expan sible injection mould design - core · expansible injection mould design buch cardona, eloi...

Expan

Expan

Expansible

Part 1 Technical Memory

sible Injection


Injection


2014-2015

Injection Mould Design


Director: Miguel Sánchez

Mould Design


Autor: Eloi Buch Cardona


Mould Design



Mould Design


Director: Miguel Sánchez-Soto

Expansible Injection Mould DesignBuch Cardona, Eloi

Abstract

Within the next project it is developed a breathing injection mould.

Its main purpose is to prod

techniques such as MuCell® which suppose a great increase of physical properties

regarding other foaming types as well as an important weight and material price

reduction.

The piece it is going to

better foamed polymer investigation.

The mould type is discussed and compared between the core pull system and the

breathing

due its cheaper cost and high quality direct piece production, although lack in terms of size

versatility.

Then, that mould is exhaustively defined and evaluated with all the

mechanizations and thermal treatments need

difficulties of properly predict all the timings and costs.


Abstract





reduction.

The piece it is going to



breathing system


versatility.





Abstract





The piece it is going to be produced is designed to contain several



system one. Once properly solved each type it is chosen the b





Expansible Injection Mould Design


Its main purpose is to produce plastic pieces that utilize different



be produced is designed to contain several



one. Once properly solved each type it is chosen the b






uce plastic pieces that utilize different








mechanizations and thermal treatments needed. The budget part is orientative due to the



uce plastic pieces that utilize different








ed. The budget part is orientative due to the



uce plastic pieces that utilize different injection



be produced is designed to contain several future test samples for a




Then, that mould is exhaustively defined and evaluated with all the pieces costs as well as


injection foaming



future test samples for a


one. Once properly solved each type it is chosen the breathing mould


pieces costs as well as


2

foaming



future test samples for a


reathing mould


pieces costs as well as



Index

Introduction

Objectives

1.Background

2.External conditioning

3.Piece design

4.Mould design


Index

Introduction................................................................................................................................

Objectives................................................................................................................................

1.Background...


2.1.Injection machine characteristics...

2.2.Material characteristics...

3.Piece design...

3.1 Technical limits...

3.2 The geometry...

3.2.1

3.2.2

3.3 Volume...

3.3.1

3.3.2

4.Mould design

4.1 Core pull system...

4.1.1

4.1.2

4.1.3

4.1.4


.............................................................................................................................

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2.External conditioning.......................................................................................................................

ection machine characteristics...

2.2.Material characteristics...

.....................................................................................................................

3.1 Technical limits...

3.2 The geometry.................................................................................................................

3.2.1 Flexion test ISO 178 [1]

3.2.2 Traction test ISO 527

3.3 Volume..................................................

3.3.1 Perimet

3.3.2 Overflow channel

4.Mould design................................................................................................................................

Core pull system...

4.1.1 Mould operation

4.1.2 Piece position

4.1.2.1 3rd plate...

4.1.2.2 Decentered piece..

4.1.2.3 Decentered nozzle...

4.1.2.4 Decision.

4.1.3 Refrigeration

4.1.4 Ejection

4.1.4.1 Core pull ejector...

4.1.4.2 Plate ejec

4.1.4.3 Decision...


.............................................................................................................................

.............................................................................................................................

...................................................

....................................................................................................................

ection machine characteristics...

2.2.Material characteristics...................................................................................................

..................................................................................................................

3.1 Technical limits.............................................................

..............................................................................................................

Flexion test ISO 178 [1]

Traction test ISO 527

...............................................

Perimeter extensions

Overflow channel..............

.............................................................................................................................

Core pull system..........................................................................................................

Mould operation...................................................................................

Piece position.......................................................................................

4.1.2.1 3rd plate...

4.1.2.2 Decentered piece..

4.1.2.3 Decentered nozzle...

4.1.2.4 Decision...

Refrigeration..........................................................................................

Ejection.................................................................................................

4.1.4.1 Core pull ejector...

4.1.4.2 Plate ejec

4.1.4.3 Decision...

.............................................................................................................................

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ection machine characteristics................................................................................

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Flexion test ISO 178 [1]...................

Traction test ISO 527-2 [2].......................................................

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extensions................................................................

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4.1.2.1 3rd plate...................................................................................

4.1.2.2 Decentered piece..................................................................

4.1.2.3 Decentered nozzle..............................................................

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4.1.4.1 Core pull ejector............................................................

4.1.4.2 Plate ejection..............................................................................

4.1.4.3 Decision......................................................................................

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5.Final mould development

6.Mechanization

7.Thermal treatment

8.Budget resume

9.Conclusions

Acknowledgements

Bibliography

Extra: Ecological footprint


4.1.5

4.2 Precise opening system...

4.2.1

4.2.2

4.2.3

4.2.4

4.2.5

4.3 Final decision...


5.1.Piece description...

5.1.1.

5.1.2.

5.1.3.

6.Mechanization

7.Thermal treatment

8.Budget resume

9.Conclusions...

Acknowledgements

Bibliography.............................................................



4.1.5 Compilation

4.2 Precise opening system...

4.2.1 Mould operation

4.2.2 Piece position

4.2.3 Refrigeration

4.2.4 Piece ejection

4.2.5 Compilation

4.3 Final decision..................................................................................................................


5.1.Piece description...

5.1.1.Static part

5.1.2.Mobile part

5.1.3.Other elements

6.Mechanization.......................................................................

7.Thermal treatment....................................................................................................

8.Budget resume..............................................................................................................

......................................................................................................................

Acknowledgements..............................................................................................................

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Compilation..................

4.2 Precise opening system............................................................................................

Mould operation........................................................................................

Piece position..............................................................................................

Refrigeration system

Piece ejection...................................................................................

Compilation......................................................................................

...............................................................................................................

5.Final mould development.............................................................................................

5.1.Piece description............................................................................................

Static part.......................................................................................

Mobile part.........................................................................

Other elements.............................................................................

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Extra: Ecological footprint..............................................................................................

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Introduction

Polym

back to the beginning of the last century. They represented a massive improvement for

some consumption goods that were

repres

lead many industry sectors to modify their products such as the automotive industry that

began lighten

the same. But in this case

savings pleasing both consumers and the increasingly stringent environment regulations

either in production or in product.

Not surprisingly,

achieved an apparent density decrease by containing micro voids in the inside

techniques were called foaming and for that different injection moulds are being needed.

Today there are still numerous

reduction due to the gas voids and to increase the

used in research purposes are needed.


Introduction

Polymers are widely used in



represented also an increase of mechanical properties due its ductility. This advantages


began lightening

the same. But in this case



Not surprisingly,







Introduction

ers are widely used in



ented also an increase of mechanical properties due its ductility. This advantages


ing its products in favor of a power increase.

the same. But in this case,



Not surprisingly, next step was lighten







Introduction

ers are widely used in piece production


some consumption goods that were notably weight reduced and in some applications



its products in favor of a power increase.

a weight reduction represents more efficiency and material



next step was lighten



Today there are still numerous studies on foaming to improve its obvious resistance



piece production industry but their first applications were


notably weight reduced and in some applications



its products in favor of a power increase.



plastic parts which with some different techniques



studies on foaming to improve its obvious resistance


industry but their first applications were





its products in favor of a power increase. Nowadays the struggle is







reduction due to the gas voids and to increase the material savings so moulds that can be






Nowadays the struggle is







material savings so moulds that can be






Nowadays the struggle is




achieved an apparent density decrease by containing micro voids in the inside. Those




5






Nowadays the struggle is still




. Those





Objecti

The project is framed in an R & D project

and V

injection foaming techniques.

mould possible for that goal.

Specifically, a breathing mould that consist in having a cavity that increases volume while

opening the mould letting the polymer expand freely without changing the general shape.

That includes the initial evaluation of mould surrounding parameters and chara

as well as multiple

produced needs to be designed as well to contain as much test specimens as possible and

to resemble to large pieces.

It does not go further so it will not

other examples, opinions and previous experiences. Foaming techniques are not discussed

but taken

Project's main structure will be:

specifications given and the CCP own machine disposal.

a conscious evaluation and the appropriate choice being aware of the different li


Objecti


VolksWagen



ecifically, a breathing mould that consist in having a cavity that increases volume while



as well as multiple





but taken in account for the design.


- Piece design, which has to adapt to th


- Mould design, which includes several different possible variations on the mould,


-Piece description and


Objectives


agen which involves the development of






as well as multiple ways to resolve the mould and the plans for the chosen one.





in account for the design.


Piece design, which has to adapt to th


Mould design, which includes several different possible variations on the mould,


Piece description and



which involves the development of

injection foaming techniques. The main objective is to design the maximum accurately





ways to resolve the mould and the plans for the chosen one.


It does not go further so it will not be produced. Solutions are subjectively chosen based in


in account for the design.






Piece description and elaboration of plans of the mould chosen.

The project is framed in an R & D project between the

which involves the development of

The main objective is to design the maximum accurately






be produced. Solutions are subjectively chosen based in






laboration of plans of the mould chosen.

between the Centre Català del Plàstic

which involves the development of foamed plastic pieces using different









Piece design, which has to adapt to the general project in terms of the





Centre Català del Plàstic

foamed plastic pieces using different









e general project in terms of the




Centre Català del Plàstic (CCP),





That includes the initial evaluation of mould surrounding parameters and characteristics

ways to resolve the mould and the plans for the chosen one. The piece






a conscious evaluation and the appropriate choice being aware of the different limitations.

6

), Seat





cteristics

The piece






mitations.


1.Background

Foaming has been an object of study since the early 70's to produce large lightweight

pieces compared to the completely solid ones

added to the polymer that helped in completely filling the volume.

weight, saved material and lightened machine characteristics, but often in exchange for

mechanical properties and surface definition and quality.

