Reasonable product design and mold design are key technologies that affect the success of injection molding. This article introduces some basic principles of injection molded product design and mold design.
1. The basic conditions of plastic product design
1.1. Record the product usage conditions as detailed as possible.
These conditions are:
A. Use environment
Outdoor conditions (sunlight, rain, ice, snow, dust), sunlight (ultraviolet rays, radiation, etc.), contact with gas (corrosive gas, water vapor), contact with liquid (water, detergent, oil, medicine, etc.), other (plasticizers), copper);
B. Use intensity
Common temperature, maximum temperature, minimum temperature (usually, special circumstances, outdoor, warehouse, window, car, etc.), repeated cold and hot
C. Use load
Common load, maximum load (normal, special circumstances. Static, dynamic, repeated, continuous, impact, drop, etc.).
Sheet metal process blanking -dgmf mold clamps co., ltdJasmineHL
Punching is a basic stamping process that uses a mold to separate materials. It can be directly made into flat parts or prepared for other stamping processes such as bending, deep drawing, forming, etc., and can also be cut, repaired on the formed stamped parts. Wait. The blanking process accounts for about 50% to 60% of the entire stamping process.
Sheet metal process blanking -dgmf mold clamps co., ltdJasmineHL
Punching is a basic stamping process that uses a mold to separate materials. It can be directly made into flat parts or prepared for other stamping processes such as bending, deep drawing, forming, etc., and can also be cut, repaired on the formed stamped parts. Wait. The blanking process accounts for about 50% to 60% of the entire stamping process.
Gravity Sand Casting of Metallurgical Bonded Bimetallic Grinding Roll Made of...IJERA Editor
Bimetallic castings are widely used in the mining industries as construction material for crushers which have to perform high abrasive resistance at the outer side and excellent machinability at the inner side. To manufacture bimetallic casting goods cconsecutive centrifugal and gravity casting methods are commonly applied. Centrifugal and consecutive casting come up with geometrical constraints at the parting line of both materials. This research dealed with the manufacturing of tapered grinding roll by applying gravity casting method. The possibilities of casting the white cast iron outer ring in the preheated ductile cast iron of the inner ring were investigated. The inner ring was first heated up by casting liquid metal around the inner side, which prevented the inner ring from cracking due to rapid expansion during the casting process and to provide adequyate shrinkage of inner ring during solidification. After achieving the desired temperature of the inner ring, the liquid metal of white cast iron was then poured into the cavity to form the outer ring. The preheating temperature of the inner ring was mainly derived from the linear thermal expansion of both quasi isotrophic material and the diffusion at the parting line. This preheating temperature has to facilitate the formation of metallurgical bonding and avoid cracks due to the difference of shrinkage value between inner and outer ring. The preheating temperature was set up in the range of 500°C -1000 °C and the flushing time was fixed for 7 seconds. Studies on the microstructure of sample material have revealed a formation of metallurgical bonding at all of the preheating temperature. The width of the diffusion at the interface area varied between 291 µm at 500 oC preheating temperature, 301 µm at 625 oC, 834,8 µm at 750 °C, 909,1 µm at 875 °C and 1027,7 µm at 1000 °C. By preheating temperature of higher than 750°C fusion occured at the interface area between inner and outer material. This research concludes that the casting of bimetallic by applying gravity casting method can be done by preheating the inner ring to 625 oC, interface temperature of 1150 oC, flushing time of 7 seconds and pouring the white cast iron outer ring at the temperature of 1430 oC
Basic requirements for plastic injection molded part designJasmineHL
Plastic Part Design Basic Requirements
Unreasonable design of plastic injection molded parts often results in some inherent defects in the product. For example, the structure of the parts is unreasonable, the parts use too much material, etc. Here are a series of basic requirements for plastic injection molded parts design for reference.
What is the difference between blow molding and injection moldingJasmineHL
What Is The Difference Between Blow Molding And Injection Molding?
First, the process is different
Blow molding: Blow molding uses gas pressure to inflate the hot parison closed in the mold into a hollow product, or the tube parison is inflated into a tube film without a mold.
Injection molding: injection molding is to melt plastic materials, and then inject them into the film cavity to form.
Continuous drawing die -dgmf mold clamps co., ltdJasmineHL
There are many types of products in the mold industry, of which the stretch mold is one of the higher technical content. The reason why the drawing mold is difficult is that 1, the calculation of the design, and the test work 2 after the mold design is completed.
Six injection molding processing technologies for plastic products for home a...JasmineHL
The molding and processing methods of plastic products for home appliances mainly include injection molding, extrusion molding, thermoforming, hollow molding, lamination molding, compression molding, transfer molding, foam plastic molding, casting molding, insert casting, sealing casting, etc., among which Mainly injection molding.
Influence of injection molding process on product quality -dgmf mold clamps c...JasmineHL
During the molding process of converting plastic particles into plastic products, plastics are often subjected to high temperature and high pressure and flow molding at high shear rates. Different molding conditions and processes will have different effects on product quality. Plastic injection molding has plastics. Raw materials, injection molding machines, molds and injection molding processes are composed of four aspects.
What are the key points of precision injection moldingJasmineHL
Precision injection molding is affected by many related factors and environmental conditions, and the most basic are the four basic factors of plastic materials, injection molds, injection molding processes, and injection molding equipment.
In the early stage of designing plastic products, engineering plastics with corresponding performance requirements should be selected according to the application environment.
Secondly, the appropriate injection molding machine should be selected according to the selected plastic material, finished product dimensional accuracy, part weight, quality requirements, and expected mold structure.
DESIGN OF MOULD TOOL & COOLING CHANNEL OPTIMIZATION OF REMOTE CONTROL TOP PANELIjripublishers Ijri
A plastic material is any of a wide range of synthetic or semi-synthetic organic solids that are moldable. Plastics are
typically organic polymers of high molecular mass, but they often contain other substances. They are usually synthetic,
most commonly derived from petrochemicals, but many are partially natural.
Molding is the process of manufacturing by shaping liquid or pliable raw material using a rigid frame called a mold or
matrix. This itself may have been made using a pattern or model of the final object.
Cooling channels are used in mold tool to reduce the temperature of the object to help molten material to solidify quickly
before the ejection. It is quite useful to increase the production rate.
