This book provides design engineers, toolmakers, moulding technicians and production engineers with an in depth guide to the design and manufacture of mould tools that work successfully in production. It highlights the necessity to design a mould tool that allows overall production to make an acceptable profit, and whilst it is recognised that not all design engineers will be able to influence the profitability factor it is an important aspect to consider.
The guide focuses on designs that will produce the required production rate and quality of mouldings in a consistent and reliable fashion; the key components of a successful mould tool. The introductory chapters outline the injection moulding process, basic moulding parameters and overall machine construction. Dedicated chapters give a full account of all the variables that should be taken into account.
All the major types of mould tools are covered in the text including two plate, three plate, split, side core, stack and hot runner. Also, some less frequently used designs are discussed including multi plate and rotary side core moulds. Additionally, there are chapters devoted to stress analysis and fatigue.
The theme through the book is based on design simplicity. The simpler the design of the mould is, the more likely it is to provide trouble free mouldings. The information contained in this book is based on over thirty five years experience in the injection moulding industry and on over 3,000 successful mould designs. It contains many tips, wrinkles and tweaks discovered over this period to equip the reader with information that will contribute significantly to successful mould tool designs and avoid common pitfalls.
There are many data tables, design examples and a gallery of full mould designs included so that useful information may be referenced quickly. A glossary of injection moulding terms gives a full explanation of the required terminology.
"An excellent treatise of reference for mould designers, tooling engineers, production engineers and others associated directly or indirectly with injection mould tooling."
Mr Rangarajan, Popular Plastics and Packaging Vol.LIII - No. 4 April 2008
2 The Injection Moulding Process
3 Plastics Materials
4 Good Design Practice
5 Design Checklist
6 Determining the Right Number of Impressions
7 Step-by-Step Design
9 Two-Plate Mould Tools
10 Ejection Systems
11 Mould Temperature Control
12 Undercut Injection Mould Tools
13 Automatic Unscrewing Mould Tool Design
14 Multiplate Tool Systems
15 Runnerless Moulding
16 Mould Materials
17 Runner and Gate Design
18 Standard Mould Parts
19 Deflection and Stress in Mould Components
21 Limits and Fits
22 Impression Blanking
23 Summary of Mould Calculations
24 Integrated Design Examples
25 Mathematical and Reference Tables
26 Glossary of Moulding Terminology
Peter Jones is a practising Consulting Engineer with over thirty five years experience within the plastics industry. He has wide experience of mould tool design, toolmaking and production management, and he has worked for a number of well-known companies including ICI, United Gas Industries and Smiths.
During his time as an employee he held positions of Chief Mould Designer, Technical Manager, Production Director and Managing Director – all within the injection moulding industry. In his capacity as a consulting engineer, he has advised several well known national and international companies in the engineering, medical, pharmaceutical, electronic, consumer industries and oil industry on mould design and construction, processing, production and management. In project management roles he has been responsible for setting up complete injection moulding plants for both internal use and as stand-alone units.