Actually, che

SCF (supercritic

pressure.

G.G., 2013]

obtain

Some of the physical agents foaming characteristics are:

•

•

•

•

•

•

•

Some of those characteristics are

maintenance pressure in favor of the inner gas pressure. The structure obtained

resembles to a sandwich one which have solid compact outer layers that provide good

physical properties combined with a microfoa

without reducing significantly the mechanical properties.


Background






Actually, chemical blowing agents are being replaced by physical ones that consist in a

SCF (supercritic

pressure. Differences between both systems are

, 2013] and suggest that the microfoaming obtained by the physical agents is the key to

obtain better results in where chemical agents fail to achieve.


• Final piece weight reduction

• Lower processing

• Dimension stability

• Reduction of superficial voids

• Lower cycle time

• Physical properties enhanced

• Usage of blowing agents respectful with the environment







Background






mical blowing agents are being replaced by physical ones that consist in a

SCF (supercritical state fluid) addition in the melt polymer that expands when reducing

Differences between both systems are

suggest that the microfoaming obtained by the physical agents is the key to

better results in where chemical agents fail to achieve.


Final piece weight reduction

processing temperatures and pressures

Dimension stability

Reduction of superficial voids

Lower cycle time

Physical properties enhanced

Usage of blowing agents respectful with the environment







Background







fluid) addition in the melt polymer that expands when reducing

Differences between both systems are




Final piece weight reduction

emperatures and pressures

Reduction of superficial voids

Physical properties enhanced compared to chemical obtained


Some of those characteristics are a direct consequence of the substitution of the






pieces compared to the completely solid ones. For that chemical blowing agents






Differences between both systems are being





compared to chemical obtained


a direct consequence of the substitution of the



physical properties combined with a microfoamed core that saves in



For that chemical blowing agents






being carefully analyzed










med core that saves in




added to the polymer that helped in completely filling the volume. That reduced the final




carefully analyzed



Usage of blowing agents respectful with the environment (N2 y CO




med core that saves in weight and material



That reduced the final




carefully analyzed [Jaime Francisco


y CO2)




weight and material

7


were

That reduced the final




[Jaime Francisco





weight and material


To make all the tests it is important to have smart designed moulds to

injection tech

Some studies

moulds" and their effect on pieces produced using physical blowing agents.

permit an opening of the machine to give space for the piece to decrease pres

injected gas adapt to the volume.

Although the foaming technology is still being studied, there are already some products

produced by it such as automotive, medical and packaging parts

basically is the MuCell® technolo

molding.



injection technology

Some studies [Spörrer, 2007]







molding.



nology

[Spörrer, 2007]








Figure 1


[Spörrer, 2007] have proved the efficiency of the so called "breathing






basically is the MuCell® technology by Trexel Inc. that allows SCF added injection

Figure 2 Automotive foamed piece

1 Sandwich structure


have proved the efficiency of the so called "breathing





gy by Trexel Inc. that allows SCF added injection

Automotive foamed piece

Sandwich structure








Automotive foamed piece






produced by it such as automotive, medical and packaging parts. The responsible of that


To make all the tests it is important to have smart designed moulds to empower that


moulds" and their effect on pieces produced using physical blowing agents. Those moulds

permit an opening of the machine to give space for the piece to decrease pressure and let


. The responsible of that


8

empower that


Those moulds

sure and let


. The responsible of that




Some parts of the design of the mould are going to be limited by external agent

the injection machine or the material used, so the proper understanding of these is

essential to understand some decisions taken.

2.1.

Centre Català del Plàstic Injectio

•

•

•

•

•

•

•


External conditioning




2.1.Injection machine characteristics


• Injection machine

(SCF) MuCell®.

• Clamping force: 1100 kN.

• Maximum overture: 507mm

• Maximum injection velo

• Injection pressure: 1287 bar.

• Nozzle diameter: 40 mm.

• Maximum injection volume: 250 cm3.






Injection machine characteristics


Injection machine Engel Victory 110

(SCF) MuCell®.

Clamping force: 1100 kN.

Maximum overture: 507mm

Maximum injection velo

Injection pressure: 1287 bar.

Nozzle diameter: 40 mm.

Maximum injection volume: 250 cm3.







Centre Català del Plàstic Injection machine disposal characteristics:

Engel Victory 110

Clamping force: 1100 kN.

Maximum overture: 507mm

Figure

Maximum injection velocity: 754 cm3/s.

Injection pressure: 1287 bar.

Nozzle diameter: 40 mm.







n machine disposal characteristics:

Engel Victory 110, equipped with the

Figure 3 Clamping unit

city: 754 cm3/s.






, equipped with the

Clamping unit




, equipped with the Supercritic Fluid System

Some parts of the design of the mould are going to be limited by external agents such as


Supercritic Fluid System

9

s such as

Supercritic Fluid System


•

•

•

Some of the previous

course with not every polymer can those values be achieved so it is very important also

which material is going to be used to properly set the machine to its own possibilities.

The rest basica

install

2.2.

As said,

one type of polymer nor the same type of injection

material parameters are going to be changed frequently and that is what is needed to be

taken in account while utilizing the mould. In many design terms raw PP values are taken

because it is one of the most used mater

industry as well as because it has one of the greatest contractions of the used polymers


• Without hydraulic slidings

• Cold runner preferred.

• Subjection plates size:

Some of the previous



The rest basically influence in maximum size and some characteristics for the mould to

install.

2.2.Material characteristics

As said, this project develops a mould to experiment with so it is not destined to have only







Without hydraulic slidings

Cold runner preferred.

Subjection plates size:

Some of the previous information are maximum values taken by experimental tests. Of



lly influence in maximum size and some characteristics for the mould to

Material characteristics

this project develops a mould to experiment with so it is not destined to have only







Without hydraulic slidings

Cold runner preferred.

Subjection plates size:

Figure

information are maximum values taken by experimental tests. Of




Material characteristics







Figure 4 Subjection plates









because it is one of the most used material in that type of applications in automotive


Subjection plates






one type of polymer nor the same type of injection method. Viscosity, shrinkage and other



ial in that type of applications in automotive







method. Viscosity, shrinkage and other















10










industry as well as because it has one of the greatest contractions of the used polymers.


3.Piece design

To know how the mould is going to be, it is needed first to completely and properl

and design the piece it is going to be produced, otherwise that could provoke mistakes

while designing the mould.

The piece needs to be representative for large ones emul

properly take conclusions without having to ac

Those pieces will be used to take out test specimens in normalized shapes so they will

need to have some dimensions depending on that. Also it will be needed to see how can

they be to resemble to large pieces in terms of flux a

ones.

3.1

For the first step is important to know in which conditions it is going to be worked at, that

will lead us to some general dimensions to decide the final geometry of the piece.

We have a g

pressure given by the machine and the pressure in the material depending on the nozzle

diameter. The nozzle utilized is the Ø 40mm one that consists in a barely 1:1 rate betwee

the values in the graph. As it can be seen, the maximum of the machine is 1700bar, but a

value of 1000bar (100Kg/cm2) is kept as the new working maximum.


Piece design









ones.

Technical limits



We have a graph of the injection machine in which it can be seen the relation between the






Piece design









Technical limits



raph of the injection machine in which it can be seen the relation between the






Piece design


















properly take conclusions without having to actually produce large pieces.













The piece needs to be representative for large ones emulat

tually produce large pieces.



they be to resemble to large pieces in terms of flux and regularity that often lack in small










ating their characteristics to




nd regularity that often lack in small








To know how the mould is going to be, it is needed first to completely and properly define


their characteristics to











11

y define


their characteristics to







diameter. The nozzle utilized is the Ø 40mm one that consists in a barely 1:1 rate between



This value is set as the new maxi

is going to be used and the viscosity can be higher in some types causing an extra pressure

need, but in similar characteristics pieces the work pressure has been usually near the

400bar.

In each of la

problems that appear when work is done near any limit and that also provides an

assurance to minimize further flaws or mistakes.





400bar.

In each of last decisions we assumed a high Security Factor in order to prevent the







st decisions we assumed a high Security Factor in order to prevent the




Figure 5 Graph with pressure relation

This value is set as the new maximum keeping in mind that more than one type of plastic






Graph with pressure relation

mum keeping in mind that more than one type of plastic






Graph with pressure relation
















12







Once the maximum pressure on the material is obtained

strength of the machine (1100 kN) we can obtain the maximum projected area of the piece

we are designing.

As I said before, we were assuming

at last some variations are allowed.

3.2

A rectangular shape is ideal for the test specimens extraction but other characteristics

need to be also taken into account.

Next step

satisfy the purpose of the project.

distribution of the flux through the piece.

zone.




we are designing.

Projected



The geometry



Next step then, is


- Lateral entrance, preferred to a central entrance because permits a better


- "Fan" entrance, prov

zone.

- No runners, fact that simplifies the mould as it is soon explained.




we are designing.

ProjectedArea



The geometry



is finally define the geometry wanted and discuss its measures to correctly


Lateral entrance, preferred to a central entrance because permits a better


"Fan" entrance, prov

No runners, fact that simplifies the mould as it is soon explained.

Figure




Area � Pressure

A � 1000

A

As I said before, we were assuming a great SF and the values obtained are used as limit, so




finally define the geometry wanted and discuss its measures to correctly




"Fan" entrance, provides a better flux distribution especially in the near


Figure 6 Approximate geometry and flux direction



PressureonMaterial

1000Kg/cm2 �

A � 110cm2

a great SF and the values obtained are used as limit, so





ides a better flux distribution especially in the near


Approximate geometry and flux direction

Once the maximum pressure on the material is obtained and using the known maximum


Material � Machine

110000Kg

2








and using the known maximum


MachineStrength










Strength





ides a better flux distribution especially in the near-entrance

13







entrance


It is good to remember that the aim of the piece is to represent large pieces so the design is

often bad for

It also have to be noticed some of the uses the piece is going to have such as test

specimens which are regulated by ISO norms.

