arrangement.
If the number of required components is '-big'
enough it
might be justified to chose it. With che help bf
3.8.4 coarse-spiral-drive (Figure 3-047)
The male spiral brings the according nut and ultimately

the core into rotation while the mould opens.
This enables the component to be removed The spiral
(11) is fixed tightly with the injection sine (fixed
side) whereas the nut is mounted with the help of
e.g. roller bearings freely rotating in the moving
side. A gear is fitted with the rotating nu~ and is
directly in touch with the gear sitting on the core.
With this system the longitudinal opening mov~ of the
mould, transfers the nut into rotation. The qe3r
sitting crt the nut drives the core which is checked
by a lead 'thread.
....._------------ '-"~""
SWiSS - ITB
Ejection of Threaded Parts 3 - 044
O1ain Drive System
Note In this system the core

does not:move axially.
The component does so. In case
it is round i.t has to be prevented
from turning in cavity_
An elegant way of doing so is to
make component with straight
10
'5
THREADED
1 Threaded core 7 Sprocket wheel
2 Sprue bush 8 Chain
3 Cavi<:.y insert 9 Sprocket wheel
4 Handle 10 Intermediate gea.r
5 Sprue puller 11 Gear to move threaded core
6 Handle arm 12 Cavity bush
Form. No . a . 00 3
1"----------~.-----.--.--.-
~POLITEKNtK
SWISS
MEKANIK
- ITS
TOOL DESIGN ,_3__ ._, ...
__ ~ L~~_~
... _68~ {
Eject.ion of Threaded Parts 3 -.

-----_._-----
G--:'arTrain Syst.e:?rl~
In t.his syst.en· the core

does not move axial)y. The
component does so. :Cn case it
is round it has t.o be prevented

from turning in cavity, An
elegant way of doing sa is to

make component with straight
kr.urling_
THREADED
1. Intermediate gear (core drive)

2. Intermediate'gear (main drive) 5. Handle
J. t1ain d r Lv i.uq gear 6. Threaderi cor,: ",i th gear
"--------_ ..
SWISS· ITB
Ejection of Threaded Parts 3 - 046
f'wbtor Drive system
fSPRUE SHOULD
Nor MOVE
ITHREADED ~
L Servorr,otor I Note :I III chis system rh e core does

2. Main d~riving gear not move axially. The component
3. Intermediate gear does so. In case it is round it has
4. Intermediate gear (coce drive) to preventc~d from turni ng in cavi ty.
5. Core An elegant way of doing so is to

make compoDent with straight
knurling.
Fo rm . No .4 .003
TOOL DESIGN 3
--"-----'-r;; - 70
POLITEKNIK MEKAHIK
t--------------------------- -
SWISS - ITB Ejection of Threac.iei Parts J - 047
14 12
Coarse Spiral Drive Systeru
FOTATING NUT
'"
11
:r
~
1-1
a..
PITCH PI = PITCH P2 10 18 8 7 6 5
a,
/
Back plate 10. Nut (threads PI P 2), Lead t.hread
2. Sprue bush ll. Spiral spindie
3. Cavity insert 12. Key
4. Cavity plate 13. Guide bush
5. Workpiece 14. Guide bush PINS F02

-----_ -_-_
U)C~~ING
..
DURING UIJSCRF,'{
6. Sprue puller 15. Guide pillar --------
7. Bush 16. Bush
8. Core driving gear 17. Back plate
9. Mai.n drive gear 18. Spacer

(press fit with nut)
~-------------------. --_._---
r------~------------_T------~----------~--------------------~------~
J POllTEKNIK MEKA~UK TOOL 01::SIGN 3 I 94 - 71
• SWISS· ITB
L
~
I
I 3.9. Mould cool~ng
In fact that popular expression "mould cooling" is

slightly incorrect. We should rather talk about
"maintaining a regular wo rki.nq temperature". It is
really important to maintain the correct mould-tem-
,.
pera ture. It var ies accord i.n
q to the different
types of plastics from 20 degrees upto about 180
degrees centigrades. Mostly we wi,ll have to deal
with temperature between 30 to 120 centigrades. To
make it clear, this are the pure' mould temperatures
whereas the temperature of the plastic at the moment
of injecting lies at about 150 to 280 de qree s C,
anything in between depending on the various sorts of
pl~stic. To maintain both of these temperature~ is
very important. The one for the plastic is controlled
by a heating-system in the moulding machine.
We from the design-side have to make sure that we can
maintain the regular mould temperature to reduce the
cycle time per component, because it can be ejected
~nly when the plastic-part is suf~iciently cooled
down. Mostly the cooling medium will be water. , I
Obviously with a higher pressure more volume of water

(or cooling medium) passes t hrouqh the system for a
-limited time, e.g. one mould cycle. So with more
pressure the temperature per cycle can be more reduced
and vice versa.
Very often to make the coo~ing system/is a really
"boring" job. Because most of the time the water
channels are simple round holes, right through cavity
and die plates. One can imagin that this can be a
quite time consuming work.
We need also extra long drills or we might make the
extension ourselves. It is important that the com-
ponent is cooled down towards the s~rue. The sprue
itself is wanted to be cold as che latest part of the
injected product.
Form No. 4.003

SWISS - ITB
Whenever the cooling holes or channels are passing

through an insert/it is essential to seal the points
of penetration against any water leakage. If water
could enter. the insert -housing, it would in a later
stage result in rusting. This sealing is often done
by "O"-rings. In case we cannot find suitable seals
we could drill a bigger hole and locate a copper tube
right through the mould.
Two or more channels will be linked together at the
ends by rub.ber or plastic tubes. The hole-diameters
should not be less .than about 8 mm.
The figures to show a few different cases of ~ooling
s~stems. But after all you find so many varieties of
cooling systems that it is imposible to show the~ all
within our theory-notes.
Notes :
SWISS· ITB Cooling System 3 - 048
Threaded plug
Plug
(pressed)
COPPER Tti"BE CCOL.rn::; SYsrE1'1 FOR REC."f'.-ANGUlAR~OJLDS
tube
Form. No • 4.003
POLITEKNIK MEKANIK "fOOL DESIGN 3 94 - 74
SWISS· ITB Oooling-S~ple-No Inserts 3 - 049
Cl.amping plate
upper
Cavity plate
uppe r
x
late
8 rom minimum
!::Jetter10 rom
or 12'maximum
* Avoid that the nibbels

of the cooling system Nibbels
are to close to each
other.
The X minimum
depends on the
size of used
adaptor
) Sealed
[\ !
SWISS - ITB
Coo ling System 3 - 050
SPIRAL LAYOur OF WATE'fWAY
r
I
L-------I STRAIGHT IAYCUr OF :·WrEro<TAY
___ -t---+~~ :..;:::;c:::;:::::::s;:.

