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 |  موضوع: كتاب Injection Mold Design Engineering الجمعة 20 ديسمبر 2019, 10:28 pm | |
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أخوانى فى الله
أحضرت لكم كتاب
Injection Mold Design Engineering
2nd Edition
David O. Kazmer
و المحتوى كما يلي :
Contents
Preface to the 2nd Edition V
Preface to the 1st Edition VIII
Nomenclature XV
1 Introduction 1
1.1 Overview of the Injection Molding Process 1
1.2 Mold Functions 4
1.3 Mold Structures 6
1.3.1 External View of Mold 6
1.3.2 View of Mold during Part Ejection 8
1.3.3 Mold Cross-Section and Function 9
1.4 Other Common Mold Types 11
1.4.1 Three-Plate, Multicavity Family Mold 12
1.4.2 Hot Runner, Multigated, Single Cavity Mold 14
1.4.3 Comparison 15
1.5 The Mold Development Process 16
1.6 Mold Standards 18
1.7 Chapter Review 20
1.8 References 20
2 Plastic Part Design 21
2.1 The Product Development Process 21
2.1.1 Product Definition 22
2.1.2 Product Design 23
2.1.3 Development 23
2.1.4 Scale-Up and Launch 24
2.1.5 Role of Mold Design 24X Contents
2.2 Design Requirements 25
2.2.1 Application Engineering Information 26
2.2.2 Production Planning 27
2.2.3 End-Use Requirements 28
2.2.4 Design for Manufacturing and Assembly 30
2.2.5 Plastic Material Properties 30
2.3 Design for Injection Molding 31
2.3.1 Uniform Wall Thickness 31
2.3.2 Rib Design 33
2.3.3 Boss Design 34
2.3.4 Corner Design 34
2.3.5 Surface Finish and Textures 36
2.3.6 Draft 38
2.3.7 Undercuts 39
2.4 Chapter Review 41
2.5 References 42
3 Mold Cost Estimation 43
3.1 The Mold Quoting Process 43
3.2 Cost Overview for Molded Parts 45
3.2.1 Mold Cost per Part 47
3.2.2 Material Cost per Part 48
3.2.3 Processing Cost per Part 49
3.2.4 Defect Cost per Part 52
3.3 Mold Cost Estimation 53
3.3.1 Mold Base Cost Estimation 54
3.3.2 Cavity Cost Estimation 55
3.3.2.1 Cavity Set Cost 56
3.3.2.2 Cavity Materials Cost 56
3.3.2.3 Cavity Machining Cost 58
3.3.2.4 Cavity Discount Factor 62
3.3.2.5 Cavity Finishing Cost 63
3.3.3 Mold Customization 64
3.4 Manufacturing Strategy 69
3.4.1 Breakeven Analysis 69
3.4.2 Prototyping Strategy 72
3.5 Chapter Review 76
3.6 References 77Contents XI
4 Mold Layout Design 79
4.1 Parting Plane Design 79
4.1.1 Determine Mold Opening Direction 80
4.1.2 Determine Parting Line 83
4.1.3 Parting Plane 84
4.1.4 Shut-Offs 86
4.2 Cavity and Core Insert Creation 87
4.2.1 Height Dimension 87
4.2.2 Length and Width Dimensions 88
4.2.3 Adjustments 89
4.3 Mold Base Selection 91
4.3.1 Cavity Layouts 91
4.3.2 Mold Base Sizing 93
4.3.3 Molding Machine Compatibility 95
4.3.4 Mold Base Suppliers 97
4.4 Material Selection 98
4.4.1 Strength vs. Heat Transfer 100
4.4.2 Hardness vs. Machinability 101
4.4.3 Material Summary 102
4.4.4 Surface Treatments 103
4.5 Chapter Review 105
4.6 References 107
5 Cavity Filling Analysis and Design 109
5.1 Overview 109
5.2 Objectives in Cavity Filling 110
5.2.1 Complete Filling of Mold Cavities 110
5.2.2 Avoid Uneven Filling or Over-Packing 111
