Tool Design & Applications - Lec2

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Tool design and

applications
‫تصميم عدد ومستلزمات االنتاج‬
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Course Contents
Injection Molding:
 Manufacturing processes of plastics,
 Types of injection moulds for thermoplastics,
 Clamping forces, Number of cavities and layout, Parting planes, Draft angles, Shrinkage,
 Feeding systems (runners, gate, sprue and vents), Cooling systems, Ejection systems,
 Tolerances, Min and max. Wall thickness, How to manufacture injection mould.
Jigs and fixtures
 Advantages of Jigs and fixtures, Principles of location, Types of locators, Over determined location,
 Principles of clamping, Types of clamping, Clamping forces, Design procedure,
 Drilling Jigs, Indexing Jigs, Milling Fixtures, Indexing table,
 Single and multiple piece Fixtures, Turning Fixtures, Welding Fixtures, Assembly Fixtures,
 Manufacturing of Jigs and Fixtures, Economy of Jigs and Fixtures.
Machining:
 Modern cutting tool materials, Coated carbide tips, Boron nitride, Ceramics, Diamond tips,
 Design and manufacturing of cutting form tools, Turning form drilling tools, Form relieved milling cutters,
 Threading tools and broaching.
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Injection Molding
Plunger
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Injection Molding
Reciprocating
Rotating screw
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Injection Molding
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Injection Molding
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Injection Molding: Sequence of operations
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Types of injection molds for thermoplastics
1- Cold-runner, two-plate mold:

This design is the simplest and most
common
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2- Cold-runner, three-plate mold :The

runner system is separated from the part
when the mold is opened.
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3- Hot-runner mold, also called

runnerless mold: The molten plastic
is kept hot in a heated runner plate.
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Injection Molding: Clamping forces
The clamp of an injection molding machine is what closes the

mold, holds it closed under pressure during injection of the
molten material and during cooling of the material to form a
solid part, and opens the mold so that the part can be ejected
and removed from the mold. In injection molding, four
different types of clamping are used: hydraulic, mechanical,
hydromechanical, and electric.
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Injection Molding: Mold Shrinkage
Mold shrinkage is one of the

properties of a material that is
needed in determining
the final part dimensions
required. This value indicates
the amount of contraction
that a part exhibits after it has
been removed from the mold
and is then cooled and
conditioned at 73°F (23°C) for
a period of 48 hours.
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Mold shrinkage can be affected by a number of variables. Slower part

cooling, injection pressures, and part thickness can change the mold
shrinkage for a given material. The addition of fillers and
reinforcements, such as glass fiber or mineral filler, can reduce mold
shrinkage from what is found with an unreinforced or neat material.
However, the type and classification of

plastic material has the most influence,
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Plastic materials can be classified into two categories:

amorphous and semicrystalline.
Amorphous materials typically have no defined melting point but have a

broader melting point range.
Semicrystalline materials do have a defined crystalline melting point. The

polymer chains arrange themselves in ordered molecular configurations.
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These ordered areas are crystals that form when the polymer is cooled from its
molten state. As a result of the cooling and formation and the increased packing of
the molecular chains in these crystalline areas, the mold shrinkage for
semicrystalline materials is higher than for amorphous materials. The degree of
crystallinity in a semicrystalline material is affected not only by the chemical
structure of the polymer, but by the process conditions that are used to
manufacture the part. In particular, the rate of cooling during the injection molding
process has the greatest effect on the degree of crystallinity. Slight variations in the
molding process, such as mold temperature, melt temperature, and part thickness,
play a major role in determining the final dimensions in semicrystalline materials.
Examples
of semicrystalline materials are nylon, polypropylene, and polyethylene.
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Injection Molding: Draft Angle
Draft angle is critical in part design

since this directly affects how easily a
part can be ejected from a tool without
causing damage to the part or tool. A
slight angle is recommended for all
thermoplastics to facilitate part
ejection. This draft angle is determined
by a number of factors, such as plastic
material used, part geometry, and mold
ejection system used, whether
mechanical or air assist.

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1

Tool design and

1- Cold-runner, two-plate mold:

2- Cold-runner, three-plate mold :The

3- Hot-runner mold, also called

The clamp of an injection molding machine is what closes the

Mold shrinkage is one of the

Mold shrinkage can be affected by a number of variables. Slower part

However, the type and classification of

Plastic materials can be classified into two categories:

Amorphous materials typically have no defined melting point but have a

Semicrystalline materials do have a defined crystalline melting point. The

Draft angle is critical in part design

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