1
2
---
2 - INDEPENDENT WATElW?AYS'
Form. No . 4 . 00 3
POllTEKNIK MEKANIK
SWISS - ITB Cooling system with Insertsealing 3 - 051
Stopper
(soldered)
Insert fixed
t-----4- . -- .-+--+--+-- ._""' __ - -:Ir----.J.+ -..,._.,....;;~_..-:-::=!=:=::t-w;;:ritthhpOTinnt="to-;;
~~--------~~~--~~--.~--~ __-1_L~---- t-_J preve~t turning
Cavity plate upper
CIRCULAR
~~TERWAY
Support plate
Cavity plate lower
, +
., I
POtlTEKNIK ME~.ANIK TOOL DESIGN 3 94 - 77
SWISS - ITS
Cooling of Core & Simple 3 - 052
I-
i
I
~I) rrn . No . t1 nn'"

POLITEKNIK MEKANIK:· TOOL 0 ES I GN 3 94 - 78
SWISS. ITB t----------------L~-~
Core COOling 3 - 053
"
~.
~
"
".,,:
--------~.---"-.- ...,.,
SWISS· ITB
Cooling of Cores 3 - 054
disolder
?ressfit
SE Rl ES
Disolder
Form.No.4.003
POLITEKNIK MEKANIK TOOL DESIGN 3 J 94 - 80
SWISS· ITS
3.10 Three plate moulds
Before deciding to design a three-plate mould, it is

advisable to check exactly whether it is really ne-
cessary to do so. This type is quite complicated
and difficult to adjust and therefore expensive.
In a 3-plate mould we find 2 or more parting lines.
This is the main difference to "normal" moulds.
The opening takes place in two exactly calculated and
adjusted steps. As one plate after the other is
going to open, it is necessary to lock parting line
No. 2 (actual punch and cavity plate) against too
early opening. A typical recommended locking system
.is shown in figure 3-055/3-056. Only when parting
line No. I is fully open (stroke 51), parting line
No. 2 must be unlocked and therefore be allowed to
move. The schematic diagrams shows four typical
opening steps of a three plate mould :
1. Plastic allready injected and cooled down.

Mould ready to open.
2. Mould starts to open, runners are hold with the

2 sprue puller on the moving side, that means
the runners will be torn of the components.
3. Stroke 51 is compleated. With the help of the

shoulder screw/the stripper plate on the fixed
half pulls out the sprue and strips the runner
of the sprue pullers (falls out of the mould).
As soon as the opening stroke S2 is co~pleated,
the locking device is unlocked and gives the
start of the opening of the cavity section. By
now, the stripper plate of the fixed half ~ill
(due to the compressed springs) move back again.
4. The upper cavity plate (floating plate) =emains

in this position with the fixed side of the mould,
whereas the moving half opens completely and
ejects the moulded components, which are still
sitting on the cavity punches (due to the shrink-
age). Now the mould will close again and a new
cycle will start.
SWISS - ITB
In figure 3-057/3-058/3-059 you find a symilar

chree plate arrangement, operated only with
shoulder screw and distance rods.
The picture in figure 3-060 shows a possiblity to

drive out slides during first opening operation (51),
before the opening of the cavity section takes place.
The sliding cores are fixed in the floating plate
(upper cavity plate) . t
I
Figure 3-061 explains the action of a cornman locking 1
I
unit.
TO RECALL BPIEFLY THE 3 PLATES :
Fixed plate on injection side :

Locates sprue bush, centering ring, cam for ope-
rating the Lock units, part of runner-system,
guide pillars, in some cases inclined pillars,
slide-locking attachment, link with the floating
~."
plate (e.g shoulder screw).
Floating (Middle) plate (remains after restricted

stroke with fixed side) accomodates part of
runner-system including pin-po~nt gate(s), mostly
upper cavity(ies), facilities for hook on locking-
system, in some cases,sliders, guide bushes.
- Punch plate (moving side)

Supports lower cavity(ies), guide-bushes, is
fixed together with $pacers and backplate (which
usually supports the locking hook). This portion
of the mould is identical to usual designs.
No t e s :
I
i
I, ;
r
1
d
,,4
I Form No. 4.003
----------_----------------
·_---------·--T----
POL I TE Y-NI f' '~E '(f'-. r~ !r T00L D[S[G~ 1 I 94 - 82
SWISS - ITS 3--055
Locking unit
consists out of :
Pivot
Lock
Ad'ustment
Shoulder crew
POLITEKNIK MEKAMIK" T()OL OeSfGN 1 94 - 83
SH!SS - ITS Three plate Mould wit~ Locking Unit 3-056
•I
POLITEKNIK MEK~NIK TOOL DESIGN 3 94 - 84
SWISS - ITB 057
Three plate M:>l.lld
with Distance Poj j -
Guidirtg moving
with stripper
Guiding fixed half

with floilting
Distance rod
with 3 stops
Stop No. 2 Stop No.1
Stop No. 4 Stop No.3

-
Mould allready starts

to open, the gates of
the pin points are
allready turn off
POllTEKNIK ME!(ANIK TOOL DESIGN 3 94 - 85
SWISS· ITB
Three plate Mould with Distance Rod 3 - 061
Opening stroke
Sl completed'.
Cavity section
starts to open.~~~~~~~~~~~~~~t
Parting line
No. 3 and 4
still closed
due to sliding
on the core
(shrinkage)
and support through the sprue puller
Opening stroke S2 comp.leted, Ejection operation starts.

r-------------""T"----------------~----" ...
-."-_
....
__
. -'~"'~~'!!
POLITEKN IK ME KANIK TOOL DESIGN 3 94 - 86

SWISS· ITS Three plate M:>uldwi th Distance Rcx.l 3 - 062
~----------------------~---------------------------------.-----.----------
Stripping operation in the cavity section is completed.

