ADVANCE INJECTION MOULD DESIGN

CORPORATE TRAINING AND 01

SPLIT MOULD

CORPORATE TRAINING AND 02

 SPLIT MOULD
• It is required for components incorporates a recess or
projection right angle to the line of draw, to relieve the
undercut before the moulding is removed.

• A moulding which has a recess or projection is termed

as undercut moulding.

• The undercut may be external, internal, local part of the

component.

• Two or more parts of the cavity closed together in a

chase bolster by using locking heels during injection.

CORPORATE TRAINING AND 03

Fig: 1.1 Fig: 1.2

CORPORATE TRAINING AND 04

 VISIBLE LINE ON MOULDING

• Parting line: The line formed on the molding

surface where the core and cavity closed together.

• Joint Line: The line formed on the molding

surface where the splits (side cores) are closed
together.

CORPORATE TRAINING AND 05

 SLIDING SPLITS

• The splits are positioned in guides on a flat mould

plate are actuated by mechanical or hydraulic system
and those are held together by locking heels which
project on the other mould half.

• The splits are possible to mount on either the moving

or fixed mould plate.

CORPORATE TRAINING AND 06

Fig: 1.3 Fig: 1.4

CORPORATE TRAINING AND 07

GUIDING AND RETENTION
OF SPLITS - SLIDING FIT

Fig: 1.5 Fig: 1.6

CORPORATE TRAINING AND 08

Fig: 1.7 Fig: 1.8

CORPORATE TRAINING AND 09

 DESIGN CONSIDERATION
OF SPLIT MOULD

• The side movement should ensure the split halves

always come together in the same plane.

• In split mould all the parts should have enough

strength to withstand the force applied to the splits by
the operating system.

• It should allow smooth movements of splits.

CORPORATE TRAINING AND 10

 SPLIT DESIGN
CONSTRAINTS
• Amount of splits movement and delay period required.

• Ease with which the molding can be removed.

• Whether a short or long production run is required.

• Whether the available machines are programmed for

ancillary cylinder control.

• Whether molding inserts are to be incorporated.

CORPORATE TRAINING AND 11

 SPLIT MOULD
ACTUATION METHODS
1. Finger cam actuation method

2. Dog-leg cam actuation method

3. Cam track actuation method

4. Hydraulic actuation method

5. Angled-lift splits

6. Spring actuation system

CORPORATE TRAINING AND 12
1.FINGER CAM ACTUATION

Fig: 1.9 Fig: 1.10

CORPORATE TRAINING AND 13

 FINGER CAM ACTUATION
MOULD FOR CAP COMPONENT

CORPORATE TRAINING AND

FINGER CAM MOULD FOR
LEDHOLDER

CORPORATE TRAINING AND

 FINGER CAM PIN

• Hardened, circular steel pins, termed finger cams are

mounted at an angle in the fixed mould plate.

• Length and angle of the finger cam determine the

distance traversed by each split across the face of the
mould plate.

CORPORATE TRAINING AND 14

FINGER CAM PIN

M = splits movement
Fig: 1.11  = Angle of finger cam, 10-25
L = working length of finger cam
C = clearance (0.75mm) 15
CORPORATE TRAINING AND
 CALCULATION

The finger cam movement can be computed by the

Formula
M = (L sin ) – (C / cos )
If the required movement is known, the following formula
used to determine the finger cam length.
L = (M / sin ) + (2C / sin 2)
Where, M = splits movements,
 = Angle of finger cam, 10-25
L = working length of finger cam
C = clearance (0.75mm)
Cam diameter is usually 13 mm.

CORPORATE TRAINING AND 16

 2. DOG - LEG CAM ACTUATION

This actuation system is used where a more

splits delay time is required compare to finger cam
actuation method.

CORPORATE TRAINING AND 17

DOG-LEG CAM

Fig: 1.12

CORPORATE TRAINING AND 18

 DOG-LEG CAM
ACTUATED MOULD

Fig: 1.13 Fig: 1.14

CORPORATE TRAINING AND 19
DOG LEG CAM ACTUATED
SPLIT MOULD

M = movement of each split,

La= angled length of cam,
Ls = straight length of cam,
 = Cam angle, C = clearance, D = delay,
e = length of straight portion of the hole .

Fig: 1.15TRAINING AND

CORPORATE 20
 CALCULATION

Formula for calculating the opening movement, the

length of cam, and the delay period
M = La tan  - C
La = (M + C)/ tan 
D = (Ls – e) + (C/tan )
Where M = movement of each split,
La= angled length of cam,
Ls = straight length of cam,
 = Cam angle, C = clearance,
D = delay,
e = length of straight portion of the hole.

CORPORATE TRAINING AND 21

 3. CAM TRACK ACTUATION
• This type of actuation system is used for components
having under cut which requires more delay period

• Due to external fitment of cam track the mold actuation

system becomes simpler and mold cost is reduced.

• The cam track is machined into a steel plate attached to

the fixed mould half.

• A boss fitted to both sides of the split runs in this cam

track.