DESIGN OF MOULD TOOL & COOLING CHANNEL OPTIMIZATION OF REMOTE CONTROL TOP PANELIjripublishers Ijri
A plastic material is any of a wide range of synthetic or semi-synthetic organic solids that are moldable. Plastics are
typically organic polymers of high molecular mass, but they often contain other substances. They are usually synthetic,
most commonly derived from petrochemicals, but many are partially natural.
Molding is the process of manufacturing by shaping liquid or pliable raw material using a rigid frame called a mold or
matrix. This itself may have been made using a pattern or model of the final object.
Cooling channels are used in mold tool to reduce the temperature of the object to help molten material to solidify quickly
before the ejection. It is quite useful to increase the production rate.
The aim of this project work is to design mold structure and optimize cooling channel system to reduce effect of warpage
of remote control top panel.
A mold is an industrial product that shapes a material by a certain structure in a specific structure, and is also a production tool capable of mass-producing industrial product parts having a certain shape and size requirement. Large to airplanes, cars, small cups, nails, almost all industrial products must rely on molding. High precision, high consistency, and high productivity of parts produced by mold are unmatched by any other processing method. Molds largely determine quality, efficiency and new product development capabilities of product. Therefore, mold has honorary title of “Mother of Industry”.
Gravity Sand Casting of Metallurgical Bonded Bimetallic Grinding Roll Made of...IJERA Editor
Bimetallic castings are widely used in the mining industries as construction material for crushers which have to perform high abrasive resistance at the outer side and excellent machinability at the inner side. To manufacture bimetallic casting goods cconsecutive centrifugal and gravity casting methods are commonly applied. Centrifugal and consecutive casting come up with geometrical constraints at the parting line of both materials. This research dealed with the manufacturing of tapered grinding roll by applying gravity casting method. The possibilities of casting the white cast iron outer ring in the preheated ductile cast iron of the inner ring were investigated. The inner ring was first heated up by casting liquid metal around the inner side, which prevented the inner ring from cracking due to rapid expansion during the casting process and to provide adequyate shrinkage of inner ring during solidification. After achieving the desired temperature of the inner ring, the liquid metal of white cast iron was then poured into the cavity to form the outer ring. The preheating temperature of the inner ring was mainly derived from the linear thermal expansion of both quasi isotrophic material and the diffusion at the parting line. This preheating temperature has to facilitate the formation of metallurgical bonding and avoid cracks due to the difference of shrinkage value between inner and outer ring. The preheating temperature was set up in the range of 500°C -1000 °C and the flushing time was fixed for 7 seconds. Studies on the microstructure of sample material have revealed a formation of metallurgical bonding at all of the preheating temperature. The width of the diffusion at the interface area varied between 291 µm at 500 oC preheating temperature, 301 µm at 625 oC, 834,8 µm at 750 °C, 909,1 µm at 875 °C and 1027,7 µm at 1000 °C. By preheating temperature of higher than 750°C fusion occured at the interface area between inner and outer material. This research concludes that the casting of bimetallic by applying gravity casting method can be done by preheating the inner ring to 625 oC, interface temperature of 1150 oC, flushing time of 7 seconds and pouring the white cast iron outer ring at the temperature of 1430 oC
Basic requirements for plastic injection molded part designJasmineHL
Plastic Part Design Basic Requirements
Unreasonable design of plastic injection molded parts often results in some inherent defects in the product. For example, the structure of the parts is unreasonable, the parts use too much material, etc. Here are a series of basic requirements for plastic injection molded parts design for reference.
What is the difference between blow molding and injection moldingJasmineHL
What Is The Difference Between Blow Molding And Injection Molding?
First, the process is different
Blow molding: Blow molding uses gas pressure to inflate the hot parison closed in the mold into a hollow product, or the tube parison is inflated into a tube film without a mold.
Injection molding: injection molding is to melt plastic materials, and then inject them into the film cavity to form.
Continuous drawing die -dgmf mold clamps co., ltdJasmineHL
There are many types of products in the mold industry, of which the stretch mold is one of the higher technical content. The reason why the drawing mold is difficult is that 1, the calculation of the design, and the test work 2 after the mold design is completed.
Six injection molding processing technologies for plastic products for home a...JasmineHL
The molding and processing methods of plastic products for home appliances mainly include injection molding, extrusion molding, thermoforming, hollow molding, lamination molding, compression molding, transfer molding, foam plastic molding, casting molding, insert casting, sealing casting, etc., among which Mainly injection molding.
Influence of injection molding process on product quality -dgmf mold clamps c...JasmineHL
During the molding process of converting plastic particles into plastic products, plastics are often subjected to high temperature and high pressure and flow molding at high shear rates. Different molding conditions and processes will have different effects on product quality. Plastic injection molding has plastics. Raw materials, injection molding machines, molds and injection molding processes are composed of four aspects.
What are the key points of precision injection moldingJasmineHL
Precision injection molding is affected by many related factors and environmental conditions, and the most basic are the four basic factors of plastic materials, injection molds, injection molding processes, and injection molding equipment.
In the early stage of designing plastic products, engineering plastics with corresponding performance requirements should be selected according to the application environment.
Secondly, the appropriate injection molding machine should be selected according to the selected plastic material, finished product dimensional accuracy, part weight, quality requirements, and expected mold structure.
DESIGN OF MOULD TOOL & COOLING CHANNEL OPTIMIZATION OF REMOTE CONTROL TOP PANELIjripublishers Ijri
A plastic material is any of a wide range of synthetic or semi-synthetic organic solids that are moldable. Plastics are
typically organic polymers of high molecular mass, but they often contain other substances. They are usually synthetic,
most commonly derived from petrochemicals, but many are partially natural.
Molding is the process of manufacturing by shaping liquid or pliable raw material using a rigid frame called a mold or
matrix. This itself may have been made using a pattern or model of the final object.
Cooling channels are used in mold tool to reduce the temperature of the object to help molten material to solidify quickly
before the ejection. It is quite useful to increase the production rate.
DESIGN OF MOULD TOOL & COOLING CHANNEL OPTIMIZATION OF REMOTE CONTROL TOP PANELIjripublishers Ijri
A plastic material is any of a wide range of synthetic or semi-synthetic organic solids that are moldable. Plastics are
typically organic polymers of high molecular mass, but they often contain other substances. They are usually synthetic,
most commonly derived from petrochemicals, but many are partially natural.