In those cases we have to take the expanded value of thickness for t

3.2.1

The only specification for this test is that accomplishes:

Where



often bad for its own production, but helpful to achieve its main goal.




.2.1 Flexion test ISO 178 [1]


Where

-l is the maximum length of the specimen

-h is the final thickness



its own production, but helpful to achieve its main goal.






maximum length of the specimen

is the final thickness










is the final thickness

Figure







l � 20h


Figure 7 Flexion test






Flexion test




In those cases we have to take the expanded value of thickness for the calculations.



he calculations.

14




Therefore

3.2.2

For type 1A the minimum length is 150 mm which is too much but for types 1BA, 1BB and

5A, 5B the requirements are

The rest of the measures are tabulated in the norm, maximum size is the value that can

affect directly to the piece.

It is important to accomplish as much types as possible for being able to do as much tests

as wanted.


Therefore

.2.2 Traction test ISO 527


5B the requirements are




as wanted.


Final thickness (mm)

Traction test ISO 527







al thickness (mm)

3

4

5

6

Traction test ISO 527-2 [2]

Figure 8 Traction test sample sizes



lmax

lmax



al thickness (mm) Maximum length (mm)

2 [2]

Traction test sample sizes


lmax � 35""

lmax � 75""



Maximum length (mm)

60

80

100

120

Traction test sample sizes


""

""



Maximum length (mm)







15





With that in mind

previous conditions and characteristics.

s1 (mm)

Maximum length (s2) is set at 150mm due to the increased amount of pressure needed in

higher values in the injection process caused by an excessive path for the polymer and its

overcooling effect.

That is because it favor orientation effects, which means that most of the polymer used is

oriented towards the same direction, also to achieve a fully developed flux, which will

make it resemble to

which consists in the non desirable effect of larger gas bobble size on the entrance.

It is needed to take in account the shrinkage of the material, which in terms of PP is

around 1.2%, t

dimension when cooled.


With that in mind


Side values

s1 (mm)

70

80

90

100

110

120



overcooling effect.

-Highlighted values are preferred

- Pieces with a high length/wide relation are preferred



make it resemble to



around 1.2%, to properly oversize the mould injection cavity finally obtaining the desired

dimension when cooled.


With that in mind we begin to search for the optimum size of the piece, achieving the


Side values

s2 (mm)

143

125

111

100

91

83



overcooling effect.

Highlighted values are preferred

Pieces with a high length/wide relation are preferred



make it resemble to large pieces, and to homogenize the foam without "entrance effect",



o properly oversize the mould injection cavity finally obtaining the desired

dimension when cooled. When using other materials it is going to be taken into account


we begin to search for the optimum size of the piece, achieving the


Projected Area







large pieces, and to homogenize the foam without "entrance effect",




When using other materials it is going to be taken into account

Figure



Projected Area

mm2

10000

10000

10000

10000

10000

10000












Figure 9 Size values


Projected Area











Size values






















16











that part of the design because contractions are not the same so won't be the pieces

neither

3.3

Finally, we have to check if the volume reaches the experimentally obtained value of

minimum volume in MuCell injection to make it reliable and constant of 50cm3.

The value chosen in this case

of injection volume, because the further expansion of 1 or 2 mm of the foam does not

influence in injected volume, consequently some solutions are presented to try to solve

that.

3.3.1

It consists in aggregate perpendicular thin extensions to the piece along its perimeter in

order to prevent a Projected Area increase, but they need to be cut afterwards.



neither.

Volume






.3.1 Perimetral










Perimetral extensions







Thickness(mm)

2

3

4

The value chosen in this case is the 2mm thick piece which means that we have a problem



extensions






Thickness(mm) Volume(cm3)

20

30

40

is the 2mm thick piece which means that we have a problem








Volume(cm3)






















17








If we take th

and thick values of 20mm and 3mm respectively, we obtain a total length needed of

Thickness(mm)

2

3

4

Which in our case surpasses the perimeter which means that larger extensions are

needed

As it can be seen, the large dimension needed and the further complicated process of

cutting them off from each piece m

option for its

3.3.2

Consists in an extra cavity added on the furthest part of the piece (considering "near" the

entrance) to easily solve the volume problem.


If we take the value of the perimeter of the preferred piece size and giving a constant wide


Thickness(mm) Volume(cm3)

20

30

40


needed.



option for its easier

.3.2 Overflow channel




e value of the perimeter of the preferred piece size and giving a constant wide


Volume(cm3)

20

30

40




easier production.

Overflow channel




Figure 10



Volume needed (cm3)

30

20

10



cutting them off from each piece make this option less desirable.

production.

Overflow channel



10 Piece with extensions



Volume needed (cm3) Extensions total length(mm)

500

333

167



ake this option less desirable.



Piece with extensions



Extensions total length(mm)

500

333

167



ake this option less desirable.




Extensions total length(mm)



ake this option less desirable. However, it is a good




Perimeter(mm)

410

410

410



However, it is a good


18


Perimeter(mm)



However, it is a good



It represents a great improvement to the extensions system in terms of facility of later

treatment, a single cut would be enough.

However, it is not possible to put it where it has no negative pr

overcomplicating the mould so that is why it is placed on the furthest part of the piece

where if there is not enough pressure it is not going to be filled. This solution represent

the best option considering that it is still go

the design.


presents a great improvement to the extensions system in terms of facility of later






the design.











Figure 11 Piece with overflow channel







Piece with overflow channel




the best option considering that it is still good because of all the SF taken on first steps of






od because of all the SF taken on first steps of



However, it is not possible to put it where it has no negative projected area effect without





ojected area effect without




19


ojected area effect without




Static

-Nozzle entrance

Mobile part

-ejection system

-refrigeration system


4.Mould design

In this part there are going to be developed some solutions for the mould as well as the

reason for the chosen ones.

As it has been seen, the produced piece is simple and that

is taken the mould that typically produce it (without the foaming process of course) as the

base to the solutions presented.

The traditional mould looks like

In whi

has to be changed in order to achieve the desired foaming technique.

achieved is a foaming only in terms of thickness while conserving the other size v

Static part

Nozzle entrance

Mobile part

ejection system

refrigeration system


Mould design







In which we can see the parts function




Mould design







ch we can see the parts function




Mould design







Figure

ch we can see the parts function



Partition line




Figure 12 Mould structure

ch we can see the parts function-defined. Note that



Partition line


As it has been seen, the produced piece is simple and that simplifies the solution as well. It


Mould structure

defined. Note that at least




simplifies the solution as well. It


at least the piece housing

has to be changed in order to achieve the desired foaming technique. What is needed to be





piece housing

What is needed to be

achieved is a foaming only in terms of thickness while conserving the other size values.

20




piece housing part

What is needed to be

alues.

Piece housing

Ejection plate

housing

Ejection plates


For that there are presented two general systems.

Each one have its own solutions for every part of the mould and in the end is able to do the

job. In that point it is nee

which is going to be manufactured.

4.1

4.1.1

Also known as "noyos",

guides to pieces or

synchronized with it which controls

In this case the cell pull need to be into a direction that cannot be controlled directly so the

piston controls

lowers the



-Core pull system

-Precise opening system


job. In that point it is nee


Core pull system

.1.1 Mould operation

Also known as "noyos",

guides to pieces or



piston controls

lowers the core pull.



Core pull system

Precise opening system


job. In that point it is needed to properly evaluate the final characteristics and choose one


Figure 13

Core pull system

ould operation

Also known as "noyos", traditionally

guides to pieces or adding



both the initial and the final thickness by actuating i

core pull.



Precise opening system (also known as breathing system)


ded to properly evaluate the final characteristics and choose one


13 Breathing m

ould operation

traditionally

adding a piston conducted by the same machine or externally

synchronized with it which controls directly a cell pull that moves when required.


the initial and the final thickness by actuating i


(also known as breathing system)



mould and cel

the system consists in

a piston conducted by the same machine or externally

directly a cell pull that moves when required.






ll pull foaming

the system consists in








g systems

the system consists in having some mechanical




the initial and the final thickness by actuating in a wedge that lifts or



having some mechanical




n a wedge that lifts or

21



having some mechanical



n a wedge that lifts or


The wedge needs to be attached to the cell pull which at the same time needs to be driven

through

thermally treated preventing the sliding surface from scoring due to the high pressures

applied.

That leads to the need of a mechanical limit system for the piston to reproduce e

same size each time because when working in terms of few mm the mismatches of a

control system can be very relevant.

This makes this system the most useful one providing endless possibilities in terms of

different tests in both initial injectio

with

from the traditional injection process, the mould stay clamped and it is the piston what

makes the rest.

Once desc

4.1.2

Taking in account the piece size and the injection machine size, it is easy to conclude that it

is only going to be produced one piece at a time.

In order to make the piece

so it is going to be decompensated and there are three different solutions.



through a cavity impeding unwanted movements. The union of both need to be specially


applied.






with a foaming technique


makes the rest.

