Can you design drawer molds? This is really difficult

Time:2020-11-17 16:25:56 / Popularity: / Source:

Mould structure design 
Part 1: Basic information of mold (customer\type\plastics\product and mold size\steel)
Part 2: Product description and requirements (difficulties in product molding and demoulding)
Part III: Mould structure design (pouring\parting\ejection reset\cooling\mould action)
Part 4: Mold manufacturing and processing (NC\EDM\WC\Province mold\Assembly, etc.)
Part V: Injection Molding Process (Requirements for Baking Material\ Mold Temperature\ Material Temperature\ Injection Cycle\ Clamping Force\ Injection Pressure)
Part VI: Summary

Basic information of mold

Mould structure design 

1. Customer requirements:

1. This product is a transparent plastic part, with high quality requirements for wire clamping and appearance.
2. Average wall thickness is only 2.3mm, and customer requires a cycle of 70S.
3. Customer accepts that front mold undercut adopts elastic front mold structure, large side undercut of drawer rear mold adopts a large inclined top to drive a small inclined top structure.

2. Mould materials and accessories specifications:

1. Original body of A board is made of 2711 pre-hardened steel; material of B board is 1.2311.
2. Lower mold, slider and other forming parts are made of 2711 pre-hardened steel, of which lifter nitrided depth is 0.15 and hardness is HRC50-52.
3. Except for AB board, mold bases are made of medium carbon steel 1050; standard mold bases adopt HASC0 equivalent specifications.
4. Hot runner adopts Mold-Master needle valve hot nozzle with two points of water inlet; junction box and power supply/electric couple socket adopt HARTING specifications.
5. Parker oil pump is used in big slider; quick plug nozzle adopts STAUBIL specification.
Mould structure design 
Product description and requirements:
This drawer product is a transparent part, welding line and structure of structure are complicated. When mold is formed, it needs to be tripped in many places.
Mould structure design 

Mold structure design

1. Gating system (hot runner system):

Adopt Mold-Master needle valve hot nozzle, water inlet at two points; entry position has been verified by MoldFlow analysis
Mould structure design 

2. Forming structure:

1. Parting surface design: pull out from R corner of product, smooth transition at the corner, no stepped sharp corners.
2 Treatment of thin steel at insertion position: inserts in two insertion positions of front mold for easy maintenance.
Mould structure design 

3. Lateral parting and core pulling mechanism:

1. Combined lifter structure:
Lifter is designed into three sections, large lifter in the middle is ejected obliquely under ejection drive, small lifter on both sides and large lifter have an angle difference in ejection direction (angle of small lifter is smaller than large lifter); Large lifter uses horizontal structural angle between large and small lifters, and small lifters on both sides are dragged by "T"-shaped strip to shrink and demold inward while being pushed out diagonally; structure is mature and reliable, which is of great promotion significance .
Mould structure design 
2. Slider inclined roof structure:
Big slider moves outwards, and slider slope is blocked by stopper fixed on B plate, so that it moves upward under action of slider chute to escape undercut; stopper is disengaged from lifter of slider, lifter of slider and large slider move outward together to complete demolding. Structure is mature and reliable, and has promotion significance.
Mould structure design 
3. Structure of bullet front mold: (front mold slider)
Inside of drawer front is inverted, front mold adopts structure of front mold; front mold travel length is 670mm long, so there are oblique guide posts on both sides to guide. There are four sets of springs in the middle of row for ejection of front mold; in addition, there are three sets of Sanda screws at both ends and middle of travel position.
Mold manufacturing and processing 
4. Ejection and reset system:
Pushing and slanting ejection, ejection is safe and convenient to take parts; because oil pump position has strict sequence requirements when opening and closing mold, so oil pump position is equipped with a card to control sequence of actions.
Mold manufacturing and processing 
5. Cooling system:
Original front mold makes mold cool quickly. Each row of lifter and hot nozzle has separate water transportation, overall cooling is sufficient.
Mold manufacturing and processing 
6. Other structures:
Product has a large projection area, about 1755CM2, design of no gap between A and B plates makes bearing surface sufficient. Stool is designed on all sides.
Mold manufacturing and processing 

Mold manufacturing and processing

1. Mold processing technology

First. Note for NC processing:
1. In view of large processing depth of lower mold, principle of segmented roughening should be adopted, different tool lengths, machining allowances and cutting depths should be set to ensure safety and efficiency.
2. In view of characteristics that lower die pushes square slot and knife is easy to spring, an arc transition should be added at the corner of push square slot to avoid sudden changes in processing direction. Side of glue position of push square groove should be appropriately increased by margin or side of draw surface should be moved to protect it to prevent knife.
Second. EDM processing precautions:
1. Pusher of lower die circumference should be installed in lower die and be galvanically eroded to prevent wire clamping at pusher.
2. When lower mold is electro-eroded, it should be electro-eroded one by one in one direction to avoid starting processing.
3. Large margin part of lower mold adopts carbon open thickness, uses a large spark level, and appropriately increases discharge margin.
Third. Note for wire cutting:
After NC processing is completed, perform wire cutting process, and pay attention to correct number of strokes according to auxiliary reference provided by NC processing.

2. Mold assembly process (production process)

Mold manufacturing and processing 

Injection process:

Baking conditions: 80ºC, 2~4 hours. Mold temperature is 40~80ºC. It is recommended to use a larger value for this product to reduce influence of weld line.
High-speed injection as much as possible, reasonable pressure holding to reduce shrinkage. Clamping force is 650 tons, injection pressure is 950kgf/cm2, injection holding pressure is 7 seconds,cooling time is 18 seconds, and ejection stroke is 105mm.
Product molding cycle is 53 seconds.

Summary and description:

1. Combined inclined roof structure: while large and small inclined roofs are ejected diagonally, large inclined roofs are pulled inward by "T"-shaped strip and small inclined roofs on both sides, are retracted and demolded. This structure is novel and creative.
2. Cooling system, pouring system and ejection system are designed reasonably.
3. Overall structure is compact, structure is simple and integrated, action is safe and reliable.
4. Overall processing is reasonable (non-adhesive part has less EDM), assembly process is reasonable, and it is easy to replace.(Two thin steel positions as inserts, easy to replace)

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