(53) now the sprue and the runner are ejected. (S4)
(51 + S2 + S3 + S4 = Maximum mould opening) .
s. S4
,
,
I
Note:
In this few pictures it is not sure whether 54 opens before S3, it: dep(~nds
on the stripping force needed to eject the components respectively the
runner system (matter of trial when production starts).
For the production side it makes no difference whether the product or the
runner falls out first of the mould.
-------------_._-----_. __ ------_ _ .. ,,,,._ ,,.

SWISS - ITB
Three plate I1::)uldwith Distance Pod 3 - 063
2 '1
Multiple point feedin~
and sliding cores
Mould opens at parting

li.ne No.1 (Sl determined
by shoulder screw not
shown in the drawing). Core
slide C is driven out by
inclined pillar P. Cavity
is free from cores. The
cam has unlocked the lock L.
rarting line No.2 is ready
for opening. (The gate will
be torn off the component).
After opening of 52, the
ejector plate comes in
operation.
1
disengaged
Note
Hi th this set-up
.we are not sure
th at the runner
will fallout it-
self. (not advis-
able for automatic
run) .
Form. No • 4 . 003
-----_.-_. __ --
. .--.
POlHEKNIK MEKANIK TOOL DESIGN 3 94 - 88
SWISS· ITB Three plate Mould with Distance RoO J - OG4
6 r-A 1
i
POT. A-A 3 POT 8-B

5 ,--------.----.----..- -_ .•. - ---,--- ._-- . -..-
1- Lock
1-9-
"
2. Cam
I II! I
3. Hook
4. Bracket.
,.....
-y tr _.
III l\
-w-- ----- -Tr -- MouJ_Q c l o s e d
1:1
S. Adjustment pin
6. pivot ~
7. Pin
8. Compression spring PANOANGAN ATAS
A. First parting line (Sl) starts to open :
B. Opening of 51 compleated; n (52)
51
C. Opening of S2
Sf
p1 a t_e
POLITEKNIK M E KArm~ TOOL DESIGN 3 I 94 - 89
SWISS - ITS
3.11. Tool Location
3.11.1. Plate-Set (Die Set) with guide pillars and bushes

Figure : 3-059 + 3-060
The majority of the tools are provided with guide

pillars and bushes. In order to guarantee perfect
location of the two mould halves the respective
pairs (pillar and bush) are to be adjusted as to a
nice sliding fit. Moreover the pillars have to be
mounted absolutely in right angle respective to the
die-set plate. It is understood that the center-
distdnce of pillars and bushes are indentical in
both the cavity plate and the punch plate. 7 The
drilling and boring of these holes can be done on
the jig-boring machine if available. If not, a
very good other way is the use of the milling
machine. Usually 4 pillars are set. If the size
or the space available does not permit 4 pillars 3
or 2 are provided. The size of the pillars should
be in a normal proportion to the toolsize, in any
case relatively strong. Their length is determined
in a way that they sufficiently guide the other
half of the tool before cavity and punch engage.
The pillars are mounted on the opposite half to the
ejector system. This is done to facilitate the ex-
tractiGn of the mOUlding. (except moulds with
stripper plates) .
Pillar~ and bushes are made out of:medium alloy
steel, hardened (about 60 Rc) and ground.
3.11.2. Taper Form Tool Location
Thin walled and deep mOUldings require extra care

regarding tool location. Even slight excentricity,
e.g. due to uneven cavity pressure, can create a
moment onto the corel relative to .the cavity. There-
fore we have to make sure that during the moulding
process the two mould halves are properly located
and unable to move. This can be done in the form
of a taper arrangement (male and female taper) as
per drawing 3-061.
Form No. 4.003

._--- ----- -- -- -------
.. ..
POll TE KN IK M E KA N IK TOO L f) E S I GN 3 1 94 - 90
~-----S-W-I-S-S-.-I-T-B----~----------------------------------~-------__i
Th~"t~per pair is adjusted to be without ~le3rance
in closed position. The taper angle might be any-
thing between 100 to 30°, depending on the tuper
length.
In addition 2 guiding pillars are to be provided in

order to check the relative rotation of either of
the halfs. Moreover the pillars serve [or con-
venient tool setting.
Notes :
In general the guide pillars and bushes should

have different sizes to avoid wrong rno un t i "lg"
For instance: An injection mould with 4 Guid~-

pillars (~esp.bushes) with a size of 0 20 should
be changed to 3 pillars with 0 20, one pillar with
18 a.s.O."
POllTEKNIK MEKM~IK TOOL JESIGN 3 94 - 91
SWISS - ITB
Tcol Location 3 - 059
Guide Pillars (Conve~tional System)
Close sliding fit with ejector plates

Ad·usted
Medium press fit
REMARKS
Form. No _4 _on 1
- _--------
TOOL DESIGN 3 9 '+ - 92

POLITEKNIK MEKANIK
SWISS - ITB
Tool location 3-060
GUIDE PILLARS
ReCCIm"ended system
See PMS - Standrd No. 1
5 12 1
,
r
\\\
10 16 18 -17 13 2 11 8 20 e 21 6
L Guide pillar 8_ Push back 15. Clampinq plate upper

