Note: Carriage return and line feed do not need to be translated, return as is. All other Chinese text should be translated into English. Injection Mold Design and Manufacturing Applications

Author: Zhang Guoqiang
Publisher:
Publishing Date: 2005-03-01
Features: This book is concise in narration, practical, and systematic, providing a detailed introduction to injection mold design, injection molding technology, mold usage, and maintenance throughout the production process. It offers rich mold design and practical examples. Additionally, it briefly introduces some advanced injection molding methods and their applications in injection molds. It is suitable for engineering technicians engaged in plastic forming processes and mold design and manufacturing, as well as for professional teachers and students in universities and colleges. This book systematically introduces the properties and applications of plastics, the process design and application of plastic products. Through typical examples, it focuses on the introduction of injection mold design. It also provides a certain introduction to injection molding technology, the use of injection molding machines, the installation, usage, maintenance, and cost estimation of injection molds. Additionally, it briefly introduces some other advanced injection molding methods and technologies and their applications in injection molds. This book combines theory with practice and is suitable for engineering technicians engaged in plastic forming processes and mold design and manufacturing, as well as for teachers and students in universities and colleges.
Introduction: This book systematically introduces the properties and applications of plastics, the process design and application of plastic products. Through typical examples, it focuses on the introduction of injection mold design. It also provides a certain introduction to injection molding technology, the use of injection molding machines, the installation, usage, maintenance, and cost estimation of injection molds. Additionally, it briefly introduces some other advanced injection molding methods and technologies and their applications in injection molds. This book combines theory with practice and is suitable for engineering technicians engaged in plastic forming processes and mold design and manufacturing, as well as for teachers and students in universities and colleges.
Table of Contents:
Chapter 1 Introduction
1.1 The Origin of Plastics
1.2 Definition and Composition of Plastics
1.3 Classification and Properties of Plastics
1.3.1 Classification of Plastics
1.3.2 Properties of Plastics
1.3.3 Forming Processing Properties of Plastics
1.4 Plastic Forming and Its Position in the Plastic Industry
1.5 Related Concepts of Injection Molding Technology
1.6 Current Status and Development Direction of China's Plastic Mold Industry
Chapter 2 Process Design of Plastic Products
2.1 Plastic Shrinkage
2.1.1 Shrinkage Rate of Plastics
2.1.2 Main Factors Affecting Plastic Shrinkage Rate
2.1.3 Principles for Selecting Shrinkage Rate
2.2 Draft Angle
2.2.1 Direction of Draft Angle
2.2.2 Representation Method of Draft Angle
2.2.3 Factors Affecting Draft Angle
2.3 Requirements of Geometric Shape of Plastic Products for Forming Process
2.3.1 Wall Thickness and Uniformity of Wall Thickness
2.3.2 Reinforcing Ribs
2.3.3 Support Surfaces (Including bosses and corner posts)
2.3.4 Rounds and Grooves
2.3.5 Holes
2.3.6 Threads
2.3.7 Inserts
2.3.8 Raised and Sunken Patterns
2.3.9 Marks, Symbols, Patterns, and Text
2.3.10 Hanging Mold Cavity
2.4 Other Process Design
2.4.1 Flow Length (Flow Distance Ratio)
2.4.2 Orientation and Crystallization
2.4.3 Internal Stress
2.4.4 Dimensional and Shape Stability
2.4.5 Fusion Lines
2.4.6 Appearance Quality and Surface Decoration
2.5 Dimensional Accuracy of Plastic Products
Chapter 3 Structure of Injection Mold and Injection Molding Process
3.1 Parting Line
3.1.1 Shape and Type of Parting Line
3.1.2 Principles for Selecting Parting Line
3.2 Structure and Classification of Injection Molds
3.2.1 Basic Types of Injection Molds
3.2.2 Classification of Injection Mold Structure
3.2.3 Typical Structure of Injection Molds
3.3 Composition and Classification of Injection Molding Machines
3.3.1 Composition of Injection Molding Machines
3.3.2 Classification and Technical Parameters of Injection Molding Machines
3.4 Relationship Between Injection Mold and Injection Molding Machine
3.4.1 Checking Main Process Parameters of Injection Molding Machine