Once described the main operation some other issues need to be solved

.1.2 Piece position







a cavity impeding unwanted movements. The union of both need to be specially







a foaming technique can adopt this system because it is the only thing that differs


ribed the main operation some other issues need to be solved

iece position






Figure 14








different tests in both initial injection and foaming thickness. Also almost every machine

can adopt this system because it is the only thing that differs





more suitable to its function the entrance was set on one side


Cell pull/Wedge system







n and foaming thickness. Also almost every machine








Cell pull/Wedge system






























That leads to the need of a mechanical limit system for the piston to reproduce exactly the








22




xactly the









4.1.2.1

When a mould is decompensated, usually tends to get damaged by its use, having

problems in closi

centralizing the it to the entrance, but as it has been explained before, it is needed a lateral

entrance for the flux to develop correctly through the piece so a corridor is added f

nozzle to the side of the piece.

In that case, what is done is add the called 3rd plate which have mechanized only the

corridor and which have to be moved to remove it at the same time that it is extracted

from the piece.

This system adds some technical difficulties and extra pieces which can increase the whole

price but it is an assurance for large production series which need good durability for the

mould.

4.1.2.2

Although it can be a cause of harm of the mould, having the piece decompensated is not

that bad if only a few pieces are going to be produced and of this reduced sizes. A direct


.1.2.1 3rd plate


problems in closi






from the piece.



mould.

.1.2.2 Decentered piec



3rd plate


3rd plate


problems in closing basically. To solve that one what is needed is to balance the piece by








Decentered piece





ng basically. To solve that one what is needed is to balance the piece by






Figure 15 3rd plate operation scheme





Entrance







3rd plate operation scheme





Entrance

Runner

Piece







3rd plate operation scheme





Runner

Piece














entrance for the flux to develop correctly through the piece so a corridor is added from the







Ejection direction

23




rom the







Ejection direction


entrance simplifies the mould but also presents some problems with its size

that it has to be mounted into a machine with size limits.

However if needed, the entrance could be diagonally placed allowing to center a bit more

the piece to the mould. That would be enough but would also add some difficulties to the

extra

static part of the mould.

4.1.2.3

Nothing prevents a change of the position of th

housing zone. If the mould size is not too large this simple solution is optimum because it

permits to center the piece without complicating the system.

4.1.2.4

In this case the 3rd plate and the decentered n

usage. Both decentered solutions are optimum in simplicity and price. The difference is

very slight in every case. The 3rd plate option would have been the optimum in a case of a

larger piece or a multiple piec

decentrage of the nozzle, as seen in other moulds in CCP, is the best option.






extraction of the piece increasing the pulling force needed for the piece to not stick on the


.1.2.3 Decentered nozzle




.1.2.4 Decision











ction of the piece increasing the pulling force needed for the piece to not stick on the


Decentered nozzle




Decision












Figure 16 Piece layout within the mould







larger piece or a multiple piece production,







Piece layout within the mould

Nothing prevents a change of the position of the nozzle more than the machine mould



In this case the 3rd plate and the decentered nozzle are the best solution in terms of mould



e production, the mould has reduced size so








e nozzle more than the machine mould



ozzle are the best solution in terms of mould



the mould has reduced size so












the mould has reduced size so


entrance simplifies the mould but also presents some problems with its size and the fact









the mould has reduced size so in this case the


24

and the fact









in this case the


4.1.3

The dynamic nature of the core pull difficults the refrigeration in the inner parts of the

piece. There are no different solutions to choose from so the solution found consists in

covering the perimeter and cooling indirectly the piece by cooling as much as possible the

core pull and surrounding pieces.

Nevertheless in other moulds of similar characteristics this system has been proven

enough by the fact that the piece is thin at least in the parts not supposed to be thrown

away (overflow channel). The uneven cooling can be a problem for

differences between the inner and outer parts of the piece

4.1.4

The traditional pin

taking in account that it is moving while the whole mould is clamped. To

are two possible solutions.

4.1.4.1


.1.3 Refrigeration


e. There are no different solutions to choose from so the solution found consists in







.1.4 Ejection

The traditional pin



.1.4.1 Core pull ejector


efrigeration









jection

The traditional pin-ejection system has some problems to move along with the core pull



Core pull ejector






Figure 17





ejection system has some problems to move along with the core pull





Perimeter refrigeration










r refrigeration












away (overflow channel). The uneven cooling can be a problem for the characteristics








the characteristics


taking in account that it is moving while the whole mould is clamped. To solve that there

25






the characteristics


solve that there


The first thing it has to be assured is that the piece remains on the moving side of the

mould by letting so

not let the piece stay once solidified

the piece to fall off.

Then what elevates the cell pull is the same wedge actuated by the piston that wou

a third position. This is one of the easiest solutions but has some difficulties when trying to

add a third position to the piston.

4.1.4.2

This solution consists in binding the ejector plate with the base plate making it move alo

with the ejection movement. By itself only passes through but modifying the piece on its

perimeter and adding some pieces fixed on the base plate interfering with the

modification the result is an effective ejection.

The piece would also need to enter

stack on the nozzle side. This needs to be in a disposable part otherwise it will be an extra

part to be taken out.



mould by letting so

let the piece stay once solidified





.1.4.2 Plate ejection










mould by letting some material pass to an entrance

let the piece stay once solidified





Plate ejection










me material pass to an entrance

let the piece stay once solidified. When ejecting the cavity no longer exists and permits

Figure 18








The piece would also need to enter to the pull cell cavity in order to assure it does not



me material pass to an entrance

When ejecting the cavity no longer exists and permits

18 Cell pull extra cavity







to the pull cell cavity in order to assure it does not


Material entrance


me material pass to an entrance to the cell pull


Cell pull extra cavity








entrance


to the cell pull while melt that would










while melt that would


Then what elevates the cell pull is the same wedge actuated by the piston that would need







26


while melt that would


ld need


This solution consists in binding the ejector plate with the base plate making it move along






4.1.4.3

The problems with the piston dealing with more than two positions a

think that a more expensive one with its control system is needed. In the other hand the

plate ejection would increase a bit the after treatment for each piece by having to remove

the extra parts. This time the budget determines the decisi

with the plate ejection.

4.1.5

Pros

•

•

•

Cons

•

•

•

•

*To reduce a bit more the total cost it would be possible to put a pneumatic piston instead

of an hydraulic one by setting a low wedge angle making the piston need to support less

force directly from the

4.2

4.2.1


.1.4.3 Decision






.1.5 Compilation

• Piece centered

• Ordinary machine needed

• Versatility in remodeling the piece

Cons

• Difficulties to refrigerate evenly

• Additional piece later treatment

• Additional thermal treatmen

• Expensive piston addition*



force directly from the


.2.1 Mould operation


ecision






ompilation

Piece centered

Ordinary machine needed

Versatility in remodeling the piece

Difficulties to refrigerate evenly

Additional piece later treatment

Additional thermal treatmen

Expensive piston addition*



force directly from the pressure on the mould.


ould operation






Ordinary machine needed




Additional thermal treatment for the friction parts

Expensive piston addition*



pressure on the mould.


ould operation








t for the friction parts



pressure on the mould.




the extra parts. This time the budget determines the decision which is to eject the piece

t for the friction parts



The problems with the piston dealing with more than two positions are big enough to



on which is to eject the piece



re big enough to






27

re big enough to







This system consists in precisely opening the mould by using the injection machine

software, increasing the cavity in one direction while a spring system maintains the piece

closed m

The springs are always compressed and act until their limiter screw allows them making

possible to eject the piece.

They work against the clamping

machine. Pressure inside the piece is lost in a greater way than the cell pull system so it is

important to properly design, mechanize and thermally treat the parts involved to

minimize its effect an

4.2.2

In terms of piece position conclusions are the same as the previous type of mould but with

extra reasons in favor of the piece centering. Springs are not externally commanded and

they are an extra mould

4.2.3

In this case the refrigeration system actuates equally both in the perimeter and in the

inner piece through a refrigeration circuit beneath the protuberance that delimits the

bottom of the piece.




closed making it expand towards the desired direction






minimize its effect an

.2.2 Piece position



they are an extra mould

.2.3 Refrigeration system



bottom of the piece.




aking it expand towards the desired direction






minimize its effect and prevent flaws on the piece.

iece position



they are an extra mould harm if not evenly placed.

efrigeration system



bottom of the piece. By doing this a better even cooling is achieved.





Figure 19 Spring system operation


They work against the clamping force so it is important to work under the limits of the



d prevent flaws on the piece.



harm if not evenly placed.

efrigeration system



doing this a better even cooling is achieved.




Spring system operation


force so it is important to work under the limits of the



d prevent flaws on the piece.



harm if not evenly placed.







Spring system operation































28












Because of the piece position the

momentarily the solid plate to reenter in a more fa

4.2.4

The ejection pretty much resembles to the traditional non

consist in a pin system ending on the surface of the piece bottom that move along with the

ejection plate that move once the mould




.2.4 Piece ejection





Figure



jection





Figure 20 Inner piece refrigeration system

Because of the piece position the perimeter





Figure

Inner piece refrigeration system

perimeter circuit cannot be continue and has to exit

momentarily the solid plate to reenter in a more favorable position.



ejection plate that move once the mould opening is complete.

Figure 21 Pin layout


circuit cannot be continue and has to exit

vorable position.

The ejection pretty much resembles to the traditional non-foamed mould pieces which


opening is complete.

Pin layout



vorable position.

foamed mould pieces which





29





Pins are placed in the ends of the piece and in predicted trouble points such as the

entrance and the overflow channel which have an extra amount of material as well.

To prevent flaws a

4mm Ø). Also

that lets melt plastic enter and prevents the piece from stacking on the wrong side when

solidifi

It is important for that to use a pin in a non wanted part of the piece that was going to be

taken out such as the overflow channel or the entrance.

4.2.5

Pros

•

•

•

Cons

•

•

•




To prevent flaws a

4mm Ø). Also, like


solidified. When the pin is released also is the said entrance that falls along with the piece.