2. Guide pin 9. Ejector 16. Riser
3. Guide bush 10. Stop pin 17. Ejector holder plate
4. Guide bush II. Cavity plate lower 18. Ejector hack plate
5. Centering sleeve 12. Cavity plate upper 19. Sprue bt;sh
6. Locating ring 13. Support plate 20. Cavity Ln s e r't; lower
7. Ejector plug 14. Clamping plate lower 21- Cavity insert Ilpper
~-------.------.. -.,. -.. .,..
/)
SWISS -rra Too1 IDeation 3 - 061
Cl Mould closed
Locating ring
Air outlet Sprue insert
Sprue bush
Guide bllsh
ring
ring
Support pla·te
Guide bush
Ejector rod
Ejector
-------------j~
Ejector holder:
plate
x--
Locating or
guide pin
w i t.h dif-
ferent sizes
to avoid
wrong
mounting
_l__ ----+------'------L-.--J
Form. No • 4 . 003
-_.- _---
._."... --------- ------ ------- ----
------------------,-----------------------------------r-----~
POllTEKNIK MEKANtK TOOL DESIGN I 3 94 - 94
SWISS· ITS
._.1 • 12. Mould - Ventilation
Sometimes it happens, due to the shape of the com-

ponent or even because of the position of the gate,
that air is trapped inside the cavity. The result
can be a partially burnt component/or an incomplete
filled cavity. Now we have to admit that it is
very difficult to predict whether air will be trap-
ped or not. Usually, the air during injection can
leave the cavity through ejector-holes and the
partingline. Preferably the parting line itself is
surface g~Qund with a slightly roughter finish,
hence allowing the air to leave. Since the air is
much "th~nner" than the plastic, no flash should
appear. In view/that it is very difficult to fore-
see airtraps , it is a common and recommended prac-
tice, while designing the tool)just to ignore any
ventilation facilities and await the first trial.
If necessary/then we always can grind a faint qroove
of 0.01 to 0.02 maximum depth and a few mm width
(according to how fluid the plastic is). While we
decide about the type of gate and its position on
the component, possible airtraps should be taken
into account.
3.13. In case of difficulties : (a bit of trouble shooting)
Now your mould is ready for the first shot, the

tool setter has tried his _level best. First o~ all
you should not expect that the mould is working
perfectly since the first shot. Most of the time
a few corrections or adjustments will have to be
carried out after the first trial. The very first
few shots should be discarded because they will
serve to put the mould into the correct temperature
and to adjust the injection pressures. Now this
should be O.K. Although you have tried hart to
think about everything while designing and m3king
the tool, it happens again and again that it just
doesn't work out first.
We shall note a few "classical" cases.
POUTEKNIK MEKANIK TOOL OE5IGN 3 I 94 - 95
SWISS - ITS
3.13.1. Plastir appears sidewards of the nozzle
Causes : - Nozzle-bore and sprue bush (or sprue

hole) are not properly aligned.
- Nozzle is not set firmly against the
sprue bush.
- The radii on the contact areas of nozzle
and sprue bush are not well correspond-
ing against each other.
3.13.2. While mould opens sprue breaks off, remains on in-

jection side and cannot be removed
Causes : a) Undercut on the sFrue cone.
- Radii on the contact areas of nozzle

and sprue bush drc not well corres-
ponding against each other (nozzle
radius bigger than sprue bush radius)
- Nozzle bore and sprue bush (hole) are
not properly aligned.
- Nozzle bore is bigger than the sprue
hole.
- Sprue bush (spruenhole) is not well
enough polished. Remember: never
polish sprue holes radial, always in
opening direction iaxial).
b) ?prue is not yet cooled dONn
- Sprue hole'is compared to the volume

of the component, too big.
- Sprue-system is not sufficient cooled.
Compoaent cannot be removed at all or damaged only
a) ; Component remains on the injuction side

j_~2yi ty plate)
Ca ussex - Undercut in sprue hole-cone or sprue
" system.
Form No.4. 003

POLITEKNIK MEKANIK TOOL I 94 - 96DESIGN 3
SWISS· ITS
~------------------~-----------------------------------------------~
..- Cavity ii not polished well enough in
opening direction.
- Cavity is insufficient tapered.
- Vacu~ between cavity and component.
- Mould temperature on Cavity-side js
.. too low.
b) Component is destroyed while ejected
Causes : - Ejectors are wrongly placed (the

ejector pressure is highest at th~
beginning of ejection).
- Ejectors too small, therefore. the
whole ejection-pressure is assembled
on a too small area. The plastic
cannot stand the stress and will be
pierced by the ejectors.
- Polishing is not done well enough in
ejection direction.
- Form part is insufficient tapereu.
- Vacuum between form part and component.
3.13.4. Cavity is not completelv filled
Causes : - ~unne~s (primary and secondary) are too

long and/or too narrow (runners cool
down earlier than the component}"
3.13.5. The result is twisted component
Causes : - Unsuitable type of gate

- Unsuitable position of gate
- Mould temperature not balanced (In case
of important different wall thickness,
it is necessary to install several
cooling circuits) .
- Wrong mould temperature
3.13.6. Surface of the component is not nice
Causes : - Cavity/punch insufficient polished

- Unsuitable type of gate
-----------"._-~-".. --., ....... _-_ .. _ ' ..

-------_------
POLITEKNIK ME KAHil TOOL DESIGN 3 , 94 - 97

SWISS - ITO
- Mould too cold

- Gate too small (burnt spots on component)
3.13.7. Shrink marks on the component
Causes : - Spr~e/runner system too small (the sprue

is cooled down before the final pressure
of the machine occurs) .
- Mould temperature too low
- Variable wall thickness of component
3.13.8. Welding - Lines on the component
Causes : - Unsuitable type of gate

- Unsuitdble position of gate
- Section of gate too sm211
- Ventilation o~ cavity is insufficient
- Mould cooling net balanced
- Plastic and/or m~uld temperature too low
3.14. And finally :-.
Your senior requests you to make a mould. Unfortu-

nately he can show you only a sample of the wanted
component. He cannot provide you with the necessary
assembly-and detail drawings for the requested mould
hut he wants you to develop it by yourself. Before
you start to cut somehow ste~l plates we recommend
you to ask a few questions :
a) On what type of machine will this mould be

operated ? (Handmoulding, auto~atic moulding
etc. )
b) What maximum opening stroke you find on that
machine ?
c} Size of the mould locating plates on machine
(distance and dia of the tie-bars ?) minimum
hight of the mould ?
d) How many components are expected to be produced
with that mould (according to that number of
oornpor.e nt s it will be decided w het.he
r you will
Form No. 4.003

