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عدد المساهمات : 18984 التقييم : 35458 تاريخ التسجيل : 01/07/2009 الدولة : مصر العمل : مدير منتدى هندسة الإنتاج والتصميم الميكانيكى
| 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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Admin مدير المنتدى
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Admin مدير المنتدى
عدد المساهمات : 18984 التقييم : 35458 تاريخ التسجيل : 01/07/2009 الدولة : مصر العمل : مدير منتدى هندسة الإنتاج والتصميم الميكانيكى
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