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Injection Mold Design Engineering

ISBN-10: 1569904170
ISBN-13: 9781569904176
Edition: 2007
Authors: David Kazmer
List price: $149.95
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Book details

List price: $149.95
Copyright year: 2007
Publisher: Hanser Publications
Publication date: 1/1/2007
Binding: Hardcover
Pages: 423
Size: 6.75" wide x 9.25" long x 1.00" tall
Weight: 2.486
Language: English

Preface
Nomenclature
Introduction
Overview of the Injection Molding Process
Mold Functions
Mold Structures
External View of Mold
View of Mold during Part Ejection
Mold Section and Function
Other Common Mold Types
Three Plate, Multi-Cavity Family Mold
Hot Runner, Multi-Gated, Single Cavity Mold
Comparison
The Mold Development Process
Chapter Review
Plastic Part Design
The Product Development Process
Product Definition
Product Design
Business and Production Development
Scale-Up and Launch
Role of Mold Design
Design Requirements
Application Engineering Information
Production Data
End Use Requirements
Product Design Methodology
Plastic Material Properties
Design for Injection Molding
Uniform Wall Thickness
Rib Design
Boss Design
Corner Design
Surface Finish and Textures
Draft
Undercuts
Chapter Review
Mold Cost Estimation
The Mold Quoting Process
Cost Drivers for Molded Parts
Effect of Production Quantity
Break-Even Analysis
Mold Cost Estimation
Cavity Cost Estimation
Cavity Set Cost
Cavity Materials Cost
Cavity Machining Cost
Cavity Discount Factor
Cavity Finishing Cost
Mold Base Cost Estimation
Mold Customization
Part Cost Estimation
Mold Cost per Part
Material Cost per Part
Processing Cost per Part
Defect Cost per Part
Chapter Review
Mold Layout Design
Parting Plane Design
Determine Mold Opening Direction
Determine Parting Line
Parting Plane
Shut-Offs
Cavity and Core Insert Creation
Height Dimension
Length and Width Dimensions
Adjustments
Mold Base Selection
Cavity Layouts
Mold Base Sizing
Molding Machine Compatibility
Mold Base Suppliers
Mold Material Selection
Strength vs. Heat Transfer
Hardness vs. Machinability
Mold-Maker's Cost vs. Molder's Cost
Material Summary
Chapter Review
Cavity Filling Analysis and Design
Overview
Objectives in Cavity Filling
Complete Filling of Mold Cavities
Avoid Uneven Filling or Over-Packing
Control the Melt Flow
Viscous Flow
Shear Stress, Shear Rate, and Viscosity
Pressure Drop
Rheological Behavior
Newtonian Model
Power Law Model
Validation
Cavity Filling Analyses and Designs
Estimating the Processing Conditions
Estimating the Filling Pressure and Minimum Wall Thickness
Estimating Clamp Tonnage
Predicting Filling Patterns
Designing Flow Leaders
Chapter Review
Feed System Design
Overview
Objectives in Feed System Design
Conveying the Polymer Melt from Machine to Cavities
Impose Minimal Pressure Drop
Consume Minimal Material
Control Flow Rates
Feed System Types
Two-Plate Mold
Three-Plate Mold
Hot Runner Molds
Feed System Analysis
Determine Type of Feed System
Determine Feed System Layout
Estimate Pressure Drops
Calculate Runner Volume
Optimize Runner Diameters
Balance Flow Rates
Estimate Runner Cooling Times
Estimate Residence Time
Practical Issues
Runner Cross-Sections
Sucker Pins
Runner Shut-Offs
Standard Runner Sizes
Steel Safe Designs
Chapter Review
Gating Design
Objectives of Gating Design
Connecting the Runner to the Mold Cavity
Provide Automatic De-Gating
Provide Aesthetic De-Gating
Avoid Excessive Shear or Pressure Drop
Control Pack Times
Common Gate Designs
Sprue Gate
Pin-Point Gate
Edge Gate
Tab Gate
Fan Gate
Flash/Diaphragm Gate
Tunnel/Submarine Gate
Thermal Gate
Valve Gate
The Gating Design Process
Determine Type of Gate
Calculate Shear Rates
Calculate Pressure Drop
Calculate Gate Freeze Time
Adjust Dimensions
Chapter Review
Venting
Venting Design Objectives