3.4.2 Checking Installation Dimensions of Injection Molding Machine
3.4.3 Checking Open Molding Stroke and Ejection Device
3.4.4 Installation and Fixation Methods of Injection Mold
3.5 Layout of Injection Mold Cavity
3.5.1 Determination of Number of Cavities
3.5.2 Arrangement of Multiple Cavities
3.6 Injection Molding Process
3.6.1 Complete Injection Molding Process
3.6.2 Selection and Control of Injection Molding Process Conditions
Chapter 4 Design of Gating System
4.1 Characteristics of Gating System
4.1.1 Function of Gating System
4.1.2 Composition of Gating System
4.2 Main Runner Design
4.3 Runner Design
4.4 Gate Design
4.4.1 Content of Gate Design
4.4.2 Common Gate Types and Their Applicability
4.4.3 Principles for Selecting Gate Type and Location
4.4.4 Simple Quantitative Calculation Method for Cross-Sectional Dimensions of Gating System
4.5 Cold Material
4.6 Flow Balance of Gating System in Mold Cavity
Chapter 5 Venting and Gas-Assist Systems
5.1 Venting System
5.1.1 Function and Source of Gas in Venting System
5.1.2 Design Points of Venting System
5.1.3 Design Example
5.2 Gas-Assist System
Chapter 6 Lateral Parting and Core Pulling Mechanisms
6.1 Basic Function and Power Source
6.2 Pulling Force and Core Pulling Distance
6.2.1 Pulling Force
6.2.2 Core Pulling Distance
6.3 Slant Pin Lateral Parting and Core Pulling Mechanism
6.3.1 Slant Pin Core Pulling Mechanism
6.3.2 Length and Open Molding Distance of Slant Pin Required for Core Pulling
6.4 Design of Clamping Wedge
6.4.1 Structural Form
6.4.2 Selection of Wedge Angle
6.5 Other Design Issues
6.5.1 Connection Between Sliders and Side Core
6.5.2 Slider Guidance Method
6.5.3 Slider Positioning
6.5.4 Dimensional Ratio of Sliders
6.5.5 Several Working Forms of Slant Pin Mechanisms
6.6 Slant Slider Lateral Parting and Core Pulling Mechanism
6.6.1 Working Form
6.6.2 Slider Assembly Form and Clearance
6.6.3 Installation Requirements of Mold Base
6.6.4 Slant Slider Ejection Stroke and Angle
6.6.5 Ensuring Plastic Part Stays on the Ejector Side
6.7 Ejection and Core Pulling Mechanism
6.7.1 Slant Push Rod Ejection and Core Pulling
6.7.2 Push Rod Translation Core Pulling
6.8 Bent Pin Core Pulling Mechanism
6.8.1 Fixation Methods of Bent Pins
6.8.2 Several Common Structures of Bent Pin Core Pulling
6.9 Slant Slot Core Pulling Mechanism
6.10 Gear and Rack Core Pulling Mechanism
6.11 Hydraulic or Pneumatic Lateral Core Pulling Mechanism
6.12 Other Core Pulling Mechanisms
6.13 Determination of Core Pulling Force
6.14 Requirements for Parts of Core Pulling Mechanism
Chapter 7 Ejection and Demolding Mechanism
7.1 Requirements and Classification of Ejection Mechanism
7.2 Simple Ejection Mechanism
7.2.1 Push Rod Ejection Mechanism
7.2.2 Push Tube Ejection Mechanism
7.2.3 Push Block Ejection Mechanism
7.2.4 Ejector Plate Ejection Mechanism
7.2.5 Ejection Mechanism Using Forming Parts
7.2.6 Multi-Component Combined Ejection Mechanism
7.2.7 Pneumatic Ejection Mechanism
7.3 Two-Stage Ejection Mechanism
7.3.1 Swing Block and Plate Two-Stage Ejection Mechanism
7.3.2 Swing Rod and Pin Two-Stage Ejection Mechanism
7.3.3 "Eight" Swing Rod Two-Stage Ejection Mechanism
7.3.4 Push Rod Hinge Two-Stage Ejection Mechanism
7.4 Ejection Mechanism in Mold and Dual Ejection Mechanism
7.4.1 Ejection Mechanism in Mold
7.4.2 Dual Ejection Mechanism
7.5 Sequential Ejection Mechanism
7.6 Ejection Mechanism for Gating System Residue
7.6.1 Ejection of Gating System Residue in Single Parting Line Mold
7.6.2 Ejection of Gating System Residue in Double Parting Line Mold
7.7 Calculation of Ejection Resistance
7.8 Design of Ejection Mechanism for Threaded Plastic Parts
7.8.1 Requirements for Threaded Plastic Parts for Ejection
7.8.2 Ejection Methods for Threaded Plastic Parts
Chapter 8 Structure and Design of Mold Forming Parts
8.1 Structure of Mold Forming Parts
8.1.1 Structure Design of Cavity
8.1.2 Design of Core and Forming Rod
8.1.3 Thread Forming Parts
8.2 Calculation of Working Dimensions of Mold Forming Parts
8.2.1 Classification and Regulations of Working Dimensions
8.2.2 Factors Affecting Dimensional Errors of Products and Their Control
8.2.3 Calculation Methods for Working Dimensions of Forming Parts
8.2.4 Mechanical Calculation of Forming Parts
Chapter 9 Design of Mold Guidance and Positioning Mechanism and Other Components
9.1 Design of Mold Guidance Mechanism
9.1.1 Guide Pin and Guide Bushing Guidance Mechanism
9.1.2 Cone Face Alignment Guidance Mechanism
9.2 Design of Locating Ring
