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CDA Sponsors Mold Design Guidelines in MM&T

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CDA Sponsors Mold Design Guidelines in MM&T CDA Sponsors Mold Design Guidelines Look for ideas that will allow faster processing of plastic and in MM&T production of higher-quality parts Keep an eye out for coming the moldmakers, molders and issues of Modern Mold and manufacturers to improve the Tooling, which will contain processing of plastic materials. injection mold design guide- The task group, supported by lines developed to make you the trade associations of the more productive. These infor- copper industry, is dedicated mative and collectable fact- to research and disseminating filled design guidelines are the information you need to being developed for the injec- take advantage of the superior tion molder, mold designer and performance of molds mold builder. The information containing copper-alloys. Also, contained in the guide-lines the association is dedicated to will maximize the mold's cycle developing an infrastructure of time and improve part quality copper producers, fabricators, with the use of copper alloys in suppliers and mold makers the mold. The articles will who are in the plastics chain. begin in the May issue. Research work, performed at These information packed Western Michigan University, is Injection Mold Design conducted to address technical Guidelines are being developed issues and remove barriers to and generated by The Copper- the use of copper alloys for Alloy Molds Marketing Task plastic processing. The Group. The group is a network development of these injection of copper-alloy suppliers, dis- Mold Design Guidelines is a tributors, and fabricators who result of this research and in have joined together to assist addition to empirical data derived from industry applications. Several molds, funded by the Interlock Plates, Leader pins and task group, were built and tested Guided Ejector Bushings to conduct research under actual 8. Plating and Coating of Copper production conditions. One Alloys studied the cycle time advantage 9. Application of Copper Alloys in the copper alloys offered over injection and Blow Molds traditional mold steels. Additionally, due to the superior These guidelines will include thermal conductivity of the properties of the various copper copper alloys, part quality alloys most commonly utilized for improvements including less their thermal and bearing warpage, better dimensional properties, compared with stability and more uniform mold traditional mold steels. Charts, temperatures resulted. Other graphs, formulas and descrip- research and testing con- tions will provide the user with centrated on eliminating mold pertinent data not available from sweating under humid operating other sources. conditions. This is accomplished by running higher mold operating temperatures with copper alloy mold cores. The test results prove that better part dimensional stability can be obtained at shorter mold cooling times without mold sweating when compared with mold steels. Exhaustive wear study is under way An exhaustive wear study is under way testing the effects of electroless nickel, hard chrome, titanium nitriting, thin dense chrome and thin dense chrome with diamond particulate in extending the mold life of the copper alloys. As a service to the plastics industry, the Task Group is fund- ing the publication of these guidelines in Modern Mold and Tooling. The greatest benefit to the people who deal with molds and molding will be to collect each issue to use as a reference in both the applications of the copper alloys and the mold design principles. Subjects for the Injection Mold Design Guidelines will include: 1. Sprue Bushings and Runner Bars 2. Mold Cores, Core Pins and Chill Plates 3. Mold Cavities and "A" Side inserts 4. Slides, Lifters and Raising Mold Members 5. Ejector Pins, Ejector Sleeves and Ejection 6. Mold Temperature Control Systems, Bubblers, Baffles, Diverters and Plugs 7. Wear plates, Slide Gibs, Injection Mold Design Guidelines Maximizing Performance Using Copper Alloys Copper Alloys for Conveying and runner faster, allowing more Plastic in Injection Molds efficient ejection or removal by The high thermal conductivity of sprue pickers or robots. copper alloys makes them ideal Sprue Bushing Radius materials for the injection mold in North America two injection sprue bushing and runner bars. mold nozzle and sprue bushing Three alloys typically are utilized radii are used, 1/2 and 3/4 inch. for the mold components, which To insure proper fit up, the nozzle will have contact with plastic. The radius is nominal -.015 inch, while copper alloys are: the sprue radius is nominal +. 