-_._- --_.- ._._-----
POLITEKNIK MEKANIK TOO DESIGN 3 I 94 - 98

SWISS· ITB
propose a simple single cavity mould with ~heap

guiding system or you suggest a fast producing
(automatic) 4 to 6 cavities mould).
e) What ejector-system is available on the injection
moulding machine ?
f) Shrinkage of the component-material in percen-
tage ?-
g) Do you have or can you get suitable die-steel
for the punches, cavities and guiding system?
h) Is your workshop equipped to make that mould ?
i) Do not hesitate to prepare well job, make sket-
ches and drawings.
3.15., Steel qualities required for Injection moulds

(normally applied).
Mildsteel: For backplates, spacers, ejector-plates,

cavity and punch plate (in case we use for the actual
form part tool steel insert only), centering plate.
Medium alloy tool steel e.g. Boehler Amutit or MST
Guiding pillars, bushes, guiding plates for sliders,
•• slider
punches
closing plates
(in case of lower number
(pressures plates,
of components
cavities
only),
and
ejectors, pushbacks, locking units (3 plate l.T!oulci.s-).
High cromium, high carbon (e.g. Boehler Spec. K)
Cavities, punches, sprue bushes.

Note: Neither tool steel equivalent to ?\IlIutit:
or
high cromium high carbon is the most suitable mate-
rial for cavities and punches. We have selected
those because they are readily available on the
market and the results are quite satisfactory.
The composition of the best suitable steel for

cavities and punches is estimated to be as follows :
Trade name : e.g. Boehler NWM

Analysis : C 0.42 Ni 4.0 Cr 1.3 -Mo 0.25%
Designation: uIN 17006 x 45 Ni Cr Mo. 4
Notes:
L- ,~"" ...
__ ,_,,..~.,~""~_,:,~,.':'"t<'~..._-...:,." ...",'t
r-------------------~~------------~------------------------~------
POliTEKNtK MEKANIK TOOL DESIGN I 3
__ 94 - 99
SWISS"- rr a
Thermoplastics
3. 16. General
Thermoplastic can be brought back from the solid

state to a more or less fluid one. All we have to
do is to heat it up. Normally by a temperature
above 80° C the material is soft enough to be
formed. Further heating makes the molecules more
mobile, the material appears more fluid and vice
versa_ Chemically seen the fficleculesare (unlike
the thermosettings) not bound (crosslinked).
This is the reason why thermoplastic scrap can be
used again. Of course too many repeated melting
processes of the same material should be avoided,
the quality of the plastic would considerably
d.ecrease.
3.17. Raw - Material sources of thermoplastics
Table 3 - 062 gives a rough iffipressionof the sour-

ces of a few popular thermoplastic families. As
_ w.e can see the basic raw materials are found in the
nature : crnde oil, natural gas or coal.
3.17.1. Polyvinyl Chloride ( PVC)
PVC is colourless and transparent to grey but may

be coloured as per requirements. It is odorless
and very resistant against acids, caustic solution,
_ petrol. PVC is basic~lly har~, but it can be made
Soft and flexible by mixing wlth so called plasti-
ciser. Plasticisers are chemicalS which are able
to force apart the molecular chains of a polymer
(e.g. PVC), thus reducing the attractive forces
of the molecules. The visible effect is the soft,
flexible plastic.
Specific weight: 1.35
Application of soft PVC
Hoses, raincoats, seals, boots, protection-gloves

(against water and chemicals), upholstery covers
Form.No.4.003
SWISS· ITB
(so called artificial leather), protection covers,

packing films, wire insulation.
Application for hard PVC
Pipes for chemical industries, tanks, flanges;

bath-containers, spacer bushes, insulation parts,
switch boards, distributor-housings, toilet con-
tainers.
Properties of soft PVC :
Cheap in price, flexible, transparent, chemical

resistant, excellent electric insulation properties.
Properties of hard PVC
Cheap in price, good chemical, electrical dnd me-

chanical properties, rigid, difficult to set on
fire.
Trade names soft PVC
Coroplast, Vestolit-soft, Miplolan.
Hard PVC
Hostalit, Vestolit, Vinnol etc.
3.17.2. Polystyrene (PS, SAN, ABS)
Polystyrene is entirely made out of coal. It:.is

resistant against acids, caustic solutions, oils
but not against petrol and benzene. It is brittle
and transparent. If standard PS-item is dropped
to the floor a characteristic metallic ringing
sound will be noticed. It is quite cheap to buy
and also the electrical (insulation) properties
are good.
Specific weight : 1.05 - 1.2
Application:
Lamps for signals on switchboards, insulation parts

in all electrical fields, packings, foam-parts
(called Styropor) ,model-kits, office items.
'-------------------~----------------.-- ..- _ __ a ,',

.
I
I POllTEKNIK MEKANIK
SWISS· ITB
I Note :
,.
In the motor-car industry more often acry-
lics then simple PS is used. This is be-
cause PS is not resistant to petrol.
Trade names: Trolitul, Lacqrene, Syrene,
Lustrex.
3.17.2.1:. Styce!'1eAcrylonitrite ( SAN )
SAN is closely related to PS but is considered to

have improved properties.
Properties
: It is also inexpensive, lisht~transparent3 higher

heat stability than PS~ better mechanical proper-
ties and better heat changing stability than PS.
SAN is a basic polystyrene-plus means roughly a
mixture of standard PS and acrylics.
~ication :
Food mixers (because very resi~tant of food oils

such as orange peels), cups, tumblers, kitchen
equi~~ent, hair curlers, laborat0ry utensils,
toys, etc.
Trade names: Luran, Vestoran B.
3.17.2.2 ~crylonitryle-Butadiene-Styrene (ABS)
ABS might be regarded as a toughened polystyrene-

plus (SAN).
Properties
It is inexpensive, heat-stable, tough and is

supplied coloured only.
Transparent it is (unlike PS and SAN) not available.
Good chemical resistance.
Application :
.:Safety helmets, tool boxes, luggage carrier, tele-

