Mould Sandwich Mould PDF
Mould Sandwich Mould PDF
Mould Sandwich Mould PDF
SandwichMoulds
TampereUniversityofTechnologySannaNyknen
Sandwichmould(orstackmould)isaspecialmoulddesignformouldingshallow, Introduction
small parts in large quantities such as tape cassettes. In this kind of moulds is
possibleduplicatethenumberofpartsusingthesameclampforcesoftheinjection
mouldingmachine.
The opening of the mould occurs with the aid of the opening of the injection
mouldingmachine.Theassemblyofthecavities(A)stayedtohalfoftheassembly
ofthecores(B),resultoftheapplicationofthesystemofratchets(seeFigure1).
Duringthemouldopeningandclose,itsimportantthatthemouldassemblycavi
ties do not leave from the main mould guides. For that we have to provide the
usingofsupportbarsinthemouldorinthecolumnsofthemould.
Theejectionofthepartscanbemadebytheinjectionmachineopeningmovement
andusingharnesses.
Figure1:Sandwichmould:a)mouldclosedb)mouldopeningc)mouldsections[1]
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CAEDSMouldDesign
Inthiskindofmoulds,cavitiesarelocatedintwoormoreplanescorrespondingto Sandwichmould
components
twopartinglinesandarefilledatthesametime(seeFigure2).
28
Figure2:Maincomponentsofasandwichmould[2]:A,BPartinglines;13Leader
for center plate; 4a4b Mould plates; 78 Cores; 910 Mould plates; 11 Leader for
mouldplates;12Leaderbushing;15Heaterforsprue;16Hotmanifold;17Sprueto
mouldedpart;18Mouldplate,asper9;1923Centralspruetomachineasextended
nozzle;24Sprue;27Stripperring;28Ejectorpins;2935Ejectorsystem:39Retainer;
42Heatednozzle;4546Interlocks.
increaseinproductivityof100%asonemightexpectfromdoublingthenumberof
cavitiescannotberealizedbecauseofthetimeneededforthelongeropeningand
closing strokes. The increase in productivity is about 80%. The clamping force
shouldbe15%higherthanforastandardmould[3].
The mould section mounted on the movable platen and the center section are Mouldoperation
moved in the direction of the machine axis during demoulding. With this, the
extensionisremovedfromthenozzle[4].Theextensionhastobesufficientlylong
thatnoleakagematerialcandropontotheleaderpinsandstickthereduringmould
opening.Thiswouldimpedetheirproperfunctioning[5,6].Forthisreasonmany
sandwichmouldsareoperatedtodaywithtelescopicextensionsandwithoutnozzle
retraction.Whiletheoutersectionontheclampingsideismountedonthemovable
machine platen and moves positively with it during mould opening and closing,
special elements are necessary to guide and control the movement of the center
section. Because of the frequently large size of the moulds utilizing the whole
platenarea,centersectionsareattachedtothetiebarsorareguided(seeFigure3)
bymeansofguidebarswithguideshoes[5,6].
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CAEDSMouldDesign
Figure3:Sandwichmouldoperation(Origin:Huskypublication)
Figure3alsoshowahotrunnersystemforsandwichmouldmanifold,spruesand
gatesmoulds.Thesprueisnormallymountedatthelevelofthemouldcentreand
feedsthemeltintothemiddleofthehotrunnermanifold.Fromthere,themeltis
distributeduniformlytoallcavitiesofbothmoulddaylights[4].
Today the motions are primarily produced by toggles or sometimes by racks (see Design
Considerations
Figure4).Previouslysystemswereemployedwhichusedseparatehydrauliccylin
dersformovingthecentersection[4].
a)
b)
c)
Movementwithracks.
Toggle and rack control open at both parting lines smoothly and simultaneously.
Toggle control also offers the option of using, within a certain range, opening
strakes of different lengths. This allows the moulding of parts with one height in
onestackandpartswithadifferentheightintheotherone.Thecurvesoftheopen
ing path can be adjusted within a wide range depending on pivotal point and
toggle geometry. At the same time ejection is actuated by the same elements that
movethecentersection.VariouskindsoftogglecontrolareshownwithFigure5.
TherackcontrolinFigure6islessrigidandpermitsagentlestartandbuildupof
demoulding forces because of springs in the pulling rods connected to the crank
drive[4].
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CAEDSMouldDesign
Figure5:Togglemechanismforsandwichmoulds(Origin:Huskypublication)
TherackcontrolinFigure6islessrigidandpermitsagentlestartandbuildupof
demoulding forces because of springs in the pulling rods connected to the crank
drive.
Movable
Stripperring
c1ampingplaten
Stripperplate
Stripperplate
Rackorleversystem
Figure6:Ejectordriveforsandwichmoulds(Origin:Huskypublication)
A4x24levelmould(96cavities)thatrunsathinwalllid(760mmdiameter)produc
ingover75,000partsperhouratcyclescloseto5secondsisshowninFigure7.
Figure7:Sandwichmould(Origin:Stackteck[7])
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CAEDSMouldDesign
References
[1]ManualdoProjectista,2004
[3]Hotz,A.,MehrEtagenSpritzBwerkseuge.Plastverarbeiter,29(1978),4,pp.185
188.
[4] Menges, G., Michaeli, W., Mohren, P. How To Make Injection Molds. 3rd
Edition.HanserPulishers,2001.612p.ISBN1569902828
[5] Lindner, E., Hartmann, W., SpritzgieBwerkezeuge in Etagenbauweise.
Plastverarbeiter,28(1977),7,pp.351353.
[6] Schwaninger, W., Etagenwerkzeuge insbesondere als Alternative zum
Schnellaufer. Der SpritzgieBprozeb, Ingenieurrwissen, VDIVerlag, Dusseldorf,
1979.
[7]http://www.stackteck.com/mold_fourlevel.asp(accessinNovember2007)
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