Injection molds for beginners / Rainer Dangel.

Format:

Book

Author/Creator:

Dangel, Rainer, author.

Language:

English

Subjects (All):

Polymers.

Physical Description:

1 online resource (339 pages)

Edition:

Third edition.

Place of Publication:

Munich, Germany : Carl Hanser Verlag GmbH & Co. KG, [2023]

Summary:

This applications-oriented book describes the construction of an injection mold from the ground up. Included are explanations of the individual types of molds, components, and technical terms; design procedures; techniques, tips, and tricks in the construction of an injection mold; and pros and cons of various solutions. Based on a plastic part ("bowl with lid") specially developed for this book, easily understandable text and many illustrative pictures and drawings provide the necessary knowledge for practical implementation. Step by step, the plastic part is modified and enhanced. The technologies and designs that are additionally needed for an injection mold are described by engineering drawings. Maintenance and repair, and essential manufacturing techniques are also discussed. With full-color illustrations, this third edition builds on the success of the previous ones, with significantly expanded coverage of molding simulation, including many new figures, and updates and small corrections throughout the book.

Contents:

Intro

Preface to the Third Edition

Foreword to the First Edition

The Author

Acknowledgments

Contents

How to Use This Book

1 Introduction

2 Mold Types

2.1 Simple Open/Close Mold

2.1.1 Classic Structure of an Open/Close Mold

2.1.2 Guiding Elements

2.1.3 Backing Plate

2.2 Molds with Moving Elements

2.2.1 Undercut

2.2.2 Slide

2.2.3 Slide Operation

2.2.4 Latch, Clip Lock

2.2.5 Inclined Ejector

2.2.6 Forced Demolding

2.2.7 Mold Size

2.3 Mold for Threads

2.3.1 External Threads

2.3.2 Internal Threads

2.3.3 Drive Types for De-spindling

2.3.3.1 Hydraulic Unscrewing Unit

2.3.3.2 Gear Rack

2.3.3.3 High-Helix Lead Screw

2.3.3.4 Multi-cavity Molds

2.4 Multi-component Injection Molds

2.4.1 Material Pairings

2.4.2 Mold Technology

2.4.2.1 Shifting Technology

2.4.2.2 Rotary Table Technology

2.4.2.3 Sealing Slide Technology

2.4.2.4 Further Technologies

2.5 Stack Mold

2.5.1 Material Combinations

2.5.2 Hot Runner

2.5.3 Opening and Closing

2.5.4 Toggle Lever

2.5.5 Ejection

2.5.6 General Information on the Stack Mold

2.6 Further Literature

3 Preparation

3.1 CAD System

3.2 Data Transfer, Procedure, and Processing

3.2.1 Data Transfer

3.2.2 Formats

3.2.2.1 IGES

3.2.2.2 STEP

3.2.2.3 STL

3.2.3 Data Size

3.2.4 Shrinkage

3.2.4.1 Shrinkage (Physical Process)

3.2.4.2 Influencing Variables

3.2.5 Calculation and Impact

3.2.5.1 Free Shrinkage, Constrained Shrinkage

3.2.5.2 Warping

3.3 Specifications

3.3.1 Location of the Component inside the Injection Mold

3.3.1.1 Demolding Direction

3.3.2 Number of Cavities

3.3.3 Arrangement of Cavities

3.4 Material Selection for Injection Molds

3.5 Mold Size

3.6 Plate Thickness

3.7 Demolding

3.7.1 Basic Principle of Demolding.

3.7.2 Draft Angles

3.7.2.1 Definition

3.7.2.2 Effect on the Opening of the Mold

3.7.2.3 Draft Angle in the Split Line Face

3.7.2.4 Demolding Problems and Solutions

3.8 Split Line Face

3.8.1 Plain Split Line Face

3.8.2 Contour-Forming Split Line Face

3.8.3 Jumping Split Line Face

3.8.4 Wear Plates in the Split

3.8.5 Visible Split Line

3.9 Injection

3.9.1 Injection and Feed Point

3.9.2 Simulation