.f'o
n casings, pipings (carrying corrosive chemicals
and natural gas), battery housing, vacuurn cleaner
housing etc,
Form.No.4.003
POLITEKNIK MEKANIK TOOL DESIGN 3 I 94 -. 102
SWISS· ITS
3.17.3 Polythylen~ or (Polythene) (PE)
PE is produced out of crude oil. The specific

weight is 0, 92-0, 94. It appears like wax.
Properties'
It is inexpensive, the electrical properties are

good.
It is considered as being chemical resistant. The
weldability and formability is appreciated.
Application
Cheap household goods such as buckets, basi~~, pick-

nic utensils, blow-moulded flasks and bottles, pags,
'packings, tins, pipes, protection-sheets, insula-
tion, bottle. crates.
Basically we distinguish between soft PE and hard

(rigid) PE. The material is the same but the diffe-
rence is c rea t.ed by the way of manufacturing it :
Soft-PE (low density-PE or LDPE) is made under high
pressure. It supports temperatures of plus 70 to
minus 50 degrees centigrades. LOPE is flexible and
very strong. It burns slowly only and smells like
a burning wax candle.
Rigid PE (high density PE or HOPE) is fabricated
under low pressure only.
This way of making PE was invented by a German named
Ziegler. HOPE is comparatively rigid, resists boil-
ing water (softens at about 120 degrees C) .
The impact strength is lower than on LOPE. Due to
the rigidity pipes, bottle-crates etc. are made out
of it.
Trade names: Hostalen, Lupolen, Vestolen, Trolen,
Plastylence, Acodur, Symalen.
POLITEKNIK ME KANIK TOOL DESIGN 3 J 94 - 103
SWISS ~··ITB
3 ..17.4 ~olypropylene (PP)
PP resembles much to PE. Often it is considered

as "FE-plus".
Properties
i
PP has similar improved properties to PE. Softening
temperature is 140 degrees. An outstand~ng feature
is the resistance to fatigue on flexing. This be-
haviour is used and taken advantage for moulding
hinges ·(e.g. on boxes). It works well provided it
:~s designed properly.
~lication
All sorts of domestic goods e.g. vacuum cleaner

casings, washing machine parts, hinges, ventilators,
mixer housings, coil-cores, pipes, flanges, films etc.
Trade names: Hostale PPH, PPN, Simona PP, Syrnalen PP,
Vestolen PP, Prylene, Daplen,
Films : Alkoron, Polyen, Pegusyn.
3.17.5 ?olyarnides (PA)
PA is condensed out of phenol. The natural colour I
is milk-white. It is difficult to light it and as

soon as the flame is removed, it stops burning. It
has a slippery feel. To improve certain properties
PA is mixed with fibreglass, graphite etc. Specific
weight 1.13
Properties
PA is of high impact strength and very resistant

against wear. It is formstab1e up to 100 degrees C
and odorless. The sliding-ability of PA is well known.
Application
Ladies stockings, drip-dry shirts, parachuts, tents,

moutaineering ropes, gears, tushes, cams, catches,
bearings, seals, rollers, slide-rails, screws.
Form No. 4.003,

----------------------- ------
---.----------,r--------------------- .....
I ---....,
-
94 - 104
SWISS - ITS
~-----------------------------------------------------------------------~
Trade names : Nylon, Per lon, U 1tramid, Gr i1or;,
Aku1on, Trogamid, Orgamid, Nylatin.
3.17.6 polycarbonates (PC)
Similar t6 PA, PC is regarded as of preferred tech-

nical use except for sliding purposes. Especially
in the baby-bottle industry it is applied. PC can be
reinforced with fibre glass which increases the impact
..
strength. Sp~cial weight: 1.2 - 1.4
Properties
It is hard (rigid), transparent, heat resis~ant

(softening point 165 degrees C) with good electrical
insulation properties and high impact strength.
The excellent dimensional stability is well known.
The only disadvantages : it is not resist~~t at all
• to alkalis and some organic solvents . The coeffi-
•
t
cient of friction is comparatively high.
Application
"Unbreakable" bottle, pum p+whee Ls , transparent cover

for relays, switchboards, safety helmets, lighting
covers, sterilisable ware, business machine parts,
film cassettes, came ra=ho cs i nq s .
Trade names: Makrolon, Lexam, Merlon, Pokalon,
Synthon, Sustonat.
3.17.7 Poly tetra flu~rethylene (PTEE)
It is very siippery to touch. The natural colour is

blue-white. When uranium 235 was purified it was
found that PTEE was suitable to handle the highly
cor~osive comvounds associ~ted with that process.
.... ------------------------- . b'· ..·~·-_ ......,~t'~:,~·

• .,...., "",.' ...
POLITEKNIK M£KANIK TOOL DESIGN 3 I 94 - 105
SWISS· ITIi
,p'~·opert
ies
,They are absolntely outstandinq in the following

point:s :
- Temperature stability from minus 2600 to plus

2800
c.
- ';Chemic?l res i stance
Lowest coefficient of friction of all kown
solid materials
- Non-stickjng (anti-adhesive) surface
Application
Bearings, guide-·rails, bushes, insula tion material

for extreme conditions, pipes, container for criti-
cal chemicals, anti-adhesive films, surface-layer
for nc~-sticking frying pans, mixing equipment for
chocolate, cofee etc.
Trade names : Teflon, Hostaflon, Fluon, Algoflon.
3.17.8 Polymethyl Methacrylate (PMMA)
Acrylic glass, is transparent and will remain so

