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Injection mold design engineering /

Detalles Bibliográficos
Clasificación:	TP1150
Autor principal:	Kazmer, David (Autor)
Formato:	Electrónico eBook
Idioma:	Inglés
Publicado:	Munich : Hanser, [2022]
Edición:	3rd edition.
Temas:	Injection molding of plastics. Mati�eres plastiques > Moulage par injection. injection molding. Injection molding of plastics

Tabla de Contenidos:

Intro
Preface
Contents
Nomenclature
1 Introduction
1.1 Overview of the Injection Molding Process
1.2 Mold Functions
1.3 Mold Structures
1.3.1 External View of Mold
1.3.2 View of Mold during Part Ejection
1.3.3 Mold Cross-Section and Function
1.4 Other Common Mold Types
1.4.1 Three-Plate, Multicavity Family Mold
1.4.2 Hot Runner, Multigated, Single-Cavity Mold
1.4.3 Comparison
1.5 The Mold Development Process
1.6 Mold Standards
1.7 Chapter Review
2 Plastic Part Design
2.1 The Product Development Process
2.1.1 Product Definition
2.1.2 Product Design
2.1.3 Development
2.1.4 Scale-Up and Launch
2.1.5 Role of Mold Design in Manufacturing Strategy
2.2 Prototyping Strategy
2.2.1 3D Printing by Material Extrusion (Fused Deposition Modeling)
2.2.2 3D Printing by Selective Laser Sintering
2.2.3 3D Printing by Stereolithography, Digital Light Processing, and Continuous Liquid Interface Production
2.2.4 3D Printing by PolyJet and Multi Jet Fusion
2.3 Design Requirements
2.3.1 Application Engineering Information
2.3.2 Computer-Aided Engineering (CAE)
2.3.3 Production Planning
2.3.4 End-Use Requirements
2.3.5 Design for Manufacturing and Assembly
2.3.6 Plastic Material Properties
2.4 Design for Injection Molding
2.4.1 Uniform Wall Thickness
2.4.2 Rib Design
2.4.3 Boss Design
2.4.4 Corner Design
2.4.5 Surface Finish and Textures
2.4.6 Draft
2.4.7 Undercuts
2.5 Sustainability
2.6 Chapter Review
3 Mold Procurement
3.1 Overview
3.2 The Procurement Process
3.3 Molded Part Cost Estimation
3.3.1 Mold Cost per Part
3.3.2 Material Cost per Part
3.3.3 Processing Cost per Part
3.3.4 Defect Cost per Part
3.4 Mold Cost Estimation
3.4.1 Mold Base Cost Estimation
3.4.2 Cavity Cost Estimation.
3.4.2.1 Insert Cost Estimation
3.4.2.2 Inserts Discount Factor
3.4.2.3 Insert Cost Machining Factors
3.4.2.4 Insert Cost Finishing Factors
3.4.3 Mold Customization
3.5 Rapid and Additive Manufacturing
3.5.1 Common Additively Manufactured Materials
3.5.2 Additive Manufacturing Process Performance Metrics
3.5.3 Design for Additive Manufacturing Guidelines
3.5.4 Preferred Workflow and File Formats
3.6 Mold Selection by Breakeven Analysis
3.7 Chapter Review
4 Mold Layout Design
4.1 Parting Plane Design
4.1.1 Determine Mold Opening Direction
4.1.2 Determine Parting Line
4.1.3 Parting Plane
4.1.4 Shut-Offs
4.2 Cavity and Core Insert Creation
4.2.1 Height Dimension
4.2.2 Length and Width Dimensions
4.2.3 Adjustments
4.3 Mold Base Selection
4.3.1 Cavity Layouts
4.3.2 Mold Base Sizing
4.3.3 Molding Machine Compatibility
4.3.4 Mold Base Suppliers
4.4 Material Selection