• The movement of the splits accurately controlled by

specific cam track design .
CORPORATE TRAINING AND 22
 CAM TRACK PLATE

Fig: 1.16 Fig: 1.17

CORPORATE TRAINING AND 23
SLIDING SPLIT MOLD
(CAM TRACK PLATE
ACTUATED)

Fig: 1.18
CORPORATE TRAINING AND 24
 ASSEMBLY OF CAM TRACK
ACTUATION MOLD IN CLOSED
POSITION

Fig: 1.19
CORPORATE TRAINING AND 25
 CAM TRACK

M = movement of each split,

La= angled length of cam track,
= cam track angle,
C = clearance, Fig: 1.20
D = delay,
R = radius of boss
CORPORATE TRAINING AND 26
 CALCULATION

M = La tan  - C
La = (M + C) / tan 
D = Ls + C/ tan  + r ( 1/tan  - 1/sin  )
M = movement of each split,
La= angled length of cam track,
 = cam track angle,
C = clearance,
D = delay,
R = radius of boss

CORPORATE TRAINING AND 27

 4. HYDRAULIC ACTUATION

The splits are actuated by hydraulic system. It

is independently opening movement of the mould.
The splits can be operated automatically at any
specific time by the operating program of the machine

ADVANTAGES
• Cycle time less
• Large delay movements and large split movements
can be achieved

CORPORATE TRAINING AND 28

 DISADVANTAGES

• The mould is more bulky as compared with the

other designs

• Mould setting more difficult and the hydraulic system

has to be connected each time the mould is set up.

CORPORATE TRAINING AND 29

HYDRAULIC ACTUATION
OF SPLITS

Fig: 1.21
CORPORATE TRAINING AND 30
 ANGLED-LIFT SPLITS

• In this method the splits are mounted in a chase-

bolster, which forms part of the moving half of the mould.

• The splits are moving outward with an angular

motion which relieve the undercut portion of the
molding and retraction of the split alignment is
controlled by using spring actuation or cam track
actuation

CORPORATE TRAINING AND 31

 ANGLED LIFT
SPLITS DIAGRAM

Fig: 1.22 Fig: 1.23

CORPORATE TRAINING AND 32
TYPES OF ANGLED LIFT SYSTEMS

• Angled guide dowel actuating system

• Cam track actuating system

• Spring actuation.

CORPORATE TRAINING AND 33

 ANGLED GUIDE
DOWEL ACTUATING
SYSTEM
• The Guide dowels are fitted at an angle to the
underside of each split which passes through holes
machined at an angle in the chase-bolster.

• When the ejector system is actuated, the relative

movement between the ejector plate and the chase-
bolster causes the guide dowels to move forward at
an angle corresponding to the splits which opens.

CORPORATE TRAINING AND 34

 ANGLED
GUIDE DOWEL ACTUATION

Fig: 1.24 35
CORPORATE TRAINING AND
 = Guide dowel angle.
Fig: 1.25
CORPORATE TRAINING AND 36
 The convenient angle for the guide dowel is 10
it may be increased if large opening movement is
required. The actual opening movement of each split
calculated by the following formula.

M = E tan 
E = effective ejector plate movement,
 = Guide dowel angle.

CORPORATE TRAINING AND 37

 CAM TRACK
ACTUATING SYSTEM
• In this method the opening movement of the splits
are controlled by a cam track. When the splits are
actuated, studs fitted to each end of the split slide
along this cam track.

• Actuation of the splits is by means of pin ejector

system. The splits are fitted into an open channel type
chase-bolster, which have wear plates.

• Studs, screwed into the splits, protrude into the cam

track machined in the cam track plate which is
attached to the bolster.
CORPORATE TRAINING AND 38
CAM TRACK ACTUATION

Fig: 1.26 39
CORPORATE TRAINING AND
 CALCULATION

The opening movement of each split

calculating by
M = E tan 
E = effective ejector plate movement,
 = Cam track angle, usually 15

CORPORATE TRAINING AND 40

 SPRING ACTUATION
• The opening movement of the split depends on
the slot provided in the chase bolster and the spring
effective expansion length.

• This ejection method is suitable for shallow

undercut components.

•The ejector pin actuates the split, the spring exerts

the a force to vertical direction, which maintains
contact between the split and the angled wall of the
chase-bolster and gives angled movement to the
splits. Thus the splits get open.

CORPORATE TRAINING AND 41

 SPRING
ACTUATION METHOD

Fig: 1.27
CORPORATE TRAINING AND 42
 SPRING ACTUATION SYSTEM
• This actuation system is suitable for small straight and
angled undercut components.
• In this method the compression springs are used to
force the splits apart and utilizes the angled faces of the
chase bolster to close them. The opening of split
movement should be limited so that they will allow to re-
enter the chase bolster when the mould is closed.
• The splits are mounted on the mould plate and retained
by guide strips. Studs project from the base of the splits
into a slot machined in the mould plate. The length of this
slot therefore controls the opening movement of each
split.
• A compression spring is fitted between the studs in a
link-shaped pocket situated in the lower mould plate. The
splits are held closed byCORPORATE
the chase bolster.
TRAINING AND 43
SPRING ACTUATION

Fig: 1.28
CORPORATE TRAINING AND 44
 SEQUENCE OF OPERATION
• The chase bolster holds the splits during the injection
phase.