5.2.3 Control the Melt Flow 112
5.3 Viscous Flow 112
5.3.1 Shear Stress, Shear Rate, and Viscosity 112
5.3.2 Pressure Drop 113
5.3.3 Rheological Behavior 115
5.3.4 Newtonian Model 117
5.3.5 Power Law Model 119
5.4 Process Simulation 121
5.5 Cavity Filling Analyses and Designs 124
5.5.1 Estimating the Processing Conditions 124
5.5.2 Estimating the Filling Pressure and Minimum Wall Thickness 127XII Contents
5.5.3 Estimating Clamp Tonnage 130
5.5.4 Predicting Filling Patterns 133
5.5.5 Designing Flow Leaders 135
5.6 Chapter Review 138
5.7 References 139
6 Feed System Design 141
6.1 Overview 141
6.2 Objectives in Feed System Design 141
6.2.1 Conveying the Polymer Melt from Machine to Cavities 141
6.2.2 Impose Minimal Pressure Drop 142
6.2.3 Consume Minimal Material 143
6.2.4 Control Flow Rates 145
6.3 Feed System Types 145
6.3.1 Two-Plate Mold 146
6.3.2 Three-Plate Mold 148
6.3.3 Hot Runner Molds 153
6.4 Feed System Analysis 156
6.4.1 Determine Type of Feed System 158
6.4.2 Determine Feed System Layout 159
6.4.3 Estimate Pressure Drops 163
6.4.4 Calculate Runner Volume 165
6.4.5 Optimize Runner Diameters 166
6.4.6 Balance Flow Rates 170
6.4.7 Estimate Runner Cooling Times 173
6.4.8 Estimate Residence Time 175
6.5 Practical Issues 176
6.5.1 Runner Cross-Sections 176
6.5.2 Sucker Pins 180
6.5.3 Runner Shut-Offs 182
6.5.4 Standard Runner Sizes 183
6.5.5 Steel Safe Designs 184
6.6 Advanced Feed Systems 185
6.6.1 Insulated Runner 185
6.6.2 Stack Molds 186
6.6.3 Branched Runners 188
6.6.4 Dynamic Melt Control 190
6.7 Chapter Review 192
6.8 References 194Contents XIII
7 Gating Design 197
7.1 Objectives of Gating Design 197
7.1.1 Connecting the Runner to the Mold Cavity 197
7.1.2 Provide Automatic De-gating 197
7.1.3 Maintain Part Aesthetics 198
7.1.4 Avoid Excessive Shear or Pressure Drop 198
7.1.5 Control Pack Times 199
7.2 Common Gate Designs 200
7.2.1 Sprue Gate 200
7.2.2 Pin-Point Gate 201
7.2.3 Edge Gate 202
7.2.4 Tab Gate 203
7.2.5 Fan Gate 204
7.2.6 Flash/Diaphragm Gate 205
7.2.7 Tunnel/Submarine Gate 206
7.2.8 Thermal Gate 209
7.2.9 Valve Gate 212
7.3 The Gating Design Process 213
7.3.1 Determine Gate Location(s) 213
7.3.2 Determine Type of Gate 215
7.3.3 Calculate Shear Rates 217
7.3.4 Calculate Pressure Drop 219
7.3.5 Calculate Gate Freeze Time 221
7.3.6 Adjust Dimensions 224
7.4 Chapter Review 225
7.5 References 226
8 Venting 227
8.1 Venting Design Objectives 227
8.1.1 Release Compressed Air 227
8.1.2 Contain Plastic Melt 228
8.1.3 Minimize Maintenance 228
8.2 Venting Analysis 228
8.2.1 Estimate Air Displacement and Rate 228
8.2.2 Identify Number and Location of Vents 229
8.2.3 Specify Vent Dimensions 232
8.3 Venting Designs 236
8.3.1 Vents on Parting Plane 236
8.3.2 Vents around Ejector Pins 238
8.3.3 Vents in Dead Pockets 239XIV Contents
8.4 Chapter Review 241
8.5 References 242
9 Cooling System Design 243
9.1 Objectives in Cooling System Design 243
9.1.1 Maximize Heat Transfer Rates 243