3.9.3 Sprue System, Sprue Type

3.9.3.1 Cold Runner

3.9.3.2 Hot Runner

3.9.4 Runner

3.9.5 Sprue on the Part

3.9.6 Tunnel Gate

3.9.7 Film Gate

3.9.8 Diaphragm Gate

3.9.9 Hot Runner Single Nozzle

3.9.10 Hot Runner Distributor

3.9.11 Hot Runner Distribution System with Needle Valve

3.9.11.1 Integral Hinge

3.9.12 Three-Plate Mold

3.9.13 Tunnel Gate Inserts

3.10 Ventilation

3.10.1 General Information about Ventilation

3.10.2 Ventilation via Components

3.10.3 Geometric Design of Ventilation

3.11 Further Literature

4 Components

4.1 Mold Inserts/Mold Cores

4.1.1 Mold Inserts

4.1.2 Mold Cores

4.2 Slides

4.2.1 Application Areas of Slides

4.2.2 Design of a Slide

4.2.2.1 Mold Contour

4.2.2.2 Split Line on Slide

4.2.2.3 Slide Body and Guiding

4.2.2.4 Operation of Slides

4.2.2.5 Locking in the End Position

4.2.2.6 Cooling in Slide

4.2.3 Further Slide Concepts

4.2.3.1 Slide in Slide

4.2.3.2 "Backpack" Slide

4.3 Ejectors

4.3.1 Types of Ejectors

4.3.2 Ejectors as Auxiliary Tools

4.3.3 Inclined Ejectors

4.3.4 Stripper Plate

4.3.5 Two-Stage Ejectors

4.3.6 Collapsible Cores

4.3.7 Forced Demolding

4.4 Cooling System

4.4.1 Cooling Type and Auxiliary Equipment

4.4.1.1 Drilled Cooling

4.4.1.2 Redirection of Cooling Circuits

4.4.1.3 Copper Cores

4.4.1.4 Heating Cartridges.

4.4.1.5 Connection of circuits

4.4.2 Connection and Sealing of Cooling Holes

4.5 Components and Marking

4.6 Surface

4.6.1 Rough Surface

4.6.2 EDM

4.6.3 Graining

4.6.4 Laser Texturing

4.6.5 Polishing

4.7 Systematic Design Approach

4.7.1 Strategy

4.7.2 Standard Parts

4.7.3 Manufactured Parts

4.8 Further Literature

5 Assembly

5.1 Systematic Assembly

5.2 Spotting

5.3 Connection of Components

5.4 Check the Cooling for Leaks

5.5 Further Literature

6 Further Knowledge

6.1 Process Chain in Mold Making

6.2 Procurement Process in Mold Making

6.2.1 Administration

6.2.2 Preparation

6.2.3 Production

6.2.4 Sampling (Trial) - Optimization

6.3 Quality Assurance

6.4 Fits and Play in the Mold: What Must Fit?

6.5 Heat Treatment

6.5.1 Annealing

6.5.2 Hardening

6.5.3 Nitriding

6.6 Coatings

6.7 Changes: What Is to Be Considered?

6.8 Further Literature

7 The Finished Mold

7.1 Mold Validation

7.1.1 Clamping and Connecting the Media

7.1.2 Filling of the Mold

7.1.2.1 Balancing Cavities

7.1.2.2 Optimizing the Parameters

7.1.2.3 Influence on the Injection Process

7.1.3 Parameters during Injection

7.1.4 Forces Acting in the Mold during the Injection Process

7.1.5 Initial Sample Inspection Report

7.2 Labels on the Mold

7.3 Further Literature

8 Maintenance and Repair

8.1 Maintenance Schedule

8.2 Welding

8.2.1 Tungsten Inert Gas Welding (TIG)

8.2.2 Laser Beam Welding

8.3 Component Replacement

8.4 Further Literature

9 Manufacturing Technologies

9.1 Milling

9.1.1 3-Axis Milling

9.1.2 4- and 5-Axis Milling

9.1.2.1 4-Axis Milling

9.1.2.2 5-Axis Milling

9.1.2.3 3+2-Axis Milling

9.1.2.4 Simultaneous 5-Axis Milling

9.1.3 CAM Programming

9.2 EDM

9.2.1 Sinker EDM

9.2.2 Wire EDM.

9.3 Grinding/Profile Grinding

9.4 Drilling/Deep Hole Drilling

9.5 Turning

9.6 New Technologies

9.6.1 LaserCUSING®/Laser Sintering

9.6.2 Vacuum Soldering

9.7 Polishing

9.8 Further Literature

10 Practical Guidelines

10.1 Design Check List

10.2 Design Color Chart

10.3 Sequential Function Chart

10.4 Maintenance Schedule

10.5 Formulas and Calculations

Index.

Notes:

Includes index.

Description based on print version record.

ISBN:

1-56990-924-5