• The compression springs exerts a force to split halves

immediately when the mould starts to open.

• The stud reaching the end of the slot in the mould plate
stops the split movement.

• Continued movement of the moving mould half

operated the ejector system to release the molding .

CORPORATE TRAINING AND 45

 CALCULATION

The formula for calculating the splits opening movement is

M = ½ H tan 
Where M = movement of each split, Approximately
H = height of locking heel
= angle of locking heel
Suitable angle for the locking heel is 20 to 25.

CORPORATE TRAINING AND 46

 SIDE CORES

• It is a local core mounted at an angle to the

mould axis for forming a hole or recess inside
the molding.

• This side core prevents the in-line removal

of the molding hence, side core must be
withdrawn prior to ejection .

CORPORATE TRAINING AND 47

 TYPES OF SIDE CORE

Internal Side Core Assembly

• The dog-leg cam actuation method
• The spring-loaded system

External Side Core Assembly

• Side cores on the parting surface

• Side cores below the parting surface

• Angled withdrawal Curved side core

CORPORATE TRAINING AND 48
 INTERNAL SIDE
CORE ASSEMBLY

• In this method the side core is T-shaped is mounted

in guides, which are securely attached to the moving
mould plate.
• The retaining plate to the carriage secures the side
core element.The actuation of the carriage is by
means of a finger cam/dog leg cam method
• The carriage is locked in the forward position by the
locking heel

CORPORATE TRAINING AND 49

 DOG-LEG CAM
METHOD OF ACTUATION

Fig: 1.29 50
CORPORATE TRAINING AND
THE SPRING-LOADED SYSTEM

The spring-loaded system is an operating

method confined to those moldings that have very
shallow undercuts or projections.

CORPORATE TRAINING AND 51

Fig: 1.30
CORPORATE TRAINING AND 52
 EXTERNAL SIDE
CORE ASSEMBLY

In this design, the side core is fixed to an

extremely mounted carriage which is actuated by
hydraulic or pneumatic means.

CORPORATE TRAINING AND 53

Fig: 1.31
CORPORATE TRAINING AND 54
 CURVED SIDE CORE
• The core is withdrawing from the mould along the
arc of a circle.

• It is suitable for components requires smooth curved

internal hole

• Example: telephone hand set and pipe fittings.

• In this type of component the side core can be

mounted on the parting surface of the mould.

CORPORATE TRAINING AND 55

MOULDS FOR
INTERNAL
UNDERCUT
COMPNENTS
05
 INTERNAL UNDERCUT

• An internal undercut is the internal protrusion or recess

formed in the molding by using matching core or cavity.

• It is prevents a moulding from being extracted from the

core in line of draw.

059
EXAMPLES OF INTERNAL
UNDERCUT COMPONENTS

Fig: 2.1 Fig: 2.2

CORPORATE TRAINING AND 060

 FORM PIN

A component, which has a local undercut portion, can

be successfully moulded in the conventional mould
by incorporating the undercut form on a pin.

CORPORATE TRAINING AND 061

UNDERCUT COMPONENTS
WHICH NEED FORM PINS
ACTUATION

Fig: 2.3
CORPORATE TRAINING AND 062
 TYPES OF FORM PIN
EJECTION

 Form Pin : Straight action

 Form pin : angled action

CORPORATE TRAINING AND 063

 FORM PIN:STRAIGHT
ACTION

This design is normally used for components, which

incorporate an undercut on one internal wall only.

CORPORATE TRAINING AND 064

Fig: 2.4 Fig: 2.5

CORPORATE TRAINING AND 065

 FORM PIN: ANGLED ACTION

• The basic feature of this design is that the working face

of the form pin is caused to move inwards relative to the
core during ejection, thereby relieving the undercut.

• It can be used for components, which incorporate internal

undercuts on one or more walls.

CORPORATE TRAINING AND 066

Fig: 2.6
CORPORATE TRAINING AND 67
 CALCULATION

The amount of withdrawal is calculated by the following

relationship:

M = E tan θ

Where, M = the withdrawing movement

E = ejection movement.
θ = fitting angle of the form pin.

CORPORATE TRAINING AND 68

 SPLIT CORE ACTUATION

This split core may be moved forward either in a

straight plane or an angled plane.

CORPORATE TRAINING AND 69

 SPLIT CORES-STRAIGHT
ACTION
• This design is used for components, which
incorporate an external undercut on one wall only.

• The moulding can be removed at right angles to the

mould axis.