Release Compressed Air
Contain Plastic Melt
Minimize Maintenance
Venting Analysis
Estimate Air Displacement and Rate
Identify Number and Location of Vents
Specify Vent Dimensions
Venting Designs
Vents on Parting Plane
Vents around Ejector Pins
Vents in Dead Pockets
Chapter Review
Cooling System Design
Objectives in Cooling System Design
Maximize Heat Transfer Rates
Maintain Uniform Wall Temperature
Minimize Mold Cost
Minimize Volume and Complexity
Minimize Stress and Corrosion
Facilitate Mold Usage
The Cooling System Design Process
Calculate the Required Cooling Time
Evaluate Required Heat Transfer Rate
Assess Coolant Flow Rate
Assess Cooling Line Diameter
Select Cooling Line Depth
Select Cooling Line Pitch
Cooling Line Routing
Cooling System Designs
Cooling Line Networks
Cooling Inserts
Conformal Cooling
Highly Conductive Inserts
Cooling of Slender Cores
Cooling Insert
Baffles
Bubblers
Heat Pipes
Conductive Pin
Interlocking Core with Air Channel
One-Sided Heat Flow
Chapter Review
Shrinkage and Warpage
The Shrinkage Analysis Process
Estimate Process Conditions
Model Compressibility Behavior
Assess Volumetric Shrinkage
Evaluate Isotropic Linear Shrinkage
Evaluate Anisotropic Shrinkage
Assess Shrinkage Range
Establishing Final Shrinkage Recommendations
Shrinkage Analysis and Validation
Numerical Simulation
"Steel Safe" Mold Design
Processing Dependence
Semi-Crystalline Plastics
Effect of Fillers
Warpage
Sources of Warpage
Warpage Avoidance Strategies
Chapter Review
Ejection System Design
Objectives in Ejection System Design
Allow Mold to Open
Transmit Ejection Forces to Moldings
Minimize Distortion of Moldings
Actuate Quickly and Reliably
Minimize Cooling Interference
Minimize Impact on Part Surfaces
Minimize Complexity and Cost
The Ejector System Design Process
Identify Mold Parting Surfaces
Estimate Ejection Forces
Determine Ejector Push Area and Perimeter
Specify Type, Number, and Size of Ejectors
Layout Ejectors
Detail Ejectors and Related Components
Ejector System Analyses and Designs
Ejector Pins
Ejector Blades
Ejector Sleeves
Stripper Plates
Elastic Deformation around Undercuts
Core Pulls
Slides
Early Ejector Return Systems
Advanced Ejection Systems
Chapter Review
Structural System Design
Objectives in Structural System Design
Minimize Stress
Minimize Mold Deflection
Minimize Mold Size
Analysis and Design of Plates
Plate Compression
Plate Bending
Support Pillars
Shear Stress in Side Walls
Interlocks
Stress Concentrations
Analysis and Design of Cores
Axial Compression
Compressive Hoop Stresses
Core Deflection
Fasteners
Fits
Socket Head Cap Screws
Dowels
Review
Mold Technologies
Introduction
Coinjection Molds
Coinjection Process
Coinjection Mold Design
Gas Assist/Water Assist Molding
Insert Molds
Low Pressure Compression Molding
Insert Mold with Wall Temperature Control
Lost Core Molding
Injection Blow Molds
Injection Blow Molding
Multilayer Injection Blow Molding
Multi-Shot Molds
Overmolding
Core-Back Molding
Multi-Station Mold
Feed Systems
Insulated Runner
Stack Molds
Branched Runners
Dynamic Melt Control
Mold Wall Temperature Control
Pulsed Cooling
Conduction Heating
Induction Heating
Managed Heat Transfer
In-Mold Labeling
Statically Charged Film
Indexed Film
Ejection
Split Cavity Molds
Collapsible Cores
Rotating Cores
Reverse Ejection
Review
Appendix
Plastic Material Properties
Mold Material Properties
Non-Ferrous Metals
Common Mold Steels
Other Mold Steels
Notes
Properties of Coolants
Statistical Labor Data
United States Labor Rates
International Labor Rates
Trends in International Manufacturing Costs
Unit Conversions
Length Conversions
Mass/Force Conversions
Pressure Conversions
Flow Rate Conversions
Viscosity Conversions
Energy Conversions
Advanced Derivations
Bibliography
Subject Index

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