.2.5 Compilation

• Piece centered

• Even refrigeration

• Cheaper than other options

Cons

• High pressure drop when first opening the mould

• Limited piece versatility

• Difficulty in equally setting all the springs




To prevent flaws and marks in the piece it is important for them to be wide enough (i.e.

like in the previous mould, the ejection system needs to have an entrance


ed. When the pin is released also is the said entrance that falls along with the piece.



ompilation

Piece centered

Even refrigeration

Cheaper than other options

High pressure drop when first opening the mould

Limited piece versatility

Difficulty in equally setting all the springs




nd marks in the piece it is important for them to be wide enough (i.e.

in the previous mould, the ejection system needs to have an entrance





Cheaper than other options


Limited piece versatility



































30








4.3

Both designs are equally valid for the

In the core cell mould the main advantage is its versatility however its elevated cost and

difficult refrigeration reduces its value whereas the controlled opening system has fast

and good quality ending

So there are no better or worse moulds in absolute terms and that implies to make a

decision.

In that case it is decided to put the economic and final quality piece factors as preferred

and, in consequence, choose to de

differ a lot in a possible future decision to produce the cell pull one.


Final decision




and good quality ending


decision.





Final decision




and good quality ending pieces in exchange for versatility.






Both designs are equally valid for the project main purpose but with obvious differences.



pieces in exchange for versatility.



and, in consequence, choose to develop the precise opening mould system which will not


project main purpose but with obvious differences.






velop the precise opening mould system which will not























31








5.Final mould

Once fully

parts are t

their own naming and price for them. Note that if taken other brand product some shapes

and sizes may change and with that the solution needed.

Pieces can be ordered by the followi

Structural:

•

•

•

•

•

•

•

•

Plate 5

Plate 4

Plate 3

Plate 2


Final mould

Once fully-defined the mould, it is time to evaluate its production needs. The following

parts are taken complete or partially almost exclusively from HASCO catalog which have




Structural:

• K12- Plate 1

• K20- Plate 2

• K20- Plate 3

• K30- Plate 4

• K60- Plate 5

• K70- Plate 6

• K40- Plate 8

• K12- Plate 7

Plate 5

Plate 3

Plate 2

Plate 1


Final mould

defined the mould, it is time to evaluate its production needs. The following

aken complete or partially almost exclusively from HASCO catalog which have




Plate 1

Plate 2

Plate 3

Plate 4

Plate 5

Plate 6

Plate 8

Plate 7

Plate 1


Final mould development





Pieces can be ordered by the following topics

Figure

development





topics:

Figure 22 Mould exterior

development





Mould exterior

development




Plate 6




32




Plate 7

Plate 8


Refrigeration:

•

•

Ejection:

•

•

Placers

•

•

•

•

•

•

•

•

•

•

•

Then

treatment and mechanization if needed.


Refrigeration:

• Z87 refrigeration male nozzle

• Z94 threaded plug

Ejection:

• Z40 ejector

• Z60 spring

Placers and guidance

• Z1000 centering disk

• Z38 limiter screw

• Z31 allen screw with cylindrical head

• Z33 countersunk screw

• Z691 spring washer with detent

• Z00 column guide

• Z10 bushing guide

• Z20 centering bush

• Z55 stop washer

• Z70 transport

• Z51 nozzle

Then it is time to



Z87 refrigeration male nozzle

Z94 threaded plug

0 ejector

Z60 spring

and guidance:

Z1000 centering disk

Z38 limiter screw

allen screw with cylindrical head

countersunk screw

spring washer with detent

00 column guide

Z10 bushing guide

centering bush

stop washer

Z70 transport flange

Z51 nozzle

it is time to proceed to an exhaustive de



Z87 refrigeration male nozzle

Z1000 centering disk


countersunk screw


flange

proceed to an exhaustive de




proceed to an exhaustive definition of each piece as well as thermal


finition of each piece as well as thermal finition of each piece as well as thermal finition of each piece as well as thermal

33

finition of each piece as well as thermal


5.1.

5.1.1.

�

�

�

�

�

�

�

�


5.1.Piece description

5.1.1.Static part

� Name: Plate 1� Code and size

� Price: 173.03� Mechanization

-Decentered nozzle drilling

-Centering disk housing milling and position screws

-Transport flange drilling

� Thermal treatment

� Material

� Quantity

� Use and position

directly by the injection machine


Piece description

Static part

: Plate 1 Code and size: K12-

: 173.03€ Mechanization: Yes

Decentered nozzle drilling

Centering disk housing milling and position screws

Transport flange drilling

Thermal treatment

Material: DIN 1.1730Quantity: 1 Use and position: First platdirectly by the injection machine


Piece description

Figure 23

-246x296x2

: Yes




Thermal treatment: Quench and: DIN 1.1730

: First plate of the mould, subjects Plate 2 and is being subjected directly by the injection machine

23 Plate 1: Nozzle support

246x296x27




Quench and Temper

e of the mould, subjects Plate 2 and is being subjected directly by the injection machine

Plate 1: Nozzle support


e of the mould, subjects Plate 2 and is being subjected

Centering disk housing milling and position screws thread


thread drilling


34



�

�

�

�

�

�

�

�




-Decentered nozzl


� Material

� Quantity


piece produced. Is bound together with Plate 1 and holds the Z00 column guidesthat guides the mould




Decentered nozzl

Thermal treatment

Material: DIN 1.1730Quantity: 1 Use and position: Is subjected by Plate 1 and consists in the upper limit for the piece produced. Is bound together with Plate 1 and holds the Z00 column guidesthat guides the mould


Figure 24 Plate 2: Upper piece delimiter

-246x296x36

: Yes

Decentered nozzle small diameter drilling

Thermal treatment: Quench and : DIN 1.1730

: Is subjected by Plate 1 and consists in the upper limit for the piece produced. Is bound together with Plate 1 and holds the Z00 column guidesthat guides the mould

Plate 2: Upper piece delimiter

246x296x36

e small diameter drilling

Quench and Temper

: Is subjected by Plate 1 and consists in the upper limit for the piece produced. Is bound together with Plate 1 and holds the Z00 column guides


e small diameter drilling





35



5.1.2.

�

�

�

�

�

�

�

�


5.1.2.Mobile part



-Piece shape milled trough the piece

-Z60 spring and Z38 limiter screw housings drilling

-Refrigeration drilling


� Material

� Quantity


steady part until the 2 mm expansion reached due to the Z60 spring action making the piece retain its general shape. Guided by Z00 column guides and Z10 bushing guide.


Mobile part



Piece shape milled trough the piece

Z60 spring and Z38 limiter screw housings drilling

Refrigeration drilling

Thermal treatment

Material: DIN 1.1730Quantity: 1 Use and position: Limited by the Platesteady part until the 2 mm expansion reached due to the Z60 spring action making the piece retain its general shape. Guided by Z00 column guides and Z10 bushing


Figure 25 Plate 3: Piece shape retainer

-246x296x36

: Yes





: Limited by the Platesteady part until the 2 mm expansion reached due to the Z60 spring action making the piece retain its general shape. Guided by Z00 column guides and Z10 bushing

Plate 3: Piece shape retainer

246x296x36



Quench and Temper

: Limited by the Plate 4 and the Z38 limiter screw. Stays in the steady part until the 2 mm expansion reached due to the Z60 spring action making the piece retain its general shape. Guided by Z00 column guides and Z10 bushing




4 and the Z38 limiter screw. Stays in the steady part until the 2 mm expansion reached due to the Z60 spring action making the piece retain its general shape. Guided by Z00 column guides and Z10 bushing





36



�

�

�

�

�

�

�

�

�



� Base material block size


-Piece shape milling until desired height

-Guide drilling

-Z38 limiter

-Z40 Pin

-Z60 spring housing drilling

-Refrigeration drilling


� Material

� Quantity


Act as the piece bottom limiter that moves when precisely opening the mouldSpring-limiter screws are bound in that plate.


Figure

: Plate 4 Code and size: Hole position based on K30Base material block size


Piece shape milling until desired height

Guide drilling

Z38 limiter and Z31 allen screw

Z40 Pin and

Z60 spring housing drilling


Thermal treatment

Material: DIN 1.1730Quantity: 1 Use and position: Bounded with Plate 8 x2 in the mobile partAct as the piece bottom limiter that moves when precisely opening the mould

limiter screws are bound in that plate.


Figure 26 Plate 4

: Hole position based on K30Base material block size: 246x296x70

: Yes


Guide drilling

and Z31 allen screw

and drilling




Bounded with Plate 8 x2 in the mobile partAct as the piece bottom limiter that moves when precisely opening the mould


Plate 4: Piece bottom expander

: Hole position based on K30-: 246x296x70


and Z31 allen screw thread


Quench and Temper



: Piece bottom expander

-246x296x36


thread drilling



: Piece bottom expander

246x296x36

drilling

Bounded with Plate 8 x2 in the mobile part with the Z31 screwsAct as the piece bottom limiter that moves when precisely opening the mould

with the Z31 screwsAct as the piece bottom limiter that moves when precisely opening the mould.

37

with the Z31 screws. .