Molding is the process of manufacturing by shaping liquid or pliable raw material using a rigid frame called a mold or
matrix. This itself may have been made using a pattern or model of the final object.
Cooling channels are used in mold tool to reduce the temperature of the object to help molten material to solidify quickly
before the ejection. It is quite useful to increase the production rate.
The aim of this project work is to design mold structure and optimize cooling channel system to reduce effect of warpage
of remote control top panel.
A mold is an industrial product that shapes a material by a certain structure in a specific structure, and is also a production tool capable of mass-producing industrial product parts having a certain shape and size requirement. Large to airplanes, cars, small cups, nails, almost all industrial products must rely on molding. High precision, high consistency, and high productivity of parts produced by mold are unmatched by any other processing method. Molds largely determine quality, efficiency and new product development capabilities of product. Therefore, mold has honorary title of “Mother of Industry”.
What is the standard injection mold development process?JasmineHL
Before drawing the final assembly drawing of the mold, the process drawing should be drawn up, and it should meet the requirements of the workpiece drawing and process data. The size guaranteed by the next process shall be marked with the words "process size" on the drawing. If, after molding, no other machining is performed except for repairing burrs, the process drawing is exactly the same as the workpiece drawing.
Mold clamp tools definition
What is mold clamp? The mold clamp (also called mould clamp) is a kind of auxiliary clamping unit often used in injection mold processing, its main function is to keep the machined parts not shaking not moving in the processing.
What determines high performance plasticsJasmineHL
The following six factors determine the high-performance plastics.
(1) The type of polymer determines high-performance plastics
The performance is also different because of the different polymer links, such as acetal resin (POM) impact strength, then the unsaturated polyester resin (UP) is more excellent. Even if the same material, structure, and polymerization degree are different, the performance varies significantly.
18 Basic Injection Molding Technologies
Below are the 18 basic injection molding technologies that injection molding technicians must know.
01. Nozzle in the injection molding technologies
The melt usually flows from the nozzle into the nozzle, but in some injection molds, the nozzle is part of the mold because it extends to the bottom of the mold. There are also two main types of nozzles: open nozzles and closed nozzles. In injection molding, open nozzles should be used more because they are cheaper and less likely to stay.
If the injection molding machine is equipped with a pressure-removing device, this nozzle can be used even for low-viscosity melts. Sometimes a closed nozzle must be used. This nozzle acts as a stop valve to block the plastic in the injection cylinder.
Make sure that the nozzle is correctly connected to the nozzle bushing, and the top hole is slightly smaller than the nozzle sprue bushing, which makes the nozzle easier to withdraw from the injection mold. The hole of the nozzle sleeve is 1mm larger than the nozzle, that is, the radius of the nozzle is 0.5mm smaller than the radius of the nozzle sleeve.
What is mold temperature in injection molding?JasmineHL
The mold temperature in injection molding is probably the most important temperature in terms of quality and this affects quality in many ways. The mold temperature is not the same thing as the cooling water temperature, it is the temperature of the actual mold cavity after it has stabilized.
What is progressive stamping die?
Progressive stamping is a metalworking method that can encompass punching, coining, bending, and several other ways of modifying metal raw material, combined with an automatic feeding system. The feeding system pushes a strip of metal through all of the stations of a progressive stamping die.
The progressive stamping die refers to a cold stamping die that uses a strip of stamping raw material to complete multiple stamping processes simultaneously with several different stations on one die in one stamping stroke, and the material strip moves at a fixed distance once for each stamping stroke until the product is finished.
Mold components refer to the general name of metal accessories used in stamping dies, plastic molds, or FA automation equipment exclusively in the mold industry.
Here we are going to introduce 60 kinds of the mold components.
1. Causes of dents
1.1 The thickness of each part of the product is different
1.2 Insufficient pressure inside the mold
1.3 Insufficient mold cooling
1.4 Deformation due to the insufficient cooling time
Precautions for injection mold maintenanceJasmineHL
Injection mold, as the most important production tool of injection molding factory, determines the shape, specification, size and appearance finish of the product. The material of the mold is steel, which is generally composed of a front mold and a back mold.
Injection mold is a tool for producing plastic products; it is also a tool for giving plastic products a complete structure and precise dimensions. The structure of the injection mold and the quality of mold processing directly affects the quality and production efficiency of plastic parts. The most common and most common causes of injection mold failures and troubleshooting methods in the production of injection molds and plastic products are described in detail as follows:
Five elements of injection molding process parametersJasmineHL
The injection molding process is one of the four major plastic molding processes. The barrels, basins, toys, and other daily products we use in our lives are all formed by the injection molding process. So what are the important factors to pay attention to in the plastic injection molding process?
The completion of the injection molding process generally requires six processes of clamping, filling, holding pressure, cooling, demolding, and opening the mold. In these six processes, we must remember these five elements, namely pressure, speed, position, temperature, and time.
What is the 4 process of plastic injection molding?JasmineHL
The plastic injection molding process mainly includes four stages: filling, holding pressure, cooling, and demolding. These four stages directly determine the molding quality of the product, and these four stages are a complete continuous process.
Plastic products are made of a mixture of synthetic resin and various additives as raw materials, using injection, extrusion, pressing, pouring, and other methods. While plastic products are being molded, they also obtain the final performance, so plastic molding is a key production process.
The following are 10 common plastic Injection molding methods.
Secrets of injection molding process adjustmentJasmineHL
The close relationship between injection speed and product quality makes it a key parameter of injection molding. By determining the start, middle, and end of the filling speed segment, And to achieve a smooth transition from one set point to another set point, a stable melt surface speed can be ensured to produce the desired molecule and the smallest internal stress.
The cold forging, cold extrusion, and cold heading are general terms for plastic processing. Cold forging, also called cold volume forming, is a manufacturing process and a processing method. Cold forging is the forming process below the recrystallization temperature of the material, and the forging performed below the recovery temperature.
Blow molding is a manufacturing process for forming and joining together hollow plastic parts. It is also used for forming glass bottles or other hollow shapes. In general, there are three main types of blow molding: extrusion blow molding, injection blow molding, and injection stretch blow molding.
The inclined top mold is also known as the inclined tip. It is the mechanism used to mold the internal barbs of the product in the mold design. It is suitable for relatively simple barbs.
