Mould Design Guide

12.7.1 Undercuts at Angle to Tool Axis

Figure 12.21 shows a typical undercut that lies at an angle to the tool split line. Basically,
the design is exactly the same as the side core design that is parallel to the split line except
that it is rotated through the angle that the undercut makes with the split line.

In this design, the undercut lies at an angle of H to the split line. Hence the whole side
core assembly has to be rotated through the same angle H.

12.7.2 Description of Operation

Figure 12.21 Angled undercut side core design

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 Undercut Injection Mould Tools
The operation of this design is exactly the same as for any normal side core design except
that it has been rotated through the angle of the undercut.

There are two features that are undercut on this component: the hole formed by the side
core pin and the boss surrounding it formed by the main side core. Clearly, the amount of
movement of the side core relative to the component must exceed the longest length
undercut – in this case the hole formed by the pin. To this distance, clearance must be
added for safety.

12.7.3 Key Design Features

These are generally the same as those given previously, with the following differences:
x Angle K must not exceed 26q.
x Angle J = sum of angles (H + K).
x S = T u sin J.
x In this case S is greater than P, hence the side core must be withdrawn a distance
S + clearance.

12.8 Curved Undercuts

Components with curved undercuts are often required in medical and laboratory
applications. Once more, the principle of releasing them in the mould tool is exactly the
same as with a normal side core. In this case, however, we have to ‘bend’ the side core
assembly into a curve that matches the form of the undercut.

Figure 12.22 shows the tool design for a component with a curved hole. The curved
nature of the part is a typical of suction devices used in operating theatres.

12.8.1 Description of Operation

1. Hydraulic cylinder D actuates rack A, which operates pinion B.

2. Pinion B is rigidly attached to the drive arm E.

3. As cylinder D operates, drive arm E rotates through angle H.

4. This in turn causes the side core carriage C to rotate through the same angle.

5. It is important that angle H gives sufficient movement to clear the core pin from the
cavity.

6. When the actuating arm is in the fully open position, ejection takes place

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