�

�

�

�

�

�

�

�

�

�

�

�

�

�

�




-Z40 ejectors housing drilling


� Material

� Quantity


holds the Z40 ejector pins that will take out the pie



-Machine ejection screw thread drilling


� Material

� Quantity



63.90€ Mechanization: Yes

Z40 ejectors housing drilling

Thermal treatment

Material: DIN 1.1730Quantity: 1 Use and position: Bound with Plate 6holds the Z40 ejector pins that will take out the pie


80.47€ Mechanization: Yes

Machine ejection screw thread drilling

Thermal treatment

Material: DIN 1.1730Quantity: 1


Figure 27 Plate 5:

-246x296x12

: Yes


Thermal treatment: Quench and: DIN 1.1730

Bound with Plate 6holds the Z40 ejector pins that will take out the pie

Figure 28 Plate 6: Ejector pins retainer

-246x296x17

: Yes



Plate 5: Ejection

x12


Quench and Temper

Bound with Plate 6 and controlled directly by the machine it holds the Z40 ejector pins that will take out the pie

Plate 6: Ejector pins retainer

246x296x17


Quench and Temper

Ejection pins housing

and controlled directly by the machine it holds the Z40 ejector pins that will take out the piece. It is guided by those ejectors.



ins housing

and controlled directly by the machine it ce. It is guided by those ejectors.



38



�

�

�

�

�

�

�

�

�



screws. It receives directly the threaded rod from the machine related to the ejection.



-Decentered nozzle drilling

-Centering disk housing milling and position screws drilling



� Material

� Quantity


and positioned by Z20 centering bushes. It gives space for the ejection system to move and retains the plates on the mobile part.


Use and position: Bound with Plate 5 with Z31 screws and centered with Z33 screws. It receives directly the threaded rod from the machine related to the




Centering disk housing milling and position screws drilling


Thermal treatment

Material: DIN 1.1730Quantity: 2 Use and position: Bound between Plaand positioned by Z20 centering bushes. It gives space for the ejection system to move and retains the plates on the mobile part.


Bound with Plate 5 with Z31 screws and centered with Z33 screws. It receives directly the threaded rod from the machine related to the

Figure 29 Plate 8: Structur

-246x296x17

: Yes





Bound between Plaand positioned by Z20 centering bushes. It gives space for the ejection system to move and retains the plates on the mobile part.


Plate 8: Structur

246x296x17




Quench and Temper

Bound between Plates 4 and 7 with Z31 screwsand positioned by Z20 centering bushes. It gives space for the ejection system to move and retains the plates on the mobile part.


Plate 8: Structural limiter


tes 4 and 7 with Z31 screwsand positioned by Z20 centering bushes. It gives space for the ejection system to move and retains the plates on the mobile part.



tes 4 and 7 with Z31 screws and positioned by Z20 centering bushes. It gives space for the ejection system to



passing throughand positioned by Z20 centering bushes. It gives space for the ejection system to

39

Bound with Plate 5 with Z31 screws and centered with Z33

passing through and positioned by Z20 centering bushes. It gives space for the ejection system to


�

�

�

�

�

�

�

�

5.1.3.

Name

Centering

disk

Allen screw

Spring

washer with

detent

Allen screw

Stop washer




-Decentered



� Material

� Quantity


mould mobile

5.1.3.Other elements

Name Code/Size

Centering K100

125x8

Allen screw Z31

12x120

Spring

washer with

detent

Z691

12x5

Allen screw Z31

12x30

Stop washer Z55


: Plate 7 ode and size: K12-


Decentered


Thermal treatment

Material: DIN 1.1730Quantity: 1 Use and position: Last plate bound to the mobile part of the machine. Sustamould mobile part and retains the Z20 centering bush

Other elements

Code/Size Price/u

K100 -

125x8 25.25

Z31 -

12x120 2.11

Z691 -

12x5 0.13

Z31 -

12x30 0.52

Z55 - 18x3 0.62


Figure 30 Plate 7: Mobile part support

-246x296x2

: Yes

Decentered machine ejection rod position



Last plate bound to the mobile part of the machine. Sustapart and retains the Z20 centering bush

Price/u(€) Qty.

25.25 1

2.11 4

0.13 8

0.52 4

0.62 4

Plate 7: Mobile part support

246x296x27

machine ejection rod position


Quench and Temper


ty. Material

1 1.1730

4 12.9

8 DIN

17221

4 12.9

4 1.0711


machine ejection rod position drilling


Material Therm. T.

-

-

-

-

-


drilling

Last plate bound to the mobile part of the machine. Sustapart and retains the Z20 centering bush.

Mechanization

-

-

-

-

-

Last plate bound to the mobile part of the machine. Sustains the

nization Use

Nozzle

holder

Bound

permanently

Impede

screw going

back

Bound

permanently

Limit

40

ins the

Nozzle

Bound

permanently

Impede

screw going

Bound

permanently


Spring

washer with

retent

Countersunk

screw

Allen screw

Centering

bush

Bushing

guide

Column guide

Refrigeration

male nozzle

Threaded

plug

Ejector

Spring

Transport

flange

Limiter screw

Nozzle


Spring

washer with

retent

Z691

12x2

Countersunk

screw Z33

Allen screw Z31

Centering

Z20

30x100

ing

Z10

24

Column guide Z00

24x55

Refrigeration

male nozzle Z87

Threaded Z94

Ejector Z40

4x100

Spring Z60

25x

Transport

flange Z70

Limiter screw Z38

16x30

Nozzle Z51

18x27


Z691 -

12x2 0.13

Z33 - 4x8 0.25

Z31 - 8x16 0.22

Z20 -

30x100 6.44

Z10 - 36 -

12.62

Z00 - 36 -

24x55 17.10

Z87 0.76

Z94 0.30

Z40 -

4x100 2.83

Z60 -

25x30 18.50

Z70 209.73

Z38 -

16x30 5.69

Z51 -

18x27 36.46


0.13 4

0.25 4

0.22 4

6.44 4

12.62 4

17.10 4

0.76 8

0.30 7

2.83 7

18.50 4

209.73 1

5.69 4

36.46 1

4 DIN

17221

4 8.8

4 12.9

4 1.0401

4 1.0401

4 1.0401

8 2.0401

7 2.0401

7 1.2516

4 2098

1

4 12.9

1 1.2826

-

-

-

Nitriding

Nitriding

Nitriding

-

-

Nitriding

-

-

Nitriding

-

-

-

-

-

-

-

-

-

2 cut 7mm, 1

piece retainer

mechanization

-

-

-

Cut in Plate 1

+2 distance

ejection

movement

Impede

screw going

back

Bound

permanently

Bound

permanently

Decrease

friction

Decrease

friction

Guide every

plate

Connect

mould to

refrigeration

Plug

refrigeration

holes

2 cut 7mm, 1

piece retainer

mechanization

Retain and

eject piece

Maintains

Plate 3 at

place

Maintain

mould

and

transport

Limit spring

stroke

Cut in Plate 1

+2 distance

Connect

machine end

with mould

41

ejection

movement

Impede

screw going

Bound

permanently

Bound

permanently

Decrease

friction

Decrease

friction

Guide every

Connect

mould to

refrigeration

refrigeration

Retain and

eject piece

Maintains

Plate 3 at

Maintain

closed

transport

Limit spring

Connect

machine end

with mould


6.Mechanization

Although most pieces are directly taken from cat

with them is not enough. Pieces such as guides and screws don't need changes but plates

do. Standardized plates have only the guidance and thread holes and lets the design up to

you. For that, mould plates need to be me

The mechanization processes needed are:

different roughnesses helps achieving both low time and good finishing for the piece

quality pieces as well as for its health.

In the mould there is a non standardized piece

completely, first rou

rough and finally grinding it.


Mechanization






-Milling. The main way to achieve the shapes wanted in the piece. Cutting off in


-Drilling. Way to obtain the round sha

-Grinding


the mould there is a non standardized piece

completely, first rou



Mechanization






Milling. The main way to achieve the shapes wanted in the piece. Cutting off in


Drilling. Way to obtain the round sha

Grinding. It is important for a mould to fit perfectly to produce regular and good



completely, first roughing until there is little thickness left to take out, then a finishing



Mechanization








Drilling. Way to obtain the round sha

. It is important for a mould to fit perfectly to produce regular and good



ghing until there is little thickness left to take out, then a finishing


Mechanization




you. For that, mould plates need to be mechanized.




Drilling. Way to obtain the round shapes through the pieces


the mould there is a non standardized piece (Plate 4


Although most pieces are directly taken from catalogs with standardized models, only



.



pes through the pieces


(Plate 4) which have to be mechanized


alogs with standardized models, only





pes through the pieces


which have to be mechanized










42









7.Thermal

For the thermal treatment there are basically two types to be taken in account:

tension the first treatment provoked. The result is a harder steel than the one in the

beginning with

them last without degrading excessively by i

(Rockwell hardness). Higher values are needed in pieces that slide to minimize friction

degradation such as Plate 3 and 4, but being careful not to harden it too much to prevent

brittle behaviors of the pieces.

first layers of material in the surface preventing them from the harm of friction. That is

why is done at the parts that move guided such as ejection pins or column gui

Depending on where normalized pieces bought those thermal treatments may be already

done but depending on the situation a different treatment would be needed anyway

mould singularities such as our example that need different Rc in some pieces


Thermal


-Quench and temperate. It consists in hardening


beginning with





-Nitriding.







Thermal t


Quench and temperate. It consists in hardening


good ductile properties. Is done basically in the structural pieces to make





Nitriding. It consists in a superficial treatment that deposits nitrides in the very







treatment









It consists in a superficial treatment that deposits nitrides in the very






reatment





them last without degrading excessively by its use.










Quench and temperate. It consists in hardening the piece and then releasing the



ts use. The final hardness is measured by Rc










the piece and then releasing the



The final hardness is measured by Rc


















why is done at the parts that move guided such as ejection pins or column guiders.


done but depending on the situation a different treatment would be needed anyway due to

mould singularities such as our example that need different Rc in some pieces.

43










due to


8.Budget

The final cost is totally approximated and may change significantly depending on the

mechanizing hours which have a huge weight in the final price

of the standardize items the hours can be reduced also.