Appropriate opening of the injection mold air vent can greatly reduce the injection molding pressure, injection molding time, holding time, and injection mold clamping pressure, making the plastic parts from difficult to easy, thereby improving production efficiency, reducing production costs, and reducing the energy consumption of the machine.
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CFD Simulation of By-pass Flow in a HRSG module by R&R Consult.pptxR&R Consult
CFD analysis is incredibly effective at solving mysteries and improving the performance of complex systems!
Here's a great example: At a large natural gas-fired power plant, where they use waste heat to generate steam and energy, they were puzzled that their boiler wasn't producing as much steam as expected.
R&R and Tetra Engineering Group Inc. were asked to solve the issue with reduced steam production.
An inspection had shown that a significant amount of hot flue gas was bypassing the boiler tubes, where the heat was supposed to be transferred.
R&R Consult conducted a CFD analysis, which revealed that 6.3% of the flue gas was bypassing the boiler tubes without transferring heat. The analysis also showed that the flue gas was instead being directed along the sides of the boiler and between the modules that were supposed to capture the heat. This was the cause of the reduced performance.
Based on our results, Tetra Engineering installed covering plates to reduce the bypass flow. This improved the boiler's performance and increased electricity production.
It is always satisfying when we can help solve complex challenges like this. Do your systems also need a check-up or optimization? Give us a call!
Work done in cooperation with James Malloy and David Moelling from Tetra Engineering.
More examples of our work https://www.r-r-consult.dk/en/cases-en/
Quality defects in TMT Bars, Possible causes and Potential Solutions.PrashantGoswami42
Maintaining high-quality standards in the production of TMT bars is crucial for ensuring structural integrity in construction. Addressing common defects through careful monitoring, standardized processes, and advanced technology can significantly improve the quality of TMT bars. Continuous training and adherence to quality control measures will also play a pivotal role in minimizing these defects.
Event Management System Vb Net Project Report.pdfKamal Acharya
In present era, the scopes of information technology growing with a very fast .We do not see any are untouched from this industry. The scope of information technology has become wider includes: Business and industry. Household Business, Communication, Education, Entertainment, Science, Medicine, Engineering, Distance Learning, Weather Forecasting. Carrier Searching and so on.
My project named “Event Management System” is software that store and maintained all events coordinated in college. It also helpful to print related reports. My project will help to record the events coordinated by faculties with their Name, Event subject, date & details in an efficient & effective ways.
In my system we have to make a system by which a user can record all events coordinated by a particular faculty. In our proposed system some more featured are added which differs it from the existing system such as security.
Automobile Management System Project Report.pdfKamal Acharya
The proposed project is developed to manage the automobile in the automobile dealer company. The main module in this project is login, automobile management, customer management, sales, complaints and reports. The first module is the login. The automobile showroom owner should login to the project for usage. The username and password are verified and if it is correct, next form opens. If the username and password are not correct, it shows the error message.
When a customer search for a automobile, if the automobile is available, they will be taken to a page that shows the details of the automobile including automobile name, automobile ID, quantity, price etc. “Automobile Management System” is useful for maintaining automobiles, customers effectively and hence helps for establishing good relation between customer and automobile organization. It contains various customized modules for effectively maintaining automobiles and stock information accurately and safely.
When the automobile is sold to the customer, stock will be reduced automatically. When a new purchase is made, stock will be increased automatically. While selecting automobiles for sale, the proposed software will automatically check for total number of available stock of that particular item, if the total stock of that particular item is less than 5, software will notify the user to purchase the particular item.
Also when the user tries to sale items which are not in stock, the system will prompt the user that the stock is not enough. Customers of this system can search for a automobile; can purchase a automobile easily by selecting fast. On the other hand the stock of automobiles can be maintained perfectly by the automobile shop manager overcoming the drawbacks of existing system.
Courier management system project report.pdfKamal Acharya
It is now-a-days very important for the people to send or receive articles like imported furniture, electronic items, gifts, business goods and the like. People depend vastly on different transport systems which mostly use the manual way of receiving and delivering the articles. There is no way to track the articles till they are received and there is no way to let the customer know what happened in transit, once he booked some articles. In such a situation, we need a system which completely computerizes the cargo activities including time to time tracking of the articles sent. This need is fulfilled by Courier Management System software which is online software for the cargo management people that enables them to receive the goods from a source and send them to a required destination and track their status from time to time.
Saudi Arabia stands as a titan in the global energy landscape, renowned for its abundant oil and gas resources. It's the largest exporter of petroleum and holds some of the world's most significant reserves. Let's delve into the top 10 oil and gas projects shaping Saudi Arabia's energy future in 2024.
Final project report on grocery store management system..pdfKamal Acharya
In today’s fast-changing business environment, it’s extremely important to be able to respond to client needs in the most effective and timely manner. If your customers wish to see your business online and have instant access to your products or services.
Online Grocery Store is an e-commerce website, which retails various grocery products. This project allows viewing various products available enables registered users to purchase desired products instantly using Paytm, UPI payment processor (Instant Pay) and also can place order by using Cash on Delivery (Pay Later) option. This project provides an easy access to Administrators and Managers to view orders placed using Pay Later and Instant Pay options.
In order to develop an e-commerce website, a number of Technologies must be studied and understood. These include multi-tiered architecture, server and client-side scripting techniques, implementation technologies, programming language (such as PHP, HTML, CSS, JavaScript) and MySQL relational databases. This is a project with the objective to develop a basic website where a consumer is provided with a shopping cart website and also to know about the technologies used to develop such a website.
This document will discuss each of the underlying technologies to create and implement an e- commerce website.
Explore the innovative world of trenchless pipe repair with our comprehensive guide, "The Benefits and Techniques of Trenchless Pipe Repair." This document delves into the modern methods of repairing underground pipes without the need for extensive excavation, highlighting the numerous advantages and the latest techniques used in the industry.
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How to design injection molding product?
1. www.moldclamps.net www.dgmfmoldclamps.com info@dgmfmoldclamps.com
Mob & Wechat: 0086-17322110281
DGMF Mold Clamps Co., Ltd
Jasmine HL info@moldclamps.net
Please browse our website or contact us for more articles, thank you.
How To Design Injection Molding Product?
Reasonable product design and mold design are key technologies that affect the success of
injection molding. This article introduces some basic principles of injection molded product
design and mold design.