CORPORATE TRAINING AND 70

 Fig: 2.7
CORPORATE TRAINING AND 71
 SPLIT CORE ANGLED
ACTION
• In this design the split core is caused to move
inwards during the ejection stroke, thereby withdrawing
the restriction and allowing the moulding to be extracted
in the line of draw.
• The advantages of this method is that the
withdrawing action automatic and the moulding does not
have to be removed at right angles to the mould’s axis.
• This design can therefore be used for components
with undercuts on opposing faces in addition to being
used for components with an undercut on one wall only.

CORPORATE TRAINING AND 72

 Fig: 2.8
CORPORATE TRAINING AND 73
 STRIPPING INTERNAL
UNDERCUT
Suitability:

• The shape of the undercut,

• The elasticity of the material, and
• Whether the external form permits expansion during
ejection.

CORPORATE TRAINING AND 74

Fig: 2.9
CORPORATE TRAINING AND 75
CURVED SIDE CORE

Fig: 1.32
CORPORATE TRAINING AND 56
MOULDS FOR
THREAD
COMPONENTS

CORPORATE TRAINING AND

 MOULDS FOR
THREADED COMPONENTS
The threaded components are usually prepare for where
the repeated disassembly or where the strength of
assembly is required. The threads can be formed in by
three methods:
 Cored or drilled holes with either thread cutting or thread
forming using self-tapping type screws.
 Molded with local inserts.
 Molded thread formed by using unscrewing threaded
inserts.

CORPORATE TRAINING AND

 TYPES OF THREADS

 External thread.

 Internal thread.

 According to thread shape subdivided into continues

and discontinuous thread.

CORPORATE TRAINING AND

Fig: 3.1 Fig: 3.2

CORPORATE TRAINING AND

 COMPONENTS
INCORPORATING THREADS

Fig: 3.3 Fig: 3.4

CORPORATE TRAINING AND
 MOULDS FOR INTERNAL
THREADED COMPONENTS
The internal thread is an internal undercut in that the
thread forms a restriction, which prevents the straight
draw removal of the moulding from the core. The types of
mould design for withdrawing the moulding, as follows:

• Stripping (jumping-off) thread design

• Fixed threaded core design
• Loose threaded core design
• Collapsible core design
• Unscrewing mould designs

CORPORATE TRAINING AND

 STRIPPING (JUMPING)
INTERNAL THREADS
1. The moulding must be free to expand during
ejection to permit the moulded undercut to ride
over the restriction on the core.
2. The outside form of the component to be formed
in a cavity, which is fully contained in one half of
the mould.
3. The internally threaded component may be
stripped (Jumped) from the core using the
stripper plate design providing a roll thread and
the plastic material has sufficient elasticity during
the ejection phase.
4. This method is recommended for polyethylene
(PE), polypropylene (PP) material.
CORPORATE TRAINING AND
 STRIPPING INTERNALLY
THREADED COMPONENTS

Fig: 3.5

CORPORATE TRAINING AND

 FIXED THREADED CORE
DESIGN
• In this method, the thread form is incorporated on a
non-rotating core fixed to the moving mould plate. An
integer type cavity forms the external shape of the
moulding.

• In operation, when the mould is opened, the moulding

remains on the core and is afterwards unscrewed by the
operator by hand or using release devices.

CORPORATE TRAINING AND

FIXED THREADED CORE
DESIGN

Fig: 3.6
CORPORATE TRAINING AND
 ADVAMTAGES

• Mould cost is cheaper than the unscrewing mould design

because of its require ejector mechanism
• Maintenance cost is minimum as there are no moving
parts within the mould.
DISADVANTAGES

• This design particularly used for multi-impression moulds

where the individual moldings to be unscrewed manually.
• Increases the moulding cycle time.

CORPORATE TRAINING AND

 LOOSE THREADED
CORES
• This method is suitable for a large component
incorporates a local internally threaded hole or has
several internally threaded holes in close proximity to
each other.
• Prevents automatic unscrewing thereby considerably
reducing the cost of the mould.
• Where a number of holes are closely spaced,
automatic unscrewing becomes impracticable.
Because it require space for gear arrangement in
automatic unscrewing operation.

CORPORATE TRAINING AND

LOOSE THREADED CORES

Fig: 3.7
CORPORATE TRAINING AND
 COLLAPSIBLE CORE

• This design is suitable for components having internal

thread and internal undercut.

• The important advantage of this method over the

rotating threaded core designs is that it eliminates the
need for complex unscrewing mechanism.

CORPORATE TRAINING AND

COLLAPSIBLE CORE

Fig: 3.8
CORPORATE TRAINING AND
EJECTOR PLATE ASSEMBLY
OPERATED USING
COLLAPSIBLE CORE

Fig: 3.9
CORPORATE TRAINING AND
 UNSCREWING MOULDS
 High labour costs and other modern production
requirements demand the maximum use of automatic
operation.
 In an unscrewing type mould either the cores or the
cavities are rotated to automatically unscrew the
moldings from the mould.
 To provide the required rotary motion an unscrewing
unit is fitted behind the moving mould plate in place
of the conventional ejector unit

CORPORATE TRAINING AND

Manually powered fixed rotating core design
CORPORATE TRAINING AND
Manually powered fixed rotating core with gear transmission
CORPORATE TRAINING AND
 POINTS CONSIDERED

• In the axially fixed core design, the threaded core is merely

rotated to remove the moulding.
• In the extractor plate design, the extractor plate is actuated
at the same time as the threaded core is rotated to remove
the moulding.
• In the withdrawing rotating core design, the threaded core
is rotated by sun & planet gear mechanism and withdraws
the moulding from the core plate.