4.4.1 Strength vs. Heat Transfer
4.4.2 Hardness vs. Machinability
4.4.3 Material Summary
4.4.4 Surface Treatments
4.5 Chapter Review
5 Cavity Filling Analysis and Design
5.1 Overview
5.2 Objectives in Cavity Filling
5.2.1 Complete Filling of Mold Cavities
5.2.2 Avoid Uneven Filling or Over-Packing
5.2.3 Control the Melt Flow
5.3 Viscous Flow
5.3.1 Shear Stress, Shear Rate, and Viscosity
5.3.2 Pressure Drop
5.3.3 Rheological Behavior
5.3.4 Newtonian Model
5.3.5 Power Law Model
5.4 Cavity Filling Analyses and Designs
5.4.1 Estimating the Processing Conditions
5.4.2 Estimating the Filling Pressure and Minimum Wall Thickness
5.4.3 Estimating Clamp Tonnage
5.4.4 Predicting Filling Patterns
5.4.5 Designing Flow Leaders
5.5 Process Simulation
5.5.1 Simulation Pre-Processing
5.5.2 Simulation Post-Processing
5.5.3 Discussion.
5.6 Chapter Review
6 Feed System Design
6.1 Overview
6.2 Objectives in Feed System Design
6.2.1 Conveying the Polymer Melt from Machine to Cavities
6.2.2 Impose Minimal Pressure Drop
6.2.3 Consume Minimal Material
6.2.4 Control Flow Rates
6.3 Feed System Types
6.3.1 Two-Plate Mold
6.3.2 Three-Plate Mold
6.3.3 Hot Runner Molds
6.4 Feed System Analysis
6.4.1 Determine Type of Feed System
6.4.2 Determine Feed System Layout
6.4.3 Estimate Pressure Drops
6.4.4 Calculate Runner Volume
6.4.5 Optimize Runner Diameters
6.4.6 Balance Flow Rates
6.4.7 Estimate Runner Cooling Times
6.4.8 Estimate Residence Time
6.5 Feed System Simulation
6.5.1 Hot Runners
6.5.2 Cold Runners
6.6 Practical Issues
6.6.1 Color Changes with Hot Runners
6.6.2 Runner Cross-Sections
6.6.3 Sucker Pins
6.6.4 Runner Shut-Offs
6.6.5 Standard Runner Sizes
6.6.6 Steel Safe Designs
6.7 Advanced Feed Systems
6.7.1 Insulated Runner
6.7.2 Stack Molds
6.7.3 Branched Runners
6.7.4 Dynamic Melt Control
6.8 Chapter Review
7 Gating Design
7.1 Objectives of Gating Design
7.1.1 Connecting the Runner to the Mold Cavity
7.1.2 Provide Automatic De-gating
7.1.3 Maintain Part Aesthetics
7.1.4 Avoid Excessive Shear or Pressure Drop
7.1.5 Control Pack Times
7.2 Common Gate Designs
7.2.1 Sprue Gate
7.2.2 Pin-Point Gate
7.2.3 Edge Gate
7.2.4 Tab Gate
7.2.5 Fan Gate
7.2.6 Flash/Diaphragm Gate
7.2.7 Tunnel/Submarine Gate
7.2.8 Thermal Gate
7.2.9 Valve Gate
7.3 The Gating Design Process
7.3.1 Determine Gate Location(s)
7.3.2 Determine Type of Gate
7.3.3 Calculate Shear Rates
7.3.4 Calculate Pressure Drop
7.3.5 Calculate Gate Freeze Time
7.3.6 Adjust Dimensions
7.3.7 Gate Verification by Simulation
7.4 Chapter Review
8 Venting.
8.1 Venting Design Objectives
8.1.1 Release Compressed Air
8.1.2 Contain Plastic Melt
8.1.3 Minimize Maintenance
8.2 Venting Analysis
8.2.1 Estimate Air Displacement and Rate
8.2.2 Identify Number and Location of Vents
8.2.3 Specify Vent Dimensions
8.3 Venting Designs
8.3.1 Vents on Parting Plane
8.3.2 Vents around Ejector Pins
8.3.3 Vents in Dead Pockets
8.3.4 Vents with Porous Metals
8.3.5 3D Printed Porous Inserts
8.4 Venting Best Practices
8.4.1 Venting Simulation
8.4.2 Vent Sensing