1. The basic conditions of plastic product design
1.1. Record the product usage conditions as detailed as possible.
These conditions are:
A. Use environment
Outdoor conditions (sunlight, rain, ice, snow, dust), sunlight (ultraviolet rays, radiation, etc.),
contact with gas (corrosive gas, water vapor), contact with liquid (water, detergent, oil, medicine,
etc.), other (plasticizers), copper);
B. Use intensity
Common temperature, maximum temperature, minimum temperature (usually, special
circumstances, outdoor, warehouse, window, car, etc.), repeated cold and hot
C. Use load
Common load, maximum load (normal, special circumstances. Static, dynamic, repeated,
continuous, impact, drop, etc.).
1.2. Assembly situation
How to install and use the product, what are the key dimensions that need to be controlled,
2. www.moldclamps.net www.dgmfmoldclamps.com info@dgmfmoldclamps.com
Mob & Wechat: 0086-17322110281
DGMF Mold Clamps Co., Ltd
Jasmine HL info@moldclamps.net
Please browse our website or contact us for more articles, thank you.
which related parts are matched, and what degree of cooperation?
1.3. Secondary processing requirements
What post-processing should be done after the plastic is formed, such as painting, bonding,
printing, hot stamping, electroplating, etc?
2. Product design procedure
2.1. Product planning
When the new product plan report was made, it was decided to use plastic materials. The new
product development report mainly discussed the properties of plastics and molding processing
issues.
2.2. Product idea
From the beginning of drawing the design sketch of the product and conceiving the shape of the
product, the question of whether it can be formed should be considered. In this process, the
relevant technical issues should be frequently contacted with plastic craftsmen and mold design
technicians.
2.3. Record the use environment, use requirements, and assembly conditions of the product in
detail and make a checklist to check whether the designed product meets user requirements in
the final stage.
2.4. Choose plastic varieties
Focus on the necessary characteristics of the products in the inspection table, and consider other
factors (such as cost, etc.) to select plastic varieties.
2.5. From the appearance and shape of the product. Dimensional accuracy, material, batch size,
delivery date, cost, and other constraints determine the forming and secondary processing
methods
2.6. Determine the parting line
Set the parting line at the largest diameter of the product. Design the mold slope with the parting
line as the limit, and the shape of the parting line is as simple as possible. After the parting line is
determined, the basic structure of the mold is roughly determined, and the parting line is closely
related to mold manufacturing and molding processing.
2.7. Ejection method
First, consider which direction to eject from. The trace of the ejector pin should be located in a
position that does not affect the appearance of the product. Products that are not allowed to
have ejector marks cannot be ejected by ejector pins, and other demoulding methods should be
considered.
Generally, the ejector mechanism is set in the movable mold. According to the shape of the
product, when it is foreseen that the product may stick to the mold, measures or improvement
measures should be taken to force the product to stick to the movable mold, especially in fully
automatic molding, to ensure product reliability fr mold ejection, the ejection method must be
considered in the product design stage.
2.8. Loss mode slope
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In order to improve the production efficiency and the qualification rate, the draft angle of the
product should be designed. The draft angle is generally 1/40. For precision plastic products with
no draft angle on the side, the slider core method must be used. The non-slope surface is made
on the slider. After the mold is opened, the slider is released first, and then the product is
ejected.
2.9. Wall thickness
The uniformity of the wall thickness should be considered when designing the product, and the
cooling time is determined by the maximum wall thickness. Too thick walls not only take too long
to cool down but also tend to shrink. The problem with thin walls is that the strength is
insufficient and easy to crack and difficult to form. Within a reasonable range, the thinner the
wall, the better.
2.10. Fillet connection
Whether it is to prevent plastic parts from cracking or from the perspective of mold
manufacturing, sharp corners are not allowed on the product. After each surface is connected
with rounded corners, stress concentration can be avoided and the fluidity of the baked material
can be improved.
3. Pay attention to the design of product appearance
In the design of product structure, it is necessary to focus on avoiding shrinkage from the
perspective of appearance. Shrinkage is the biggest problem in appearance quality in plastic
injection molding. The design conditions to prevent shrinkage are:
3.1. The wall thickness of plastic products is generally 2.5~3 mm for electronic engineering shells.
Daily necessities shell 1.5~2mm, and thin-walled shell 0.5~0.8 mm (not too thick, otherwise it will
affect the processing efficiency)
System wall thickness. Change the design of the wall thickness disparity, and uniform the wall
thickness by designing process holes and other means; Thinning particularly thick parts;
3.2. Simulate the flow state of the melt and improve the part that hinders the flow of the melt
(thin wall part);
3.3. In order to increase the strength and rigidity of plastic products and prevent deformation,
stiffeners are often used. The thickness of the ribs is about 0.5~0.8 mm
3.4. Corresponding surfaces of ribs and bosses are prone to shrinkage, so attention must be paid
when designing.
4. Design to ensure dimensional accuracy
4.1. First of all, it should be realized that the dimensional accuracy of plastic products is different
from that of metal parts because there are many reasons that affect the accuracy of plastic
products. There are:
A. the thermal expansion coefficient of plastic is large;
B. the plastic has molding shrinkage;
C. Plastic products will undergo aging changes (post-shrinkage); d. The size of plastic products is
affected by humidity;
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E. Part of the dimensional accuracy of plastic parts is difficult to guarantee by the accuracy of
mold parts;
F. The accuracy of plastic products is affected by the accuracy of mold manufacturing.
4.2. There are three main factors affecting the dimensional accuracy of plastic products:
A. Mold manufacturing error accounts for 50%;
B. Hangers in molding conditions account for 30%;
C.The error between material batches and within batches accounts for 20%.
4.3. Some high-precision dimensions on plastic parts cannot be achieved by molding. For
example, the size of the shaft hole matched with the metal shaft must be embedded in the
plastic part with a metal sleeve in the form of an insert, and a combination of plastic and metal is
used. It can not only ensure the dimensional accuracy of a certain part, but also improve the
production efficiency, and the economic benefits are very obvious. When plastic and metal are
combined, due to the difference in the thermal expansion coefficient of the two materials (the
linear expansion coefficient of polystyrene is 7×10-5/℃, and aluminum is 4×10-8/℃), it is
necessary to prevent the temperature from changing drastically Stress cracks have occurred.
