Medical Venturi Filter Body injection mold design

Injection Molding Mold Design Tutorial

Section 1: Injection Mold Design

The following information defines the minimum requirements for Upmold injection molds produced by Upmold Engineering. Alternatives that will contribute to improved tool life, minimum wear, ease of molding, and ease of Manufacturing will be considered within the confines of the original quotation and Customer supplied mold design and build standards. The Engineering Manager must approve any deviations from the Upmold standards, and any deviations must be documented and approved by the Customer.

a) Upmold injection Mold Standard Description
b) Mold Series Description
c) Common mold steels and applications for Upmold molds
d) Drawing format and standards
e) Solid Model Geometry format, construction, and standards

A)Upmold injection Mold Standard Description

Cycles: 50’000 to 250’000 Save
*Built for medium production. Upmold molds are not recommended for abrasive or corrosive materials without written customer approval, and appropriate plating of all part related items.
*All mold plates must be a minimum of SAE 1030 steel. AISI 4130 steel is commonly used due to price and availability of SAE 1030 steel.
*Core and Cavity blocks (In-solid designs), Core and cavity inserts, sub-inserts, and other non-moveable items are to be constructed with a minimum of P-20 steel.
*Slides, lifters, bar ejectors, and similar actions can be constructed of P-20 steel also, but must have a minimum of 3-degrees shut-off on all seal surfaces. Nitriding is required otherwise, as in the case of straight wall lifter designs. Hardened S-7 steel should be considered for all lifter designs.
*Slides must have lamina bronze wear plates with grease grooves.
*Ejector plates must be guided with two guide pins and ejector guide bushings minimum. The amount will be determined based on the mold size and number of ejector plate activated actions.
*Integral parting line locks must have lamina bronze wear plates if the interlock angle is less than 10-degrees. Standard inserted hardened interlocks are acceptable as the part design permits. All interlock designs must protect internal shut-offs.
*Cooling is required in all part-related features insofar as possible, and in mold plates as required for specific temperature control, such as in plates encompassing hot runners, valve gate actuators, etc.

B) Mold Series Description

  1. Upmold  A Series Mold: Design allows for through pocketing of inserts (refer to drawing S1-1)
  2. Upmold  B Series Mold: Design allows for blind pocketing of inserts and “in solid?core/cavity (refer to drawing S1-2)
  3. Upmold  X Series Mold: Style “A?Design allows for through pocketing of inserts and stripper plate ejection (refer to drawing S1-3).
  4. Style  B design allows for blind pocketing of inserts and stripper plate ejection (refer to drawing S1-4)
  5. Upmold AX Series Mold: Design allows for cavity floating plate action (refer to drawing S1-5)
  6. Upmold  T Series Mold: Design allows for three-plate runner with pin point gating requiring two floating plates to remain with the stationary side (refer to drawing S1-6)
  7. Upmold  RG Series Mold: Design allows for injection and ejection to be on the stationary side (refer to drawing S1-7)

C) Common mold steels and applications for Upmold molds

Defines the common steel types and their applications.

Examples given are the most common types as used by Upmold. The Customer will specify the general steel types.

HRS – Hot rolled steel –SAE 1030: Ejector housing plates, clamping plates, back-up plates, support pillars, mold “feet” (NOTE: Due to the limited availability of HRS, all mold plates can be 4130/4140 (#2) steel.)

4130/4140 (#2 Steel) – Prehardened 30-36 RcC : General mold base plates

P-20 – Prehardened 30-36 RcC : High grade base plates, large cores and cavities, core and cavity inserts, slides, sub-inserts

420M (Prehardened 420 stainless steel) – Prehardened 30-35 RcC : large cores, cavities, inserts, slides

S-7 – Air hardening 54-56 RcC – Cavities, Cores, inserts, lifters, stripper rings, slides

420 SS – Stainless 50-52 RcC – Cavities, cores, slides, inserts

FP-100 Lamina Bronze – Wear plates – Must provide grease grooves.

O-1 – Oil hardening 58-62 RcC – Gibs, slide guides, wear plates

Ampco-18 – Gibs, slide guides, and wear plates

D) Drawing format and standards

Defines the Upmold 2-D drawing layout and standard drafting aids for the Block-out, Preliminary, and final design drawings.

Final drawing 2-D Mold Layout to include:

  •  Over-all dimensions (length, width, mold stack height, stroke, plate thickness. Etc.).
  •  “Top?of mold designated
  •  Ups to clarify actions, water layout, and special features
  •  “Exploded?Ups as required (Example: 3-Plate molds, Floating cores, etc.)
  •  Enlarged Up of gate(s) with dimensions
  •  Steel types and hardness
  •  Watts, Volts, Amps per zone, Hot Runner information
  •  Power and Thermocouple connectors/junction box
  •  General Notes and tolerances, Texturing information, special sequencing notes, paint requirements, coating/plating requirements, etc.
  •  Material List to include quantity required, detail number, over-all dimensions, catalog number, material type, and supplier (Standard Upmold format)
  • Water and hydraulic connector information noted.
  • Water and hydraulic thread sizes noted.
  • Eyebolt sizes noted.
  •  Completed title block with material and shrink, press size and model, etc.
  •  Press tie bars shown in plan Ups
  •  Layer list if applicable
  •  Detail Ups and dimensions as required. NOTE: The 3-D solid model will be considered “dimensioned details?unless the Customer requires dimensioned detailed Ups. We will maintain the “data-driven?approach unless otherwise specified by the customer and compensated appropriately.
  • Tooling Data Sheets

E) Solid Model Geometry format, construction, and standards

Defines the Unigraphics Solid Modeling requirements, Upmold data layering specifications, Upmold construction techniques, general mold functionality fit and function standards, and Upmold design for manufacturability requirements.

Final 3-D Mold Data to Include:

  1. All components, actions, and blocks in Solid Model format. NOTE: The Upmold layer list must be followed. The data must represent the actual steel conditions insofar as possible
  2. all vents, vent clearances, and parting line clearances
  3. any sub-inserts required for in-process ECN’s and/or corrections (NOTE: Design data must reflect steel conditions insofar as possible)
  4. Engraving information (2-D Geometry with depth and width noted is acceptable)
  5. All Hot Runner/Nozzle components, including electrical connector pockets/junction boxes, etc.
  6. All hydraulic cylinders. NOTE: Complex hydraulic plumbing should be modeled as needed
  7. All lifting holes, brackets, lifting straps, safety straps, protecting pillars (i.e.: “feet?, etc.
  8. Water manifolds if required
  9. Press platen and tie bars