Budget

final cost is totally approximated and may change significantly depending on the

chanizing hours which have a huge weight in the final price



Budget resume




Extra pieces

Standardized pieces

Thermal treatments

Mechanized and finishing

Other costs

+21% IVA

Total Mould Cost


resume




Extra pieces

Standardized pieces

Thermal treatments


Other costs

+21% IVA

Total Mould Cost

resume




Standardized pieces

Thermal treatments


Total Mould Cost




250

1.558

600

Mechanized and finishing 12.000

1.230

3.284

18.922


chanizing hours which have a huge weight in the final price. Depending on the quality

250€

1.558€

600€

12.000€

1.230€

3.284€

18.922€


. Depending on the quality

44

. Depending on the quality


9.Conclusions

As it has been seen, breathing mould is a simple idea mould with a not so simp

application. The spring system may not be technically the best for testing but surely it is

the cheapest an

personalized simplifying things such as refrigeration, but in the end the price increase

would had been huge.

This project stopped in the design state defining (or

a mould designer have to do before beginning to produce any piece. Next step would be

buying all the normalized items and beginning to thermally treat and mechanize the ones

which need that.

Finally just a reminder of what this technology r

products can be improved and that begins with big investing companies such as the

automotive ones doing what this project is aimed to, testing new technologies and

bringing them to the industry first making profit of it b

other companies.


Conclusions



the cheapest an






which need that.





other companies.


Conclusions



the cheapest and assures good quality pieces. The project could had been completely






which need that.





other companies.


Conclusions



d assures good quality pieces. The project could had been completely
























This project stopped in the design state defining (or approximately defining)



Finally just a reminder of what this technology represents, a whole new spectrum of



bringing them to the industry first making profit of it but inevitably spreading it





approximately defining)



epresents, a whole new spectrum of



ut inevitably spreading it





approximately defining) all the things






ut inevitably spreading it to the

45

As it has been seen, breathing mould is a simple idea mould with a not so simple




all the things






to the


Acknowledgements

I would like to specially thank to my project tutor Miguel Sánchez for being

comprehensive of my mistakes and for guiding

plastics

Also, of course, my family

And to my recent English teacher Nicky who I hope never reads this project or else I will

be degraded to a lower course.

Finally I would like to thank to all the other peopl

more external way but enough to make me think twice and improve what I was doing.


Acknowledgements



plastics which I was rece

Also, of course, my family






Acknowledgements



which I was recently presented with.

Also, of course, my family that gave me support every moment.






Acknowledgements



ntly presented with.

that gave me support every moment.





Acknowledgements


comprehensive of my mistakes and for guiding and helping

ntly presented with.



Finally I would like to thank to all the other people in CCP and friends that helped me in a



and helping me



e in CCP and friends that helped me in a



me entering this world






this world of




46

of





Bibliography

References

GÓMEZ, J.F. (2013) Caracterización y estudio comparativo de materiales celulares poliméricos obtenidos mediante moldeo por inyección con espumación física o química.Doctoral Thesis. SPÖRRER, N.J. (2007) Controlling Morphology of Injection Molded Structural FoamsMold Design and Processing

Norms

Notes

Catalogs

Websites

TREXEL INC.

[Online]Available from:

http://www.trexel.com/en/mucell

[Accessed on 10th May]


Bibliography

References

GÓMEZ, J.F. (2013) Caracterización y estudio comparativo de materiales celulares iméricos obtenidos mediante moldeo por inyección con espumación física o química.

Doctoral Thesis.

SPÖRRER, N.J. (2007) Controlling Morphology of Injection Molded Structural FoamsMold Design and Processing

Norms

• [1]UNE

• [2] UNE

Notes

• The injection moulding machine / Miguel Sánchez

Catalogs

• HASCO catalog

Websites

TREXEL INC. MuCel





Bibliography


SPÖRRER, N.J. (2007) Controlling Morphology of Injection Molded Structural FoamsMold Design and Processing

[1]UNE-EN ISO 178 Pl

[2] UNE-EN ISO 527

The injection moulding machine / Miguel Sánchez

HASCO catalog

MuCell Molding Technology





Bibliography


SPÖRRER, N.J. (2007) Controlling Morphology of Injection Molded Structural FoamsMold Design and Processing Parameters

EN ISO 178 Plastics.

EN ISO 527-2 Pl


HASCO catalog

l Molding Technology

http://www.trexel.com/en/mucell-injection


SPÖRRER, N.J. (2007) Controlling Morphology of Injection Molded Structural FoamsParameters. JOURNAL OF CELLULAR PLASTICS

stics. Determination of flexural properties

2 Plastics. Determination of tensile properties


l Molding Technology

injection-molding


SPÖRRER, N.J. (2007) Controlling Morphology of Injection Molded Structural FoamsJOURNAL OF CELLULAR PLASTICS

Determination of flexural properties

Determination of tensile properties


molding


SPÖRRER, N.J. (2007) Controlling Morphology of Injection Molded Structural FoamsJOURNAL OF CELLULAR PLASTICS



The injection moulding machine / Miguel Sánchez-Soto


SPÖRRER, N.J. (2007) Controlling Morphology of Injection Molded Structural Foams by JOURNAL OF CELLULAR PLASTICS Vol. 43



47

iméricos obtenidos mediante moldeo por inyección con espumación física o química.

by



In this chapter it is determined the environmental impact associated to this project in

particular.

The CC

regarding final projects done in their installations.

In the beginning of a new PFG student, he is given a questionnaire where he has to fill with

the different activities which h

environmental surface impact.

Objectives:

Elec

1 KwH = 0,264 KG

Quan

Plac

Desk

Vario

TOT




particular.

The CCP has a system of environmental management which controls several parameters





Objectives:

• Determine the environmental impact of each PFG done in CCP

• S

the implantation of the

ctrical co

1 KwH = 0,264 KG

ntity of CO2

ce Co

k Co

ous Lig

TAL ESTIMA




P has a system of environmental management which controls several parameters





Determine the environmental impact of each PFG done in CCP

Sensitize the students regarding environmental impact of their project and

the implantation of the

onsume

1 KwH = 0,264 KG of CO2

2 absorbed p

oncept

omputer

ghts

ATED







the different activities which have their energetic consumption and the equivalent in



the students regarding environmental impact of their project and

the implantation of the environmental management system.

per hectare a






ave their energetic consumption and the equivalent in



environmental management system.

and year= 4,58 Tn

Time in h

40

100









= 4,58 Tn of CO

Power in

11

0.1









CO2

n Kw Kwh

440

10

Kwh

450








Kg CO2

118.8

48






Kg CO2 Hecta

0.026

ares


Mob

1 l of

1l of

Tran

Walk

Train

TOTAL ESTIMA

Fina

Envi

Elect

Mob

TOTAL ESTIMA


bility

f gasoline = 0

gasoline = 4

nsport

king

n

TOTAL ESTIMATE

al values

ironmental

ctrical consu

bility

TOTAL ESTIMAT


0,88 kg CO2

40MJ

Km.

15

3200

ED

s

l Aspect kg CO2/Pro

ume 11

25

TED 14


2

MJ/Km.

0,16

0,35

kg CO2/Project

18.8

5.06

43.86

MJ

2.4

1120

ject

Equivalent

l of gas

0,48

28

MJ

1122.4

Hectares

0.026

0.0055

0.0315

Equivalent in

soline Kg CO2

0,4224

24.

Kg CO2

4 25.

Kg CO2

0,4224

.64

Kg CO2

.06

49

Hectares

0.0055

2 13

11

67 5 4

8

9

10

22

20

19

18

16

17

21

2324

14

15

12

13

Mould assembly Est.sup.UNE 1037/Tol.gral.ISO 2778-K/Tol.geom.ISO 2778-m

Calificación:Fecha:Escala:

A1

Código plano:

Denominación plano:

Denominación proyecto:Escola d'Enginyeria de Terrassa - E E T Expansible Injection Mould

Design

a1 1 : 2 16/05/15

Buch Cardona, Eloi

396

76

105

23

246

64,2

84,

9

79,

1

102,6

19,

8

G

G

38 H7

18 H7

1x4

5º

3x4

5º

4,1

21,

1

27

15,5

20

14

30

15,8 13,2

M8

SECTION G-G

N6

20,

4

M8

15

1. ( )

Mechanization-Hole for the nozzle-Threads for subjecting-Housing stopper

N8 N6

Buch Cardona, Eloi

16/05/151 : 2p1


Escola d'Enginyeria de Terrassa - E E TDenominación proyecto:


Código plano:

A3

Escala: Fecha: Calificación:

Est.sup.UNE 1037/Tol.gral.ISO 2778-K/Tol.geom.ISO 2778-mPlate 1SolidWorks Student Edition. For Academic Use Only.

296

246

85,5

121

,5

26

55

23

H

H

36

36

30

6,3

22,

1 18 M12

17,

6

SECTION H-H

2.

Mecanization-Hole for the nozzle

N8

Est.sup.UNE 1037/Tol.gral.ISO 2778-K/Tol.geom.ISO 2778-m


A3

Código plano:


Denominación proyecto:

Escola d'Enginyeria de Terrassa - E E T Expansible Injection Mould Design

p2 1 : 2 16/05/15

Buch Cardona, Eloi

Plate 2SolidWorks Student Edition. For Academic Use Only.

130

72,

6

152

,6

70

226

70

106

70

166

60

192

,6

128

,6

125

80

70

8x4

5º

29

40

81,

5

81,5

I

I

N8 N6

N6

M10 2

5

30

16

10

8

36 10,2

29,

7

SECTION I-ISCALE 1 : 2

N6 N6

3. ( ) Refrigeration view

Mechanization-Piece shape through-Spring housing-Refrigeration drills

Plate 3 Est.sup.UNE 1037/Tol.gral.ISO 2778-K/Tol.geom.ISO 2778-m


A2

Código plano:



Design

p3 1 : 2 16/05/15

Buch Cardona, Eloi

SolidWorks Student Edition. For Academic Use Only.