5. Design to ensure product strength
The disadvantage of plastic products is poor rigidity, and deformation and cracking should be
considered in advance when designing plastic parts. The principle of ensuring product strength is:
A. Do not make the wall of the product too thin
B. Remove sharp corners
C. Investigate the impact strength of the plastic used at low temperatures. In fact, plastic parts
often have strength problems in winter
D. The punch-out test method should be close to the actual use of the product, such as a drop
test
The specific measures to increase the strength of the product are:
(1). Set reinforcement ribs.
Reinforcing ribs can effectively increase the rigidity and strength of the product
It is more economical and reasonable than simply increasing the wall thickness. The ribs on the
large flat products also have the function of preventing warping.
In order to achieve a better reinforcement effect, the design of the reinforcement must be paid
attention to.
A. The height of the ribs should not exceed 3 times the wall thickness
B. The width of the bottom of the rib cannot exceed 2/3 of the wall thickness,
C. Design a 2~5 degree inclination of the mold on the stiffener;
D. The distance between the two reinforcing ribs shall not be less than twice the wall thickness.
(2). Circle corner connection.
In plastic products, there are many cases of cracking at the sharp corners. The reason is that
during the injection process, the flow of the bakery material at the sharp corners changes sharply,
resulting in natural stress, and remains at the sharp corners. The design of the stiffener is for
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strengthening. If the bottom of the stiffener is not rounded, the stiffener will not only fail to
strengthen but will reduce the strength of the product. Except for the mold structure reasons
such as the inlay core and parting surface, the other surfaces should be connected with rounded
corners. Due to the determination of the corner size, set the wall thickness as T and the radius of
the rounded corner is R, then R/T20.25
The specific measures to increase the strength of the product are:
(3). Determine the safety factor.
The safety factor based on tensile strength is 3 for steel and 10 for plastic under static load.
Although the safety factor of plastic is set very large. However, due to molecular orientation and
other reasons, the strength of each part of the product is very different. It is better to use a larger
full coefficient.
(4). Self-tapping thread strength.
The strength of self-tapping threads is determined by the rigidity of the material, and the
strength of self-tapping threads of high-rigidity materials is greater. The self-tapping threaded
boss should be as large as possible without causing shrinkage.
6. Product design to facilitate mold manufacturing
6.1. Change the parting surface of the inclined plane or other shapes to the parting surface
perpendicular to the ejection direction
6.2. The mold structure of the inlay core is often used, and the inlay method should be
considered when designing the product.
6.3. Do not design rounded corners for the parts that are to be inlaid
6.4. The core mating surface looks very well inlaid, and it will deform slightly after being
subjected to molding pressure, and the inlaid traces will become obvious. Therefore, the inlay
part and the cavity forming the outer surface of the product should not be a flat surface, and a
step should be provided to cover the traces of the inlay line.
6.5. The small holes on the product are difficult to mold because the slender small core is easy to
bend or break under injection pressure. The improvement method is to design rounded corners
at the root of the thin core and thicken the lower half.
6.6. The groove on the product should not be a thin blade or a thin-walled shape. The
blade-shaped core is not only difficult to process but also easy to damage
6.7. Symmetrical products, easy to manufacture molds
6.8. The straight knurls on the side of the product should not extend to the parting surface, and
the upper mouth of the cavity should be straight to simplify the shape of the parting surface.
6.9. Turning processing is faster than milling, and the cost is low, try to use a circular design
6.10. Embossed characters on the product, the mold is easy to engrave
6.11. With the vertical and horizontal design steps on the lattice surface products, the mold is
easy to finish processing.
7. Product design for spraying and printing
7.1. Design of plastic parts:
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7.1.1. If the surface of the plastic part is stained with a release agent, abrasive, paraffin, etc., it
will not be painted or cause the paint layer to fall off. When designing spray-painted plastic parts,
the key considerations are to make the plastic parts better out of the mold, such as increasing the
inclination of the mold, improving the surface finish of the mold cavity, and plating the surface of
the mold cavity with hard chrome.
7.1.2. There should be no defects such as flashing and welding lines on the painted surface.
7.1.3. The designed product should have a shape that can disperse internal stress. Products with
concentrated internal stress will produce stress cracks under the action of the paint thinner.
7.1.4. Chromatic spray paint or partial spray paint must have obvious boundaries. It is difficult to
chromatic in the deep groove and the design must be changed
7.1.5. The apex of the two-color spray paint surface should be a right angle, and the bottom
should be rounded
7.2. Printed wood grain
7.2.1. When shrinkage is caused by uneven wall thickness such as stiffeners and bosses, wood
grains are often printed to cover up the defects.
7.2.2. The printed and non-printed surfaces must have obvious steps (above 2mm), and the steps
smaller than 2mm shall be pasted on the non-printed surface with pressure-sensitive adhesive.
7.2.3. The design conditions are the same as those of spray-painted plastic parts, with special
attention to chamfering (about 0.5mm) and removing flash.
7.2.4. Print wood grains on the circumference or three sides of the box-like plastic parts. In order
to maintain the continuity of the printed pattern, the fillet radius of each connecting surface
should be less than 8mm.
7.3. Screen printing
7.3.1. The screen-printed surface should be flat. The cost of screen printing on curved surfaces
with a radius of less than 200mm is very high.
7.3.2. The recessed part on the product will damage the screen.
7.3.3. There should be no shrinkage on the screen-printed surface (it is better not to have ribs
and bosses on the back of the screen-printed surface, as the shrinkage part will be missed).
7.3.4. The small concave and convex shapes such as knurling on the plastic parts can only obtain
unclear print patterns.
8. Design of bonding, hot welding, and hot stamping products
8.1. Design of bonded products
8.1. 1. The design conditions are the same as the spray-painted plastic parts, and the demolding
angle should be large.
8.1. 2. If the bonding surface shrinks, it will affect the bonding fastness, and the uneven wall
thickness must be completely changed. During solvent bonding, part of the solvent remains in
the shrinking part, causing cracks on the surface of the plastic part.
8.1.3. Use double-sided adhesive tape to bond with good reliability, but poor bonding force
8.1.4. The use of solvents or adhesives to bond plastic products is a manual operation. Reliability
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becomes a problem in mass production. It is not as reliable as screw mechanical bonding.
8.1.5. From an economic point of view, try to replace the bonding process with mechanical
methods such as snap connection, which can simplify the process.