CORPORATE TRAINING AND

 IMPRESSION LAYOUTS

1. The pitch circle diameter .

2. The In-line layout.

CORPORATE TRAINING AND

 MACHINE POWERED
IN-LINE UNSCREW SYSTEM

Fig: 3.12 TRAINING

CORPORATE AND
THE PITCH CIRCLE
DIAMETER LAY-OUT

Fig: 3.13
CORPORATE TRAINING AND
CORPORATE TRAINING AND
MULTIDAYLIGHT
MOULD

CORPORATE TRAINING AND 01

 MULTIDAYLIGHT MOULD

• It is a complex mould having more than one-daylight

when the mould is opened.
•It consists of three main parts:

• Fixed mould plate or feed plate,

• Floating cavity plate or stripper plate,
• Moving mould plate.

CORPORATE TRAINING AND 0102

 TYPES OF MULTI DAY
LIGHT MOULDS
1. Double day light, stripper plate mould

2. Double day light, under feed mould

3. Triple day light, underfeed and stripper

Plate mould.

CORPORATE TRAINING AND 0103

 DOUBLE DAYLIGHT,
STRIPPER PLATE MOULD
Suitability : The circular box-type moulding, which have thin
wall section.

Stripper plate:

•The stripper plate is a rectangular plate, has aperture to sliding

on the core for ejection.

•It is mounted between the cavity plate and the core plate.

•These types of ejection will not leave any depression on the

molding.

CORPORATE TRAINING AND 0104

• The moulding and feed system are removed in the
first day light between the stripper plate and the fixed
mould plate from the cavity plate.

• Second daylight between the core plate and stripper

plate for ejection.

CORPORATE TRAINING AND 0105

STRIPPER PLATE EJECTION

Fig: 4.1 Fig: 4.2 Fig: 4.3

CORPORATE TRAINING AND 0106

 DOUBLE DAYLIGHT
STRIPPER PLATE MOULD

Fig: 4.4 Fig: 4.5

Fig: 4.6 Fig: 4.7

Double Day Light With Underfeed Mould

CORPORATE TRAINING AND 0107
 DOUBLE DAY LIGHT WITH
UNDER FEED MOULD

• An Underfeed mould is one in which the feed system is

arranged to feed into the underside of the component.
• In this mould the extra plate is added behind the cavity
plate to allow a runner system to be incorporated below the
cavity or cavities.
• It consists of three main parts
1. Feed plate.
2. Floating cavity plate.
3. Moving mould plate.

CORPORATE TRAINING AND 0108

 USE OF UNDERFEED TYPE
OF MOULD
1. Multi-point feeding can be accomplished on single-
impression moulds and on multi-impression mould.

2. Off-centre feeding can be achieved for both single

and multi-impression moulds.

CORPORATE TRAINING AND 0109

 TRIPLE DAY LIGHT WITH
UNDERFEED AND STRIPPER
PLATE MOULD
• A three-plate mold or triple daylight mould differs from a
two plate in that it has two parting planes and the mold
splits into three sections, every time the part is ejected.
• Since the mold has two parting planes, the runner
system can be located on one, and the part on the other.
• Three plate molds are used because of their flexibility in
gating location.
• A part can be gated virtually anywhere along its surface.

CORPORATE TRAINING AND 110

 TRIPLE-DATLIGHT,
UNDERFEED-STRIPPER
PLATE MOULD

Fig: 4.8 Fig: 4.9

CORPORATE TRAINING AND 111

A THREE PLATE MOULD
ASSEMBLY

Fig: 4.10
CORPORATE TRAINING AND 112
 THREE PLATE MOULD

• This mould is mostly prepared for multi

impression circular cap components.

• It is the combination of stripper plate and

under-feed system.

CORPORATE TRAINING AND 113

STRIPPER PLATE
MOVEMENT

Fig: 4.11

Fig: 4.12
CORPORATE TRAINING AND 114
 SECONDARY SPRUE BUSH

Multi daylight moulds are having two sprue bushes.

• Primary sprue bush is mounted at fixed plate backside.

• Secondary sprue bush is mounted in the floating cavity

plate.

CORPORATE TRAINING AND 115

SECONDARY SPRUE BUSH

Fig: 4.13
CORPORATE TRAINING AND 116
• It is the simplest form of feed system.

• It is not practicable for all types of components. The shape

of the component affects the design of the floating cavity
plate, which in turn determines the type of feed system can
be adopted and it requires the extra operation for removal of
runner from the moulding.