9.1.2 Maintain Uniform Wall Temperature 244
9.1.3 Minimize Mold Cost 244
9.1.4 Minimize Volume and Complexity 245
9.1.5 Maximize Reliability 245
9.1.6 Facilitate Mold Usage 245
9.2 The Cooling System Design Process 246
9.2.1 Calculate the Required Cooling Time 246
9.2.2 Evaluate Required Heat Transfer Rate 252
9.2.3 Assess Coolant Flow Rate 253
9.2.4 Assess Cooling Line Diameter 254
9.2.5 Select Cooling Line Depth 257
9.2.6 Select Cooling Line Pitch 260
9.2.7 Cooling Line Routing 262
9.3 Cooling System Designs 266
9.3.1 Cooling Line Networks 266
9.3.2 Cooling Inserts 269
9.3.3 Conformal Cooling 269
9.3.4 Highly Conductive Inserts 270
9.3.5 Cooling of Slender Cores 272
9.3.5.1 Cooling Insert 273
9.3.5.2 Baffles 274
9.3.5.3 Bubblers 275
9.3.5.4 Heat Pipes 275
9.3.5.5 Conductive Pin 276
9.3.5.6 Interlocking Core with Air Channel 277
9.3.6 One-Sided Heat Flow 278
9.4 Mold Wall Temperature Control 281
9.4.1 Pulsed Cooling 281
9.4.2 Conduction Heating 284
9.4.3 Induction Heating 285
9.4.4 Managed Heat Transfer 286
9.5 Chapter Review 288
9.6 References 289Contents XV
10 Shrinkage and Warpage 291
10.1 The Shrinkage Analysis Process 293
10.1.1 Estimate Process Conditions 294
10.1.2 Model Compressibility Behavior 294
10.1.3 Assess Volumetric Shrinkage 297
10.1.4 Evaluate Isotropic Linear Shrinkage 300
10.1.5 Evaluate Anisotropic Shrinkage 301
10.1.6 Numerical Simulation 303
10.1.7 Shrinkage Analysis Validation 306
10.2 Shrinkage Design Practices 310
10.2.1 “Steel Safe” Mold Design 310
10.2.2 Processing Dependence 311
10.2.3 Semicrystalline Plastics 313
10.2.4 Effect of Fillers 314
10.2.5 Shrinkage Range Estimation 314
10.2.6 Final Shrinkage Recommendations 315
10.3 Warpage 317
10.3.1 Sources of Warpage 318
10.3.2 Warpage Avoidance Strategies 323
10.4 Chapter Review 324
10.5 References 324
11 Ejection System Design 327
11.1 Objectives in Ejection System Design 330
11.1.1 Allow Mold to Open 330
11.1.2 Transmit Ejection Forces to Moldings 330
11.1.3 Minimize Distortion of Moldings 331
11.1.4 Maximize Ejection Speed 331
11.1.5 Minimize Cooling Interference 332
11.1.6 Minimize Impact on Part Surfaces 332
11.1.7 Minimize Complexity and Cost 333
11.2 The Ejector System Design Process 333
11.2.1 Identify Mold Parting Surfaces 334
11.2.2 Estimate Ejection Forces 334
11.2.3 Determine Ejector Push Area and Perimeter 340
11.2.4 Specify Type, Number, and Size of Ejectors 343
11.2.5 Layout Ejectors 345
11.2.6 Detail Ejectors and Related Components 348
11.3 Ejector System Analyses and Designs 350
11.3.1 Ejector Pins 350XVI Contents
11.3.2 Ejector Blades 353
11.3.3 Ejector Sleeves 355
11.3.4 Stripper Plates 356
11.3.5 Elastic Deformation around Undercuts 359
11.3.6 Core Pulls 361
11.3.7 Slides 366
11.3.8 Early Ejector Return Systems 369
11.4 Advanced Ejection Systems 371
11.4.1 Split Cavity Molds 371
11.4.2 Collapsible Cores 373
11.4.3 Rotating Cores 375
11.4.4 Reverse Ejection 377
11.5 Chapter Review 378
11.6 References 380