8.1.6. The assembly of bonded parts must be designed with gaps
8.2. Design of hot welding products
8.2.1. Hot soldering is to use a soldering iron with a hemispherical concave front end to heat the
plastic solder foot to deform it and firmly bond with other parts (the solder foot diameter is less
than 20 mm with a 6oW soldering iron and above 20 mm with a 100W soldering iron).
8.2.2. The diameter of the welding foot is at least 2mm, the root is small fillet, the height of the
welding foot is insufficient, the surfacing is not large enough, the strength is poor, the thickness
of the hot welded piece is at least 1mm, and the length of the welding foot is calculated by the
formula:
The thickness of the hot welded piece +1.5×the diameter of the welding foot.
8.2.3. Hot welding requires that the hot welding parts do not move during and after the hot
welding, and the positioning structure should be designed according to the design.
8.2.4. Hot welding methods are commonly used for high production efficiency and good reliability.
Rotary friction welding, ultrasonic welding, high-frequency welding, etc. (the welding ribs of
ultrasonic welding should be small and large)
8.3. Design of hot stamping products
Hot stamping is the use of a hot mold engraved with pixels or cross-characters under a certain
pressure to transfer the colorful blessing foil on the hot stamping material to the surface of the
molding material to complement the pattern or cross-learning.
8.3.1. The back of the hot stamping surface should not have a convex shape with uneven wall
thickness. No pattern can be stamped in the recess, and the stamping surface must be flat.
8.3.2. The hot stamping surface is higher than other parts. If the hot stamping part has a shape
just higher than the hot stamping surface, the foil will be wrinkled. There should be a fixed pitch.
8.3.3. Hot stamping at the weld line, the pattern is easy to peel off, try to move the weld line to
another place.
8.3.4. The design conditions are the same as those of sprayed products.
8.3.5. The hot-stamped product is placed flat and cannot be warped.
8.3.6. The products to be hot stamped should pay attention to the process and hygiene, and
cannot touch the hot stamping surface with your hands.
8.3.7. The back of the hot stamping surface should be supported by force. If the hot stamping
force is insufficient, the lines will peel off.
8.3.8. Hot stamping on the entire surface, no part of the printed surface is allowed to protrude.
8.3.9. Fully hot stamping. The junction of the two faces cannot have rounded corners.
9. Design of metalized plastic parts and plastic parts for installation of nameplates
9.1. Design of vacuum evaporation plastic parts
The metallization of plastic parts not only maintains the original characteristics of the plastic,
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such as lightweight, easy processing, and high production efficiency, but also overcomes some
shortcomings in the material properties of the plastic itself, such as heat resistance,
non-conductivity, easy aging, and moisture absorption, etc. The plastic surface has a beautiful
metallic texture.
The metallic luster will make the original shrinkage of the plastic part more obvious, so the
uneven wall thickness of the product must be completely changed to avoid shrinkage.
Plastic plating parts used in cold areas consider the bonding force between plastic and plating.
Because the thermal expansion coefficient of plastic and metal is an order of magnitude, at low
temperatures, the plastic shrinks, and the plating floats, looking like bubbles.
Take the following measures to improve the quality of evaporated products
A. Use electroplating grade plastic.
B. Fully dry the plastic particles to avoid the defects of silver wire and air bubbles in the product.
In the molding temperature range, try to increase the melting temperature.
C. It is strictly forbidden to use mold release agents. In order to ensure the smooth ejection of
plastic parts without using mold release agents, the mold should increase the angle of ejection
and improve the surface finish.
D. Do not use beryllium-cyan alloy as the molding material. If the surface of the plastic part is
attached with a very thin copper film, it will hinder the adhesion of the metal coating.
E. Scratches and scars are not allowed on the surface of the mold cavity. Any defects left in the
mold will become more obvious due to metalization. Therefore, the appearance inspection of
semi-finished plastic parts should be strengthened.
9.2. Design of electroplated plastic parts
9.2.1. The basic requirements are the same as vacuum evaporation.
9.2.2. There must be no weld lines on the plastic parts.
9.2.3. There must be no parting line and core inlay line on the plating surface.
9.2.4. Avoid hundreds of holes. The plating solution remaining in the blind holes is not easy to
clean and cause pollution in the next process.
9.2.5. The depth of the groove should not exceed 1/3 of the groove width. The deeper the groove,
the higher the voltage required for electroplating, and the higher the electroplating voltage, the
poor quality of the coating.
9.2.6. The wall thickness of electroplated plastic parts should be moderate, and the rigidity of
plastic parts that are too thin (less than 1.5mm) is poor, easy to deform during electroplating, and
the adhesion of the coating is also poor.
9.2.7. The electroplating process has the phenomenon of thickening of the sharp edges. During
electroplating, the sharp edges bow and discharge at the tip, causing the corner plating to bulge,
and the fillet radius is at least 0.8mm. Flat plate-shaped plastic parts are difficult to electroplate.
The central part of the plated part has a thin coating. The closer the edge is, the thicker the
coating. The entire coating is uneven. The flat shape should be changed to a slightly rounded
surface, or an orange peel Glossy. The larger the surface area of electroplating, the greater the
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difference in gloss between the center and the surrounding edges. A slightly parabolic surface
can improve the gloss uniformity of the plating surface.
9.3. Install the plastic part of the nameplate
9.3.1. The nameplate is flat on the plastic part, and the edge is easy to turn up. The nameplate
should be buried in the nameplate prefabricated frame of the plastic part. There must be a
certain gap between the nameplate and the frame to prevent the thermal expansion of the two
materials from deforming.
9.3.2. When using adhesive to bond the nameplate, there must be adhesive holes on the plastic
part
9.3.3. The larger the bonding surface between the nameplate and the plastic, the better
9.3.4. It is difficult for the end face of the stretched nameplate to be in a square shape. The frame
should be designed on the plastic part so that the edge of the nameplate is buried in the frame to
cover the end face
9.3.5. In order to make the nameplate and the plastic part fit well, the nameplate burr groove
should be set on the plastic part to make the burr on the nameplate empty.
10. Product design to prevent shrinkage
10.1. The wall thickness of the entire product should be uniform, and the wall thickness change
should not exceed 20%.
10.2. Change the big stiffener into several small stiffeners, see figure 3.36. Connecting lattice
shapes can significantly increase the strength.
10.3. Change the thick wall to a thin wall supported by stiffeners, and the stiffeners are in the
direction of the force.