9.3 Design of Other Structural Components
9.4 Common Mold Materials
9.4.1 Requirements for Steel
9.4.2 Steel Suitable for Plastic Molds
9.4.3 Rational Selection of Steel
9.5 Mold Standardization and Selection of Mold Base
9.5.1 Importance and Current Status of Mold Standardization
9.5.2 Design of Mold Base
9.5.3 Standard Mold Base
Chapter 10 Temperature Control System
10.1 Heating of Injection Mold
10.1.1 Heating Methods of Injection Mold
10.1.2 Calculation of Heating Power
10.2 Cooling of Injection Mold
10.2.1 Calculation of Cooling System
10.2.2 Key Points of Cooling Water Channel Design
10.2.3 Cooling Methods and Cooling System Circuits
10.2.4 Cooling System Connectors, Seals, and Sealing Forms
10.2.5 Design Example of Injection Mold Cooling System
Chapter 11 New Technologies in Injection Mold Forming
11.1 Injection Molds for Hot-Run Plastic Without Runner
11.1.1 Advantages of No-Runner Injection Molds
11.1.2 Main Types of No-Runner Injection Molds
11.2 Injection Molds for Thermoset Plastics
11.2.1 Characteristics of Thermoset Plastic Injection Molding
11.2.2 Key Points of Design for Thermoset Plastic Injection Molds
11.3 Temperature-Run Channel Injection Molds
11.4 Reaction Injection Molding
11.4.1 Reaction Injection Molding Process and Characteristics
11.4.2 Reaction Injection Molding Equipment
11.4.3 Process Requirements and Design Key Points for Mold Design
11.5 Co-Injection Molding
11.5.1 Two-Color Injection Method
11.5.2 Dual-Layer Injection Method
11.6 Gas-Assisted Injection Molding
11.6.1 Gas-Assisted Injection Molding Process
11.6.2 Classification of Gas-Assisted Injection Molding Technology
11.6.3 Gas-Assisted Injection Molding Equipment
11.6.4 Characteristics of Gas-Assisted Injection Molding Technology
11.7 Application of CAD/CAM/CAE Technology in Injection Molds
11.7.1 Necessity of Using CAD/CAM/CAE Technology
11.7.2 Concept of CAD/CAM/CAE Technology
11.7.3 Application Areas of Computer Technology in Injection Molds
11.7.4 Development Overview of CAD
11.7.5 Development Overview of CAE
11.7.6 Current Status of Application of Injection Mold CAD/CAM/CAE Technology
Chapter 12 Operation of Injection Molding Machines and Common Quality Problems in Injection Molding Process
12.1 Operation of Injection Molding Machines
12.1.1 Action Sequence of Injection Molding Machines
12.1.2 Control of Injection Molding Process Conditions
12.1.3 Precautions for Injection Molding Machine Operation
12.1.4 Causes and Solutions of Defects in Injection Molded Products
12.2 Common Quality Problems and Solutions
Chapter 13 Steps of Injection Mold Design, Trial Molding, and Maintenance Technology
13.1 Steps of Injection Mold Design
13.1.1 Acceptance of Task Book
13.1.2 Collection, Analysis, and Digestion of Original Data
13.1.3 Determination of Forming Method
13.1.4 Selection of Forming Equipment
13.1.5 Specific Structural Scheme
13.1.6 Drawing Mold Diagram
13.2 Mold Installation and Trial Molding
13.2.1 Inspection of Injection Molding Machine Working State
13.2.2 Mold Installation
13.2.3 Trial Injection of Mold
13.3 Mold Rectification
13.3.1 Rectification of Mold Holdback
13.3.2 Rectification of Unreasonable Mold Structure Design and Dimensions
13.3.3 Rectification of Manufacturing Accuracy Not Meeting Requirements
13.3.4 Rectification of Incomplete Supporting Parts
13.4 Overall Evaluation
13.4.1 Conditions for Mold Qualification
13.4.2 Conditions for Mold Non-Qualification
13.5 Mold Acceptance
13.5.1 Quality Control Check Points
13.5.2 Process Quality Inspection
13.5.3 Product Inspection
13.5.4 Mold Inspection
13.6 Mold Usage, Management, and Maintenance
13.6.1 Mold Usage
13.6.2 Mold Management
13.6.3 Mold Maintenance
Chapter 14 Examples of Injection Mold Design
14.1 General Injection Molds
14.2 Typical Structure of Injection Molds
Chapter 15 Methods for Estimating Mold Costs
15.1 Price Influencing Factors
15.2 Simple Estimation Methods
15.2.1 Empirical Estimation Method
15.2.2 Material Price Coefficient Method
15.2.3 Analogous Method
15.3 Detailed Calculation Method
15.3.1 Mold Price Composition
15.3.2 Mold Price Calculation Method
15.3.3 Mold Price Calculation Formula
Appendix
Appendix A: Chinese-English Correspondence of Common Injection Mold Terms
Appendix B: Chinese-English Correspondence of Common Plastic Names
Appendix C: Common Materials and Heat Treatment for Injection Mold Parts
Appendix D: Injection Molding Process Parameters for Various Plastics
Appendix E: Main Technical Parameters of Some Domestic SZ Series Injection Molding Machines
References