CORPORATE TRAINING AND 117

 REVERSE TAPER
SECONDARY SPRUE
REVERSE TAPER SPRUE

Fig: 4.14
CORPORATE TRAINING AND 118
 REVERSE TAPER
SECONDARY SPRUE

• Standard type of pin point gate is used.

• The main use of this sprue is to release the component

with automatic de-gating in three-plate mould.

• Drawback of this method: the feed system is not free to fall

when the mould is opened because the secondary sprues
are retained within the floating cavity plate.

•The feed system is removed by hand if the basic underfeed

mould design is used.

CORPORATE TRAINING AND 119

 UNDERCUT RUNNER
SYSTEM SECTION VIEW

Fig: 4.15

Fig:CORPORATE
4.16 TRAINING AND 120
Fig: 4.17
CORPORATE TRAINING AND 121
 DESIGN CONSIDERATION
• The float period must be sufficient to permit the floating
cavity plate to clear the reverse-tapered sprues before the
puller pulls the sprue.
• Considerable runner deflection is necessary to ensure
that the secondary sprues are not pulled back into their
holes when the puller is actuated.
• To ensure that the puller is pushed back to its moulding
position when the mould is closed, the diameter of the
puller must exceed the width of the runner.

CORPORATE TRAINING AND 122

RUNNER STRIPPER PLATE

• The fixed secondary puller is fitted directly below each

secondary sprue.

• To release the feed system from this fixed secondary puller a

runner stripper plate is introduced between the feed plate and
the floating cavity plate.

CORPORATE TRAINING AND 123

UNDERFEED MOULD
SECTION VIEW

Fig: 4.18 124

CORPORATE TRAINING AND
 UNDERFEED MOULD

Fig: 4.19 Fig: 4.20

Fig: 4.21 Fig: 4.22

CORPORATE TRAINING AND 125
 STACK MOULD

• When two injection moulds are operated in tendem in the

same molding machine it is called stack mould.

 Used for molding shallow, small parts in large quantities

like tape cassettes.

 The cavities are located in two planes corresponding to

two parting lines and are filled.

 The clamping force required is 15% higher than a

standard mould.

CORPORATE TRAINING AND 126

• It is a simplest mould design, from a runner point of view
is a single-cavity, single-face mold arranged in back to back
configuration of same impression or different impressions.

• The machine nozzle injects plastic directly into the mould

cavity. The single-face mould can also be extended to a
multi-cavity layout.

• The machine nozzle injects the melt into a runner system

that feeds each individual cavity.

• It is suitable of which has the thin-wall injection molding

with hot runner designs.

CORPORATE TRAINING AND 127

STACK MOULD IN IMM

Fig: 4.23
CORPORATE TRAINING AND 128
 Fig: 4.24

CORPORATE TRAINING AND 129

 TYPES OF STACK MOULD

1. FOUR-FACE (FOUR-LEVEL) STACK MOLDS

2. THREE-FACE (THREE-LEVEL) STACK MOLDS

CORPORATE TRAINING AND 130

 1.FOUR-LEVEL STACK
MOULDS
• Four-level stack molds quadruple output over single-face
molds, and are suited to very high production volumes of
shallow parts.

• Quick Change molds switch from one product to another in

less than an hour in both single-face and two face stack mold
applications.

•Two-cavity slack molds allow molding of large parts in a back-

to-back configuration, thus doubling the machine capacity.

CORPORATE TRAINING AND 131

• The four-face stack mold is two stack molds placed
back to back and it increases the mold shut height.
• It operates in the same molding machine as a
conventional slack mold.
• Cycle limes identical to those of a conventional mold.
• Shot-to-shot changeover time of less than one hour
required for both mechanically and air ejected parts in the
stack mold.
• Machine shut height remains the same from one
product to the next.

CORPORATE TRAINING AND 132

 2.THREE-LEVEL STACK
MOULDS

• Three-level stack molds permit molding of deep-draw or

tall pans to maximize the productivity of machine shut
height.

•It is the development of a proprietary melt transfer system

to pass the plastic across the mold parting line.

•The system avoids drooling on mold opening due to the

self-decompression of the central hot-runner system.

CORPORATE TRAINING AND 133

• The three-level stack mold uses triple valueless melt
transfer system (VMTS) crossover nozzles to provide
equal pressure and flow characteristics to the plastic melt
to each cavity.

• This stack mold configuration fills in when a two-level

mold cannot produce enough pans and a four-level mold
is too large for the machine.

• Three-level stacks is used to mold both shallow draw

(for example, packaging lids) and deep draw pans (such
as tall containers).

• They can be combined with quick-change systems to

give added flexibility to high-production tooling. 134
CORPORATE TRAINING AND
HOT RUNNER
MOULD

CORPORATE TRAINING AND 01

TYPES OF INJECTION MOULD

1. COLD RUNNER

2. HOT RUNNER

A runner is the channel in the mold that

conveys the molten plastic material from the
barrel of the injection-molding machine to the
part.

CORPORATE TRAINING AND 02

 COLD RUNNER MOULD

 The runner is cooled and ejected with the part.