even after being exposed for a long time to the sun.
It is not as heavy as real glass, but it can be
scratched easily. Above 700
to 100 0
C it can be
formed.
Specific weight 1.2, if burnt a little blue flame
with a yellow top is observed.
Properties
It is hard, extremely resistant to weathering, high

clarity. It is resistant to water, alkalis, and
most dilute acids. Benzene and alcohol are creating
cracks.
Application
Outdoor signs, boat windshields, cockpit-covers for

sports planes, replacement for conventional glazing,
inspection windows, safety goggles, watchglasses etc.
POLITEKNIK M EKANIK TOOL DESIGN 3 I 94 - 106
SWISS - ITS
r---------------------~-----------------------------------------~----------~
Trade names : Perspex, Plexiglas, Resartglas
(Plates, rods, etc.)
For injection moulding only :
Plexigum, Resart.
3. 1 7.9. polyacetal ( POM )
polyformaldehyde is the standard POM. A.lthough

associated with formaldehyde, POM is clearly a
thermoplastic (unlike formaldehyde with phenol,
this is thermosetting). The trade name of this
standard POM is Delrin. It is hard and has.a
high melting point (176°C). POM's are rigid and
remain so upto quite high tem?eratures. The coef-
ficient of friction is very low (but still higher
than PTEE).
The best known application is for small gear

wheels (watch-and meter industries). But also in
• other fields it serves often as substitute of light
metals_
..._--------------~----------.------ --.-.... ,.,,--., .•.-.. ..-.~. _ ..... " .. , .•..,...

_------- -----------

SW:SS - ITB 3-- 06S
Raw Material Sources
ICRUDE OIL] I\'ATURAL GASI
/) L.. - __ "
/ )
1/
1/
/ I
/ (
I I
I
+CLOROFORH
+ HYDROfLUORIC
ACID
PE PA PC PMMA PTF[
POlY POLY.4MfOE PCi...Y POL YTE TR
£THYL£M CA~TE
L-- __ __I '-- .J '--------'
HUORO
THYLENE
POLITEKNIK..
SWISS - ITB
MEKANIK
TOOL DES I GN 3 ~4 - 1 U3
~erhit~gan Paulding
1. Layout roouId ,
1.1. Nama sifat-sifat dal-i mould _
_pe..:...9<-o:_::_s_t..::...ek__ sn.. ~G~r~1~J

£,""je;:_;:c'-'-t:o_:.or ------------N. , ,
Plat dukung
--_--- ---------_,
Ir,serf
insert
.__----------~-------------.
TeOL DESI GN 3 ~4 - 109
POUTEKNIK MEKAN1K
SWISS· ITB Perhitungan Moulding
1.2. Menentukan jumlah cavitL
Junlah cav.iti pada rnouId seear a teori tis I adalah
volune injection max. dari roesi n Sv dalcrn (1)

volune produk + sprue Vv da Lem OnJ
Kalau kita hitung secara praktis
Aliran L dalam On3/min

(2 )
Banyaknya caviti yang dapat diisi z/min. Vv dalcrn
Karena pada C2 ini sprue d.i hi.t.unq juga, maka C2 harus-<

atau = dengan C1.
C ~ C
2 1
Dalam prcktek diambi1 (3)
(4)
Pdapun Kekuatan Injection ia1ah
F (kp) (5)
Dirnana F Caya pres, A = Luas proyeksi dari eaviti + sprue

P =: tekanan spesi fik massa pemberrt.ukan dalam cavi ti.
Tekanan kerja dari cavity dan sprue.
Sv =: 100 Qn3 L 17 kg/h = 283 Qn3/r.tin. dan V = 12 On).
Menur'Jt rumus (1) maka banyaknya cavity C1 ialah
Sv 100
C1 = Vv
12- ~ 8
Menurut rumus (2) I maka banyaknya Caviti C

dengan m::mperhitungkan
2
banyaknya injection sebesar 4 .i.nject.i.orr/rreru.t , rnaka :
L 283
C2 = z Vv- 4 . 12
~ 5
Karena C2 menw:ut ruITnJS (3) harus ~Cl' rnaka unt.uk rrenentukan

banyaknya caviti menurut rumus (4)
C =: 8 . 0,8 ~ 6
POllTEKNIK MEKANIK TOOL OESIGN 3 ~4 - 11U
SWISS - ITS Perhitungan .['.bulding
2. Gates.
2.1. Sprue gates dimensioning
Tabe1 13.
Berat bahan yang dl.inject (gr) Bahan yang diinject Diarreter sprue (rnn)
100 Semua Terrroplastik 4 - 6