10.4. The brighter the surface of the product, the more obvious the shrinkage. The surface of the
product is made into a matte surface with dermatoglyphics or pulse pattern, which can
effectively cover the shrinkage.
11. Product design to prevent deformation
11.1. The upper edge of boxes, basins, corners, and other products is easy to deform, and frame
reinforcement is required
11.2. The bottom of the box products is easy to deform, and it is reinforced with uneven
deformation or framed.
11.3. Asymmetrical products are easily deformed due to uneven shrinkage. The approximate
symmetrical design can prevent deformation
11.4. The main causes of deformation are uneven shrinkage (including molding shrinkage and
post-shrinkage) and stress effects (such as excessive injection pressure, unbalanced force during
demolding, etc.). Products with less deformation should be simple in shape and uniform in wall
thickness.
11.5. Reinforcing ribs or frames on thin-plate products will increase deformation, which is caused
by uneven shrinkage.
11.6. The anti-deformation measure for large plane products is to change the plane shape to a
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large arc (such as a radius of 10M) curved surface. In order to improve the appearance and
impact strength, the large plane should be designed as a parabolic surface of about 0.5 mm per
100 mm.
12. Product design to prevent cracking
12.1. The stress of the product is often concentrated at the sharp corners or notches. The
primary condition to prevent cracking is to maintain continuity in the shape of the product,
change the sharp corners to rounded corners, and the gaps to arc transitions.
12.2. The distance between the hole and the hole is too close or the hole is too close to the edge
of the product will weaken the strength, and the distance should be increased.
12.3. The orifice is a stress concentration area, and the hole is the most prone to cracking, so the
orifice should be reinforced with a frame.
12.4. The convex steps in the paint products are prone to stress cracking due to the action of the
paint thinner, and must be connected with rounded corners.
13. Product design to reduce molding failure
13.1. The holes, grooves, and text marks on the side of the product all form an undercut for the
product, and any undercut shape needs to be formed with a horizontal core-pulling mold
structure. The horizontal beat core mold is not only complex in structure, but also poor in
molding stability, prone to failure, and low production efficiency. If it is changed to a U-shaped
hole or a hole formed by the upper and lower core slopes, the core pulling structure can be
eliminated.
13.2. The convex ribs inside the product also form a concave cut, which needs to be formed by
the inner core pulling method. The structure of the inner core-pulling mold is more complicated,
and the corresponding bottom surface has a through-hole, which can eliminate the core-pulling
action.
13.3. It is difficult to form small and deep holes on plastic parts because the core is easy to break
or bend under injection pressure. Post-processing drilling is more economical and effective than
molding holes. It is recommended to mold a cone pit in the drilling position of the plastic part for
post-processing drilling positioning.
13.4. The lower butt hole will be eccentric, and there should be obvious steps on both sides.
13.5. Products with sharp corners are difficult to demold, and the products are easily scratched
during demolding. It is a design to eliminate sharp corners.
13.6. Simplify the shape of the product and try not to have a high or slender core in the fixed
mold.
13.7. The sidewall of the transparent product must have sufficient out-of-mold oblique hair to
prevent the sidewall from fuzzing.
13.8. Simulate the flow of molten material and determine the position of the weld line to
determine the gate position. Cup products should have a gate at the bottom.
13.9. The gate is located in the thick-walled part of the product for easy molding. When the
material flow flows from the thick-walled part to the thin-walled part, the injection pressure loss
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is small, and it is conducive to maintaining pressure.
14. Prevent waste caused by metal inserts
14.1. The surrounding edges of metal inserts should be chamfered. The large internal stress
concentrated around the inserts with sharp edges will cause the product to crack.
14.2. The threaded metal insert should make the thread protrude out of the plastic part.
14.3. Due to the difference in thermal expansion between metal materials and plastics, plastic
products with metal inserts have greater internal stress. The larger the metal insert, the greater
the internal stress of the product. The plastic around the insert is often cracked, affecting the use.
It is best to avoid inserts.
14.4. The embedded round nut should be flush with the installation surface of the plastic part,
and lower than the plane, the insert will hang out during installation.
14.5. In order to prevent the insert from rotating or falling off in the product, the straight knurled
cylindrical insert is fixed with a groove in the middle, the groove depth is 1~2mm, and it has a
strong resistance to tension and torsion. Small inserts are under very small force, and diamond
knurling can be used without grooves.
14.6. The price of metal inserts is relatively high, the inserts are time-consuming, the production
efficiency is low, and the cost of products increases. Therefore, try to use butterfly bolt
connections or self-tapping screws to replace inserts.
15. Avoid problems caused by product assembly
15.1. Screwing the metal rod into the plastic part is prone to stress cracking.
15.2. If two plastic parts are butt-connected, if there is no barrier, it is not easy to connect flat,
and the apparent effect is poor. The product designed to be connected should be left with a gap.
15.3. The lid and box body is often not closed due to deformation and high seams. It is
recommended that the edges should be framed or reinforced to prevent deformation.
15.4. Avoid applying large loads to the plastic parts, for example, the bottom of the dark bar has
no rounded corners and cannot withstand lateral impact.
15.5. Where other parts are installed, you must study in detail what problems will occur after
assembly, and think about improvement measures in advance, such as the parts that are set on
the boss, because the bottom of the boss is rounded, it cannot fit closely with the assembly
parts.
16. Other issues to be considered in product design
16.1. Add a border around the words and trademarks. The words or trademarks can be
separately made into the molding core and inserted into the mold cavity. The mold is easy to
process and grind, and the words and trademarks can be exchanged easily.
16.2. According to the use and assembly function of the product, dig out the redundant function
part and hug it to make the product lighter and save raw materials.
16.3. Carefully design the position of the parting surface so that even if a flash occurs, the
appearance is not affected, or it is easy to repair the flash.
16.4. In plain acrylic-body hinges, it may be better to make the arc of the hinge into two stages.
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16.5. The use of a one-time molding method for some products will make the shape of the cavity
very complicated or weak. The products are difficult to process and are prone to failure during
molding. It may be more economical and reasonable to adopt post-processing on part of the
shape of the product.
16.6. The boss of the self-tapping thread must have a certain strength, and the chamfer of the
orifice is of great significance to facilitate the screwing of the self-tapping screw and to enhance
the mold core.
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