Week 12 Challenge

Aim

To design mold for plastic knob

Introduction

A mold is a hollowed out block that sets the shape of the product being made. It can be made of different materials, the most common of which are aluminum, steel, alloys and copper

Procedure to design the mold tool

If there is no sufficient draft given for the part, it will damage the mold hence it is necessary to modify. Me considering as a Mold Engineer it must be reported to the product design team to modify the part. once it is revised, we can move forward to design the mold.

1) Draft Analysis- to check if sufficient draft is given.

2) Scaling - considering material as ABS (shrinkage - 0.6%).

3) Parting line- it will be used to create a line at the intersection of the core and cavity.

4) Shut off surface - to shut of all the hole in the model.

5) designing the core and cavity block.

6) designing sliders to solve the problems of undercut.

7) designing the ejector pin and plates- this is required for the ejection of the part from the core.

8) designing the runners and gates- the injected materials enter through runners and gate.

9) air vents- air vents must be created to remove the air present in the mold, and this is done to prevent from overheating and to prevent burn marks.

10) cooling system it is necessary to cool the part adequately by doing so we can prevent the warping of the part.

Here are the tools used for the design.

a) mold tools

draft analysis, parting line, shut off surface, split line and core.

b) direct editing

move copy bodies, move face, delete body, split, combine and fillet.

c) surfaces command

Surface trim, Planar surface, offset surface, surface knit, surface cuts

d) under features

Extrude boss, extrude cut, hole wizard, sketch driven pattern.

e) others

float ,mate, move component- Rotate component ,weldment

Given plastic component for which the mold has to to be designed

screenshots of the mold designed

Cavity

Cavity- The cavity is the female part which forms external shape of molding.

Core and the other components of the mold

Core-The core is the male part which forms the internal shape of molding.

Inserts-in certain case when the depth of the cuts in the designed mold is greater and as it can be manufacturable in the real scenario due to the absence of the tool in this condition the inserts will be designed

Ejector Pin- They apply a force to eject a part from the mold, and in some cases can leave marks. Once the mold is opened, the pins extend into the mold cavity, push the part out, and then retract, allowing the mold to close and be refilled.

Air vents-Vents are cuts within the mold steel that allows air to escape. Air inside of the mold must be allowed to escape so that the plastic can fill the entire space. Without vents, the trapped air will compress as the plastic tries to force the air out of the mold and will cause burning.

cooling system- it is necessary to cool the part adequately by doing so we can prevent the warping of the part.

Sprue,sprue,Runner and Gate

Sprue- A sprue is the vertical passage through which liquid material is introduced into a mold and it is a large diameter channel through which the material enters the mold. During casting or molding, the material in the sprue will solidify and need to be removed from the finished part.

Sprue puller- it has been provide so that spur comes along with the core block when mold is opened

Runner- it is a channel cut into the mold that allows plastic material to flow from the nozzle to the cavity.

Gate- In injection molding, each cavity in a mold must contain a small opening called a gate, which allows hot plastic to enter the cavity before passing through and around its internal features until filled

Slider

Sliders-sliders are designed when there is presence of undercut in the plastic component

Conclusion

The mold for the given plastic component was designed successfully