015 • Ampcoloy 83, high hardness inch, required tolerances to use. beryllium-copper alloy Swing points and tolerances used • Ampcoloy 95, high conductivity Illustration I,Sprue Radius in establishing the radius on a beryllium-copper alloy sprue bushing are shown in • Ampcoloy 940, NiSiCr hardened illustration I. high conductivity copper alloy Sprue Bushing Orifice These Copper alloys have six to Machine nozzle orifices come in nine times greater heat transfer nominal 1/16" fractional inch rates than conventional mold sizes. To insure that the slug in steels as indicated by the thermal the nozzle will pull through the conductivity. sprue, the orifice must be .031 Mold Material Thermal (1/32 inch) larger in diameter. This Conductivity dimension is referred to as the "0" (BtU/Hr/Ft2/°F) dimension. The relationship is Ampcoloy 83 60 shown in this chart. Ampcoloy 95 135 Ampcoloy 940 125 H-13 17 P-20 20 Nozzle “O" Sprue “O" 420 SS 14 1/16" 3/32" 1/8" 5/32" The sprue or runner system must 3/16" 7/32" never control the cooling phase 3/8" 9/32" and/or overall molding cycle. 5/16" 11/32" Plastic in contact with copper Nominal +1/32' alloys will set the sprue Sprue Bushing Taper Also, a sprue bushing that is not To aid in the removal of the sprue keyed will rotate creating from the bushing, a taper of one- misalignment with the runner half inch per foot is normally used machined into the face of the in injection molding. Calculate the sprue bushing and the runner sprue orifice at the parting line system. To prevent these face, multiply the tangent of the problems, retain and key the taper angle times the length, plus sprue into position with the use of the "02". Knowing this dimension, a cap screw as illustrated in informed decisions can be made figure IV. on primary runner sizing. The sprue frequently controls the Sprue Fit molding cycle when larger orifice Heat must be transferred from Illustration II, Sprue taper conventional steel sprue bushings the sprue through the copper are used. The application of a alloy sprue bushing to the mold copper alloy sprue bushing cools plates,interference fit is rec- the sprue more quickly and ommended for optimum cooling. efficiently, allowing the molding The bore through the "A" plate cycle to be controlled by the piece should be nominal size to plus part. .0005 inches with a surface finish of at least 16 RMS. The shank of Pressure loss is high in the sprue. the sprue bushing should be the This is the only place in the feed nominal size, plus .0005 to plus system where the channel .001 inches. progresses from a smaller area to larger. Frequently, smaller orifices Standard Sprue Bushing are used on long sprue bushings Availability in an effort to reduce the mass. Copper alloy sprue bushings with This results in extremely high patented stainless steel nozzle Illustration III, Pressure, injection pressure losses, making seats are commercially available. Sprue Length the part hard to fill. An insulator between the nozzle The chart in illustration lll is a and sprue is beneficial in guide for determining the effect controlling the flow of heat from that the specific "0" dimension the nozzle to the sprue. Special has on the pressure required to sprue bushings may be deliver plastic through the length constructed to suit using standard of a sprue. Note that the differ- 1/2 inch per foot sprue bushing ence between a 3/32 and 9/32- tapered drills and reams. Sprue inch sprue is about 1,000 PSI bushings with tapers of up to 3/4 over a short sprue and almost inch per foot have been used for 1,500 pounds on a long sprue. difficult to remove plastics. Care must be taken to insure that the Using a copper alloy sprue taper is draw polished and free bushing allows for an increased from undercuts or rough surfaces size orifice, thus reducing that could hinder sprue removal. Illustration IV, Anti – rotation pressure loss while maintaining screw reasonable cooling times. Conventional Injection Mold Runner Systems The shape of the runner, full Sprue Retention and round or trapezoidal, or other Anti-Rotation configuration, is dictated by mold Pressure acting on the parting design. The most efficient runner line face of the sprue, due to cross section is full round. The projected area of the runner efficiency of the runner cross system or part detail, exerts section can be calculated with a pressure on the sprue bushing. formula, figure V, the larger the ratio the better. Illustration V, Formula runner system Injection Mold Runner Bars runner with one-half the area is not Runner systems for high cavita- the same as a runner of one-half tion molds normally have larger the diameter. diameters due to runner balancing. The runner system extends the Formulas for calculating the area of molding cycles as heat is slowly the runner: transferred from the thick plastic to Runner Bar Mating steel mold plates. Inserting copper alloy runner bars in the mold "A" Best results are obtained by and "B" plates, cooling the runner Full Round Runner faster, is beneficial, in reducing the A = 0.7854 d2 overall molding cycle. Trapezoidal Runner A= (w1 +w2)h/2 A = area, d = diameter, I = length, Runner Sizing w = width, h = height Runner sizing is dependent on Illustration VI, Runner Bars many things, including: plastic designing and building the runner material; part size, weight and wall bars to have zero to negative thickness; molding machine contact with each other when the capabilities and processing mold is closed.
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