296

246

125

29

8x4

5º

81,

50

81,50

128

,61

70

40

A

A

N6

N6

25

75

26

23

55

75

25

52 119

126

3

3

74

37

100

1

50

181,50

18

51

100,04 122,55

112,55

30

14 4

30

10

20 36 5

7 70

SECTION A-AN

6

4. ( ) Refrigeration view

Mechanization complete-Mechanize inner protuberance-Drill guider holes-Drill screw threads-Drill ejectors path-Drill refrigeration-Drill spring housing

N8



A1

Código plano:



Design

p4 1 : 2 16/05/15

Buch Cardona, Eloi

119

74

37

84,5

43,

5 6

,9

28,

9 52

33

14

296

158

126

I

I 1

2

6,8

4 H7

8 9

3

SECTION I-I

N6

5. ( )

Mechanization-Ejector pins housing

N6N8



A3

Código plano:



Design

p5 1 : 2 16/05/15

Buch Cardona, Eloi


296

158

16

33

14

210,5

H

H

11 1

1

11 3,3

15 9

17

M14

9,3

SECTION H-H

6.

Mechanization-Expulsion rod thread

N8



A3

Código plano:



Design

p6 1 : 2 16/05/15

Buch Cardona, Eloi


76

105

23

246

396

H

H

90 4

20

14

30

27

15,

5 135,5

SECTION H-H

7.

Mechanization-Space for theinstallationand acting of the ejection rod

N8



A3

Código plano:



Design

p7 1 : 2 16/05/15

Buch Cardona, Eloi




Part 2 Budget



2014-2015



Director: Miguel Sánchez-Soto


Buch Cardona, Eloi

Index

Standardized pieces...........................................................................3

Extra pieces.......................................................................................4

Mechanization..................................................................................5

Thermal treatments..........................................

Other costs.......................................................................................7

Final budget.....................................................................................8



a pieces.......................................................................................4

Mechanization..................................................................................5

Thermal treatments..................................................................

Other costs.......................................................................................7

Final budget.....................................................................................8

2


a pieces.......................................................................................4

Mechanization..................................................................................5

.........6

Other costs.......................................................................................7

Final budget.....................................................................................8


Buch Cardona, Eloi

Standardized pieces

Usually in moulds some standardized pieces are used such as guides, screws, retainers

and so, but other items like plates are often fully personalized to have a bigger

freedom to design their own mould. That also increases the price so in this case if

possible it has been taken the maximum standardized pieces by the fact that the

mould is not being designed t

the standard elements are enough for what is wanted.

Name

Centering disk

Allen screw

Spring washer with detent

Allen screw

Stop washer

Spring washer with retent

Countersunk screw

Allen screw

Centering bush

Bushing guide

Column guide

Refrigeration male nozzle

Threaded plug

Ejector

Spring

Transport flange

Limiter screw

Nozzle

Plate1

Plate2

Plate3

Plate5

Plate6

Plate7


Standardized pieces


tems like plates are often fully personalized to have a bigger



being designed to produce many pieces and the lower quality

the standard elements are enough for what is wanted.

Code/Size Price/u(€) Qty,

K100 - 125x8 25,25 1

Z31 - 12x120 2,11 4

Spring washer with detent Z691 - 12x5 0,13 8

Z31 - 12x30 0,52 4

Z55 - 18x3 0,62 4

Spring washer with retent Z691 - 12x2 0,13 4

Z33 - 4x8 0,25 4

Z31 - 8x16 0,22 4

Z20 - 30x100 6,44 4

Z10 - 36 - 24 12,62 4

Z00 - 36 - 24x55 17,1 4

Refrigeration male nozzle Z87 0,76 8

Z94 0,3 7

Z40 - 4x100 2,83 7

Z60 - 25x30 18,5 4

Z70 209,73 1

Z38 - 16x30 5,69 4

Z51 - 18x27 36,46 1

K12-246x296x27 173,03 1

K20-246x296x36 114,23 1

K20-246x296x36 114,23 1

K70-246x296x17 80,47 1

K12-246x296x17 173,03 2

K12-246x296x27 173,03 1

TOTAL

3


tems like plates are often fully personalized to have a bigger



quality provided by

Price(€)

25

8

1

2

2

1

1

1

26

50

68

6

2

20

74

210

23

36

173

114

114

80

346

173

TOTAL 1.558€


Buch Cardona, Eloi

Extra pieces

In this mould the only customized piece is the Plate4 which have a huge protuberance in the

middle and any standard item have enough d

piece would also had been possible to produce with a standardized plate with a thin housing

for a steel block that would be bounded by screws in the bottom of the plate.

A regular 1.1730 steel is used taking the other plates as similars. The price includes the exterior

sizing.

In this case the decision of taking standardized elements really reduces the final price although

some design changes have to be done in terms of piece position, refrigeration and spring

position for example.

Name Code/Size

Plate4 block 246x296x70


Extra pieces


middle and any standard item have enough dimensions to take it and then mechanizing it. The





esign changes have to be done in terms of piece position, refrigeration and spring

Code/Size Price/u(€) Qty, Price(€)

246x296x70 250 1 250

4


imensions to take it and then mechanizing it. The





esign changes have to be done in terms of piece position, refrigeration and spring


Buch Cardona, Eloi

Mechanization

Although most pieces are directly taken from catalogs with standardized models, only with

them is not enough. Pieces such as guides and

Standardized plates have only the guidance and thread holes and lets the design up to you. For

that, mould plates need to be mechanized.


-Milling. The main way to achieve th


-Drilling. Way to obtain the round shapes through the pieces

-Grinding. It is important for a mould to fit perfectly to prod


The non standardized piece (Plate 4

until there is little thickness left to take out, then a finishing rough and finally grinding it.

The approximate number of hours working in Plate 4 are

The approximate number of hours working in the standardized elements including plates are

200h.

Workshop cost per hour is 40

The amount in hours is appro

as tolerances. Pieces entering

changes that increase the fina


Mechanization


them is not enough. Pieces such as guides and screws don't need changes but plates do.


that, mould plates need to be mechanized.




Drilling. Way to obtain the round shapes through the pieces

Grinding. It is important for a mould to fit perfectly to produce regular and good


(Plate 4) which have to be mechanized completely, first roughing


approximate number of hours working in Plate 4 are 100h.


40€

oximate and depend on the final finishing wanted

g or being entered need special care and that req

al hour amount.

TOTAL COST OF MECHAN

5


screws don't need changes but plates do.


e shapes wanted in the piece. Cutting off in


uce regular and good

) which have to be mechanized completely, first roughing



d in pieces as well

quires several tool

NIZATION: 12000€


Buch Cardona, Eloi

Thermal treatments

For the thermal treatment there are basically two

-Quench and temperate. It consists in hardening the piece and then releasing the

tension the first treatment provoked. The result is a harder steel than the one in the beginning

with good ductile properties. Is done basical

without degrading excessively by its use. The final hardness is measured by Rc (Rockwell

hardness). Higher values are needed in pieces that slide to minimize friction degradation such

as Plate 3 and 4, but being careful not to harden it too much to prevent brittle behaviors of the

pieces.

-Nitriding. It consists in a superficial treatment that deposits nitrides in the very first

layers of material in the surface preventing them from the harm of friction. That i

at the parts that move guided such as ejection pins or column guiders.



mould singularities.

Nitriding the mobile parts have an approximate cost of 200

Quenching and tempering all the plates have an approximate cost of 400


Thermal treatments




with good ductile properties. Is done basically in the structural pieces to make them last



g careful not to harden it too much to prevent brittle behaviors of the

Nitriding. It consists in a superficial treatment that deposits nitrides in the very first

layers of material in the surface preventing them from the harm of friction. That i

at the parts that move guided such as ejection pins or column guiders.



Nitriding the mobile parts have an approximate cost of 200€.

Quenching and tempering all the plates have an approximate cost of 400€

TOTAL COST OF THERMAL TREATMENTS: 600

6

types to be taken in account:



ly in the structural pieces to make them last



g careful not to harden it too much to prevent brittle behaviors of the

Nitriding. It consists in a superficial treatment that deposits nitrides in the very first

layers of material in the surface preventing them from the harm of friction. That is why is done


done but depending on the situation a different treatment would be needed anyway due to

TOTAL COST OF THERMAL TREATMENTS: 600€


Buch Cardona, Eloi

Other costs

In extra costs there are design

In design, combining the mod

related to the production pre

With the technical office base

Transporting and mounting th


n and mounting.

del design, 3D CAD development, CAD-CAM evalu

evious work, the amount of hours dedicated are 3

e pay of 30€ per hour it makes a total of 1050€

he mould is set at 6h at a price of 30€ makes a to

TOTAL COST OF DESIGN AN

7

uation and work

35h.

otal of 180€

ND MOUNT: 1230€


Buch Cardona, Eloi

Final Budget

Extra pieces

Standardized pieces

Thermal treatments


Other

+21% IVA

Total Mould Cost

The final cost is totally ap

mechanizing hours which hav

standardize items the hours c


Final Budget

Extra pieces 250€

Standardized pieces 1.558€

Thermal treatments 600€

Mechanized and finishing 12.000€

costs 1.230€

+21% IVA 3.284€

Total Mould Cost 18.922€

pproximated and may change significantly de

ve a huge weight in the final price. Depending on

can be reduced also.

8

epending on the

n the quality of the

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