 Every cycle, a part and a runner are produced.
 There are two major types of cold runner molds: Two
plate and Three-plate mould.

CORPORATE TRAINING AND 03

 ADVANTAGES OF COLD RUNNER
MOULD
• Mold requires less maintenance.
• The mold design is very simple and much
cheaper than a hot runner system.
• Less skill to set up and operate.
• Color changes are also very easy, since all of
the plastic in the mold is ejected with each cycle.

CORPORATE TRAINING AND 04

 DISADVANTAGES OF COLD
RUNNER MOULD
• The waste plastic is generated.
• The runners are either disposed of or reground and
reprocessed with the original material.
• This adds a step in the manufacturing process.
• Regrinding increases variation in the injection
molding process, and decreases the plastic's
mechanical properties.

CORPORATE TRAINING AND 05

 HOT RUNNER MOULD
 The hot runner mould contains a heated runner manifold
block, insulated from the rest of the mould keeps the
runner permanently melt.

 The hot runner mould replaces the conventional sprue

bushing with a hot sprue bushing or a heated nozzle.

 The polymer material directed to the mould cavities

without heat loss and pressure loss.

 Large moulding like automotive dash board, bumpers,

computer housing, multi colour moulding etc. are
produced in this process.
CORPORATE TRAINING AND 06
 HOT RUNNER MOULD
• In a three-plate cold runner mold the runner system must
be reground and the material is reused.
• It is possible to eliminate the runner system entirely by
keeping it fluid.
•The material is kept plasticized by the hot runner manifold,
which is heated with heating element (like electric
cartridges).
•The block is usually thermostatically controlled.
•Heater bands, which are individually controlled, can be
mounted round the nozzle.
•The plastic is kept fluid and the injection pressure is
transmitted through the hot runner manifold.

CORPORATE TRAINING AND 07

Assembly of hot runner mould
CORPORATE Fig:AND
TRAINING 5.1 08
Hot runner mould section Fig: 5.2
view TRAINING
CORPORATE AND 09
 TYPES OF HOT RUNNER
MOULD
A hot runner system is divided into two parts
• The manifold
• The drops .
• The manifold has channels that convey the plastic on a
single plane, parallel to the parting line, to a point above the
cavity.

• The drops, situated perpendicular to the manifold, convey

the plastic from the manifold to the part.

CORPORATE TRAINING AND 10

 HOT RUNNER WITH
EXTERNALLY HEATED
MANIFOLD AND DROPS

Fig: 5.3
CORPORATE TRAINING AND 11
TYPES OF HOT RUNNER SYSTEM

• Internally drops and manifolds.

• Externally heated drops and manifolds.

CORPORATE TRAINING AND 12

 EXTERNALLY HEATED HOT
RUNNER
• Externally heated hot runner channels have the lowest
pressure drop of any runner system (because there is no
heater obstructing flow and all the plastic is in molten
state).

• They are better for colour changes none of the plastic in

the runner system freezes.

• There are no places for material to hang up and degrade,

so externally heated systems are good for thermally
sensitive materials.

CORPORATE TRAINING AND 13

 INTERNALLY HEATED
RUNNER SYSTEM

• Internally heated runner systems require higher molding

pressures, and color changes are very difficult.

• There are many places for material to hang up and

degrade, so thermally sensitive materials should not be used.

• Internally heated drops offer better gate tip control. It

separate runner heat from the mold because an insulating
frozen layer is formed against the steel wall on the inside of
the flow channel.

CORPORATE TRAINING AND 14

INTERNALLY HEATED CORE
ROD SECONDARY NOZZLE

Fig: 5.4
CORPORATE TRAINING AND 15
 DESIGN CONSIDERATION
FOR HOT RUNNER MOULD
• Insert plug close off manifold bores should be smooth.
• Runner diameters should impart shear stress not more
than 1 percent of the resin’s tensile strength.
• The pressure drop from sprue bushing to tip should not be
more than 25 percent of the maximum plastic fill pressure,
with the resulting temperature increase remaining as close
to the desired melt as possible.
• A runner volume of 25 percent of the part volume, and a
shear rate of about 1000 sec-1, are good
• Sufficient heating elements should be incorporated so that
the hot-runner unit heats quickly to the required moulding
temperature from cold.

CORPORATE TRAINING AND 16

.
• Sufficient heat energy must be supplied to the hot-
runner unit it replaces conduction, convection and radiation
heat losses.
• To ensure that the temperature of the melt in the flow-
way is maintained without either hot or cold regions, careful
location of the heating elements is essential.
• Considerable production time may be lost if a heater
fails. Thought must be given therefore to choice of heating
element; its location and the facilities for. removing it.

CORPORATE TRAINING AND 17

• The layout of the wiring system should be
neat and easily traceable.
• Heating element wires, which are subject to,
heat or abrasion attack should be protected.
• Use manufacturer’s recommended
clearances when fitting heating elements of the
cartridge type.
• Flat-type heating elements and induction
heating elements should be completely
enclosed within the unit for maximum efficiency.