8.5 Chapter Review
9 Cooling System Design
9.1 Objectives in Cooling System Design
9.1.1 Maximize Heat Transfer Rates
9.1.2 Maintain Uniform Wall Temperature
9.1.3 Minimize Mold Cost
9.1.4 Minimize Volume and Complexity
9.1.5 Maximize Reliability
9.1.6 Facilitate Mold Usage
9.2 The Cooling System Design Process
9.2.1 Calculate the Required Cooling Time
9.2.2 Evaluate Required Heat Transfer Rate
9.2.3 Assess Coolant Flow Rate
9.2.4 Assess Cooling Line Diameter
9.2.5 Select Cooling Line Depth
9.2.6 Select Cooling Line Pitch
9.2.7 Cooling Line Routing
9.2.8 Cooling Simulation
9.3 Cooling System Designs
9.3.1 Cooling Line Networks
9.3.2 Cooling Inserts
9.3.3 Highly Conductive Inserts
9.3.4 Cooling of Slender Cores
9.3.4.1 Cooling Insert
9.3.4.2 Baffles
9.3.4.3 Bubblers
9.3.4.4 Heat Pipes
9.3.4.5 Conductive Pin
9.3.4.6 Interlocking Core with Air Channel
9.3.5 One-Sided Heat Flow
9.4 Conformal Cooling
9.4.1 Spiral and Serpentine Designs
9.4.2 Network Designs
9.4.3 Lattice and Generative Designs
9.4.4 Comparison and Discussion
9.5 Advanced Temperature Control
9.5.1 Pulsed Cooling
9.5.2 Conduction Heating
9.5.3 Induction Heating
9.5.4 Managed Heat Transfer
9.6 Chapter Review
10 Shrinkage and Warpage.
10.1 The Shrinkage and Warpage Analysis Process
10.1.1 Estimate Process Conditions
10.1.2 Model Compressibility Behavior
10.1.3 Assess Volumetric Shrinkage
10.1.4 Evaluate Isotropic Linear Shrinkage
10.1.5 Evaluate Anisotropic Shrinkage
10.1.6 Warpage Estimation
10.2 Shrinkage and Warpage Simulation
10.2.1 Methodology
10.2.2 Pressure and Temperature Prediction
10.2.3 Shrinkage Prediction
10.2.4 Warpage Prediction
10.3 Shrinkage and Warpage Design Practices
10.3.1 Gating Dependence
10.3.2 Injection Compression Molding
10.3.3 Processing Corrections
10.3.4 Semicrystalline Plastics
10.3.5 Effect of Fillers
10.3.6 Shrinkage Range Estimation
10.3.7 Mold Commissioning and Shrinkage Validation
10.3.8 "Steel Safe" Mold Design
10.3.9 Warpage Avoidance and Compensation
10.4 Chapter Review
11 Ejection System Design
11.1 Objectives in Ejection System Design
11.1.1 Allow Mold to Open
11.1.2 Transmit Ejection Forces to Moldings
11.1.3 Minimize Distortion of Moldings
11.1.4 Maximize Ejection Speed
11.1.5 Minimize Cooling Interference
11.1.6 Minimize Impact on Part Surfaces
11.1.7 Minimize Complexity and Cost
11.2 The Ejector System Design Process
11.2.1 Identify Mold Parting Surfaces
11.2.2 Estimate Ejection Forces
11.2.3 Determine Ejector Push Area and Perimeter
11.2.4 Specify Type, Number, and Size of Ejectors
11.2.5 Lay Out Ejectors
11.2.6 Detail Ejectors and Related Components
11.3 Ejector System Analyses and Designs
11.3.1 Ejector Pins
11.3.2 Ejector Blades
11.3.3 Ejector Sleeves
11.3.4 Stripper Plates
11.3.5 Elastic Deformation around Undercuts
11.3.6 Core Pulls
11.3.7 Slides
11.3.8 Early Ejector Return Systems
11.4 Advanced Ejection Systems
11.4.1 Split Cavity Molds
11.4.2 Collapsible Cores.

Injection mold design engineering /

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