12 Structural System Design 381
12.1 Objectives in Structural System Design 382
12.1.1 Minimize Stress 382
12.1.2 Minimize Mold Deflection 387
12.1.3 Minimize Mold Size 388
12.2 Analysis and Design of Plates 388
12.2.1 Plate Compression 389
12.2.2 Plate Bending 392
12.2.3 Support Pillars 395
12.2.4 Shear Stress in Side Walls 402
12.2.5 Interlocks 404
12.2.6 Stress Concentrations 407
12.3 Analysis and Design of Cores 410
12.3.1 Axial Compression 410
12.3.2 Compressive Hoop Stresses 412
12.3.3 Core Deflection 414
12.4 Fasteners 417
12.4.1 Fits 417
12.4.2 Socket Head Cap Screws 422
12.4.3 Dowels 424
12.5 Review 426
12.6 References 428Contents XVII
13 Mold Technologies 429
13.1 Introduction 429
13.2 Coinjection Molds 431
13.2.1 Coinjection Process 431
13.2.2 Coinjection Mold Design 433
13.3 Gas Assist/Water Assist Molding 434
13.4 Insert Molds 437
13.4.1 Low Pressure Compression Molding 437
13.4.2 Insert Mold with Wall Temperature Control 439
13.4.3 Lost Core Molding 441
13.5 Injection Blow Molds 443
13.5.1 Injection Blow Molding 443
13.5.2 Multilayer Injection Blow Molding 445
13.6 Multishot Molds 447
13.6.1 Overmolding 447
13.6.2 Core-Back Molding 449
13.6.3 Multi-station Mold 451
13.7 In-Mold Labeling 453
13.7.1 Statically Charged Film 454
13.7.2 Indexed Film 455
13.8 Review 456
13.9 References 457
14 Mold Commissioning 459
14.1 Mold Commissioning Objectives 459
14.1.1 Certify Mold Acceptability 459
14.1.2 Optimize Molding Process and Quality 461
14.1.3 Develop Mold Operation and Maintenance Plans 461
14.2 Commissioning Process 462
14.2.1 Mold Design Checklist 465
14.2.2 Component Verification 465
14.2.3 Mold Assembly 466
14.2.4 Mold Final Test 466
14.2.5 Preliminary Molding Recommendations 467
14.3 Molding Trials 470
14.3.1 Filling Stage 471
14.3.2 Packing Stage 473
14.3.3 Cooling Stage 475XVIII Contents
14.4 Production Part Approval 476
14.4.1 Quality Assurance 476
14.4.2 Gauge and Process Repeatability & Reproducibility 477
14.4.3 Image-Based Dimensional Metrology 479
14.4.4 Process Capability Evaluation 481
14.5 Mold Maintenance 485
14.5.1 Pre-Molding Maintenance 487
14.5.2 Molding Observation and Mold Map 488
14.5.3 Post-Molding Maintenance 489
14.5.4 Scheduled Regular Maintenance 489
14.5.5 Mold Rebuilding 490
14.6 Summary 491
14.7 References 493
Appendix 495
Appendix A: Plastic Material Properties 497
Appendix B: Mold Material Properties 502
B.1 Nonferrous Metals 502
B.2 Common Mold Steels 503
B.3 Other Mold Steels 504
Appendix C: Properties of Coolants 505
Appendix D: Statistical Labor Data 506
D.1 United States Occupational Labor Rates 506
D.2 International Labor Rate Comparison 506
Appendix E: Unit Conversions 508
E.1 Length Conversions 508
E.2 Mass/Force Conversions 509
E.3 Pressure Conversions 509
E.4 Flow Rate Conversions 509
E.5 Viscosity Conversions 510
E.6 Energy Conversions 510
Appendix F: Estimation of Melt Velocity 511
The Author 515
Index 517
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