100 400 G 8
400 1000 8 10
..
1000 10 12
2.2. Ring gates dimensioning
E
E
'"
Pengukuran karalcteristik
2. 3. Flash gates dimensioning
~
(
I
I
i
~~~~,
1
E
I' E
I
l}
.
~_I
\:)
-r-
\:)
p'" UTEKNIK MEKANIK TOOL DESIGN 3
SWISS· ITB
Perhitungan moulding
2.4. Sub marine gate design
o eSIngn kONl:rukSi qctr

~ntuk mouIC,.-:;
3. tbuld ventilation
Detail X
Molding untuk wudah deogan

ve nutc si scturcn melingl<or
E
E
""c"
c
m
A
'>1oulding mencetak
r1*;ngon venittosi
'
be bercron
s ctorco
~5d.5mm
Potongongo
pro duk
A-A
j_
-~ '1"
POllTEKNIK MEKANIK TOOL DESIGN 3 I 'J4 - 11 2
SWISS - ITB
Perhitunqan tvlouldin
'" . t-buld Cooling
4 .1. Processing and mould temperatures

Te mpe r a t u r p ro se s uan t emp e rn t u r moulding uncw< m:!~Oi:r,
B .l han r c- ) T~mp. ~~:- .~ .1
i'o lv.t r hvl en dengan k e r ap a t an rcnd ah I -I) 260 i) 70

1'\)I\':Jth~'len dengan k e r ap a tan t in!:gi 220 :;: 'J 0 70
"0 1 vs t r o I -.\.t:mJar ZOO :30 :;0 60

"0 t y s t ro 1 t ahan ke j u t an 200 250 31.) 60
t') Po l v arn i d :10 ~90 60 1:)0
n Po l v am i d + fiber glas 260 310 SO 120

6,6 1'0 I vami d 260 :;00 10 I ~O
6,b ~ 1'0 t yam i d ~ f i b e r ::sl~\s 2 ~O 3::C 1
60 120
I'. I') . r" I:. amid :;0 26C 1

50 I.?0
vc ri Ln i t r i l - styrol : :;0 :~O 5('1 80
Po t vme t tta c r y lme t hac r y: at 1-0 : :;0 ~L1 90
Po I yc a rb o n a t 280 :;;0 55 120

vce r a i .:opo
. 1 vme r isat [:;0 .: 30 -0 ISO
ro! ,'\'1 n :.' l c a 10 r id I una k ISO 20 80
PQl~'vln~l~hlorid ke~~s 160 :;h~ :'.1 so

Polypropylc-n I SO : SO SO
Cellulost;!,:.H.:etat I SO 230 .1.0 30
~..:~ l u !'.)je~\...:.et.obut:-!·:l;: ISO ~.: ~} -'. so

........~ :~Ji..I::)t!':)!-,:)piU:1;lt 1S0 .,' 50
vc ry l n i r r i I - Styrol - g,,::tc!i<"n (.-\BS) ! SO :~J :;0 SO
4.2. Cooling holes distances
Harga - harga yang t er tul~

berdasarkan p e nqokirncm
unlUi( lubong ~endingin
CKK = (2.5 sId 3,5 ) 0
st<K ::>:: (0,8 ~ 1,5 ) OKK
4.3. Cooling Media
Air 'I'emJ?eratur yang dapat dicapai 50 sarrpa.i 90° C
Oli Temperatur yang dapat dicapai
('
POLfTEXNIK ME:KANIK ~ TO_O_L O_ES_I_G_N 3 ~~94~" - 113
SWISS - ITS
5. Ejector Systems.
S.L Ring ejector
Per,nUkoan tirus s~bogal pt!'nE'pot
Molding untuk congl<ir dengon ejector mel'ngkar Corp moulding don ~.«tor mehngkar
5.2. Disc ejector dan air ejector
Sudut exdalarn praktek diarrbil ex
Pan "d'r.lQsi sebagoi

eJect:r udora
e:j~tnr piring dilenglcapi

(I.ngan oliron pen ding;n
-'-------~--.~------------,._..-----
TOOL DESIGN 3
POLITEKNIK MEKANlK
SWISS: ITB Perhitungan Moulding
r-------------...L...----_::_----.:.....------,-.------4
6• TaI_:er fo.rmt.cx:>llocation.
./
//
./
/,,///
/ /
/
, ,
, "I
~,
" ''Y'
'''\
"-...i ,
-, ''''.;'
------~--------:;;,;__-.-_._ ~.;_:,-, .'----,-----

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INSTITUT T E K N :) LOG BAN 0 U N G

BANDUNG NSTITUTF UF TECHNOLOGY

PROYEK POLYTEt<".NIK MEKANIK SWISS

A PROJECT OF THE SWISS TECHNICAL COOPERATION

AND SWISSCONTACT. THE SWISS FOUNDATION

SWISSCONTACT FOR TECHNICAL ASSISTANCE. Z(JAICH

PROYEK POLYTEKNIK MEKANIK SWISS

Compiled by H.R. Luchsinger

Gener~l Calculations 109

Mould Ventilation 111

r·1ould Cool inq 112

Ejector Systems llJ

Taper Formtool Location 114

Edition April 1982

3. INJECTION MOULDING ( General .)

If we observe some typical parts produced by injection

(a) More or less uniform wall thickness

This observations we shall discuss side by side when we

An injection mould is a tool for producing plastics

Form No. 4.00.3

As it is clear form the name of the tool that it ~on-

Figure 3-001 shows a systemic diagram of a mould, a

Before we move to that, a short explanation about

3.1. Cavity and punch

A cavity in a mould is~the hollow space (female part)

Moving pla_!:._ten Plastic granules in hopper

Pressure from hydraulic pump

Pressure from hydro pump stops

C~oling ~ime is over/Injection side moves back/completes dosing operation/

Form. No.4 .003

In ptets o( Ill'In)KtlOft .,,,14

, $'lC,_e:: ~).I:c UoO\IIiiIri ( It, t ...

In this case we would locate the cavity (with a hollow

~-- ..,_ if nn"l

parated by the parting line.

3.1.2. Arrangement of cavities

The layout of cavities in multicavity tools require

(i) Best possible disposition of caviti0s to ac~icvc

(ii) Correct .layout of cavities to obtain o a La ric.e

(iii) Due to the excessive length of runner, a high

'iv) Attainment of balanced clamping is imp6rtant

In figure 3-004 we see some possible layouts for

FOrlll No. 4.003

In case the section is comparatively too big the

3.2.1. INSULATED Runner

In this type of mould the sprue bush has a -["(~(".;h;:,mbl2r

In this case the injection nozzle temperature lS

rnaintained electr ica 11 y to avo id coa t ing of .nater ial .

Also this system permits fully automatic working,

Form No. 4.003

SWISS - ITB Layout of cavities 3 - 003

Ideal solution for this part in

bett.0.r so l o c i o n Centre still liquid

la = 1,25b/r 0,2 iJ ~ough surface

Runner Sections Section of filled Runner

The small passage (or passages) which is leading

Ejected components still linked by runners ( q~tes

A TYPICAL FOUR - CAVITY MOULD

.Sprue Gate (depending u po r: if u i~~ very

Jo ining mark will -y---.....~~""--"-.;:--'>.,~ttlf-~-t+.r--

Sprue pull-2= if (Li,:,=, -::-.:'s c.t is

s h r ; :-_>-_::-_ :::'2:_- Y _;, s no u 1(.1

Diffic~ ection Easy Ejection

C~~=ted the Ejector-