CORPORATE TRAINING AND 18

• The hot-runner unit must be insulated from
the rest of the mould structure.
• For many materials, close control of the
temperature of the melt is vital. Hence Careful
consideration to be made for the location of
thermocouples.
• To minimize degradation, color-changing and
material-changing problems the melt flow-way
must be as streamlined as possible, without
sharp corners, ledges or other stagnation points
which tend to hold back the polymer melt for
extended periods.

CORPORATE TRAINING AND 19

 APPLICATIONS OF HOT
RUNNER MOULD
• It allows for the pin gating of mouldings on
multi-impression types of mould
• It allows for multi-point gating on single-
impression and multi-impression mould
• It allows for side or film gating of large
mouldings.
• It permits the semi-runnerless design to be
adopted, where small groups of impressions
are fed from secondary sprues.

CORPORATE TRAINING AND 20

 THE MANIFOLD BLOCK

• Rectangular Manifold Block

• Circular manifold block

CORPORATE TRAINING AND 21

Fig:5.5 Fig:5.6

CORPORATE TRAINING AND 22

 RECTANGULAR
MANIFOLD BLOCK

Fig:5.7
Fig:5.8

Fig:5.8
CORPORATE TRAINING AND
Fig:5.9 23
THE MELT-FLOW-WAY

Fig: 5.10
CORPORATE TRAINING AND 24
 RUNNER PLUG
It is made from stainless steel for plugs in the flow path of
hot runner system to direct the plasticized materials.
It has larger thermal expansion than the manifold
material. As the manifold is heated to operating
temperature, the stainless plugs will expand at a greater
rate making the possibility of leakage impossible.

CORPORATE TRAINING AND 25

 TYPES OF NOZZLES

1. Extended nozzle

2. Barb nozzle

3. Antechamber nozzle

CORPORATE TRAINING AND 26

 1.EXTENDED NOZZLE

• On the extended nozzle a resistance type band heater is

provided which is controlled by means of thermocouple.

• To minimize the transfer of heat from the heated nozzle to

the mould, a circumferential clearance of at least 7mm must be
provided between the two parts.

• The main advantage of this nozzle is to minimize the length

of the sprue gate as short as possible.

CORPORATE TRAINING AND 27

Fig:5.11 EXTENDED NOZZLE
CORPORATE TRAINING AND 28
 2.BARB NOZZLE
 This type of nozzle is used to minimize the blemish on
the component at the gate point.
 The plastic material flows through to the nozzle, sprue
and gate. After solidification, the sprue is pulled from the
sprue bush by the barb of the nozzle.

Fig:5.12
CORPORATE TRAINING AND 29
 3.ANTECHAMBER NOZZLE

 It is termed as hot well design, a small mass of plastic

material is retained in the antechamber which insulates
the central core of plastic material.

 The plastic material remains fluid to allow it to pass

intermittently through the antechamber into the
impression.

 This type of nozzle is used for moulding thin-walled

components.

CORPORATE TRAINING AND 30

 INSERT

ANTECHAMBER

CORPORATE
Fig:5.13 TRAINING AND 31
 INSULATED RUNNER
MOULD
 In this type of mould the melt flows from standard or
extended nozzle into a large diameter runner via the
reverse taper sprue and gate.

 The outer layer of the melt solidifies against the cold

runner wall which forms an insulating shell, while the
centre core of the material retain in the molten state.

 The outer layer of runner acts as an insulating media

and avoids heat loss from the polymer melt to the mould.

CORPORATE TRAINING AND 32

Fig:5.14
CORPORATE TRAINING AND 33
 EXPANSION PROBLEMS
•The hot-runner unit mould is that metals expand when
heated.

• The manifold block increases in all three dimensions

when the temperature is increased.

•The distance between the centers of the secondary

nozzles increases with respect to the ‘fixed’ distance
between the centers of the impressions machined in the
cavity plate.

•When designing the hot-runner mould, allowance must

be made for this expansion to ensure that the
centerlines are in line during production
CORPORATE TRAINING AND 34
EXPANSION PROBLEMS

Fig:5.15

CORPORATE TRAINING AND 35

 NOZZLE 200 250 300
LENGTH
48 mm 0.13 0.17 0.21
68 mm 0.20 0.20 0.30

The equation for calculating expansion is as follows:

e=L X  X T
Where e = expansion (mm or in)
L = length dimension (mm or in)
 = Coefficient of thermal
expansion (mm/mm C or in / inC)
 T = increase in temperature ( C)

CORPORATE TRAINING AND 36

DESIGN OF HOT RUNNER
MOULD FOR CAP

CORPORATE TRAINING AND

HOT RUNNER MOULD FOR
CAP SEAL

CORPORATE TRAINING AND

THREE PLATE HOT RUNNER
MOULD FOR CAP

CORPORATE TRAINING AND

THREE PLATE HOT RUNNER
MOULD FOR LEAD FRAME

CORPORATE TRAINING AND

 UNSCREWING HOT RUNNER
MOULD FOR CAP COMPONENT

CORPORATE TRAINING AND