Not all problems require the expense and complexity of FEA software. You can calculate many common mold design problems with programs that only require you to enter sizes, forces or other known quantities, including the following:
Reynolds Number to determine if your flow rate is turbulent or laminar. (Turbulent flow is important in cooling because it increases heat transfer. Laminar flow is important for hydraulic systems, so that the oil doesn’t absorb too much heat, which causes the oil viscosity to deteriorate).
Pressure lost through a waterline, bubbler, hose, cooling passage, etc.
How much a leader pin (core pin, ejector pin, etc.) will bend when a load is applied.
The thermal expansion for various materials that go through changes in temperature.
How much a screw, or any item in tension, will stretch.
The gallons per minute of hydraulic oil required to activate a hydraulic cylinder.
The amount a cylinder or cavity will expand due to internal pressure.
How much will a mold plate for a side action mold expand and deform due to molding pressure.
Trigonometric, electrical, production and machining problems and much more
Basically they are the problems that you can solve with a calculator, if you know or have time to find and solve the equations. This type of software organizes what a mold designer might have in his notebook binder and then automates the calculation, which reduces the risk of error.
This software acts like an intelligent calculator to solve deflection and stress in common geometric shapes (e.g., mold plates), long column buckling (e.g., ejector pins), and expansion and compression due to loading. Thermal expansion constants for various materials are available, as well as the ability to calculate the initial size, final size or the total expansion. You also can determine runner and gate sizes and shop calculations, such as effective cutting diameter, trigonometry, tooling ball dimensions, roll dimensions, etc.
These packages are very easy to use and require no training. They eliminate the drudgery and potential for errors, compared with manual calculations.
Simply choose the type of calculation you want, enter the information required and press calculate. The answers appear in a flash. They also can be a great source of reference information, such as hot runner checklists, galvanic tables, screw thread properties, three wire measurements, unit conversions, gate and runner sizes and material properties.
Calculating software is often used to check the output from an FEA package to make certain that the results make sense. For instance, while looking at the results of a cooling analysis it was noticed that there was only one Reynolds Number shown for a water bubbler inside a core pin. It was then asked, “Is that the inside of the bubbler or the outside?”
Using the calculator software, the flow rates shown on the FEA images were used to calculate the Reynolds Number inside the bubbler, calculate the equivalent hydraulic diameter between the bubbler and the drilled hole in the core, and finally the Reynolds Number of the area outside the bubbler.
Whatever your engineering calculation software requirements, choose the option that performs the type of analysis you need. Look at the training required and support needed, then after being shown that the software delivers what you need, use it.
Over-designing your molds is expensive, under-designing is more expensive and often disastrous. Under-design often results in a mold failure, and not all of them are repairable.
Molds are occasionally designed and built where the plates are not strong enough to withstand molding pressure. This is particularly true of “A-side” side-action molds, which results in flashed parting lines. Using the improper sizes for bubblers and holes results in unnecessary pressure losses or poor cooling, and can increase the cycle time.
Injection molding is one of the technique and methodology to create mold of various complex shapes with more detailed structure. The techniques involve various parameters to be checked for effective output. This should be done on design stage itself. We have come up some suggestion on how to approach an injection molding process. Simplified design the problems which may occur in the development phase of the product are solved in the design phase itself. Aim of the work is to calculate the injection mold parameters using pro/plastic Advisor. Using diametral method 3D model of the spur gear is created in PRO/E system. The 3D model spur gear is imported in the Pro Plastic Advisor to perform Numerical simulation. The physical Mold orientation, the dimensions for each of the element in the Mold, the location of the gate, runner, requirement of insert, draft angle requirement, shrinkage factor, location of cooling channels were calculated using Pro Plastic Advisor. Pro Plastic Advisor results give confident to designers to ensure the quality components. The correct Injection molded parts can be molded by concentrating on these areas of plastic technology is proper design and material selection included with material processing.
Plastic shrinkage or mold shrinkage is an important consideration when designing any part for injection molding. The two terms may be used interchangeably but it is important to note that mold shrinkage refers to the dimensional change of the injection molded object as it cools, while plastic shrinkage can be used to refer to the characteristics of a specific plastic. Designers must take into account the shrinkage and contraction rate of the injected material and how that will affect the shape of the part.
Mold shrinkage is the dimensional change that occurs in a molded part as it cools after injection. Mold shrinkage is usually stated as a percentage. Most of the shrinkage occurs while the part is still within the molding tool during the cooling stage, but a small amount of plastic shrinkage may occur after ejection, as the part continues to cool. This is especially true for plastic materials like Delrin or Polyoxymethylene.
The majority of excess heat has been already dissipated and the most of shrinkage has occurred before the part is ejected from the mold. The part may continue to shrink slightly for several hours or even days until the temperature and moisture content stabilize to match the surrounding environment. Any dimensional inspection should wait at least a day after part ejection to maintain consistency and suitable part stabilization
Basically they are the problems that you can solve with a calculator, if you know or have time to find and solve the equations. This type of software organizes what a mold designer might have in his notebook binder and then automates the calculation, which reduces the risk of error.
In the last 10 years engineering tools for the mold designer have become much less expensive and the need to use these tools to be more competitive is imperative. The minimal expense of calculation-assist software should make this an easy decision. Due to their expense, FEA tools will require more thought and justification. Given the relative ease-of-use and broad range of problems solved maybe the time is right for your company to invest in these tools. Next year might be too late.
Many professional engineers have developed many powerful plug-ins for mold design, which greatly improves the efficiency of mold design
I am a junior mold designer. I learned the correct mold design method from this article. Thank you very much.
Now the mold design CAD software is more and more intelligent, CAD software calculation assistant functions can replace the manual calculation
Have you ever wondered how many cavities your machine is suitable for when calculating the number of cavities in an injection mold design? I don’t think you would want to use a 250-ton machine to produce small items, which is very wasteful. Your money. How to calculate the number of cavities in the injection mold is crucial to the selection of the mold.
The number of cavities in the mold is the first requirement to pay attention when designing the injection mold. Because after determining the number of cavities, the gate, runner, die size, ejection system, etc. are also designed according to the number of cavities.
When a mold needs a set of hot runner system, our mold designer must communicate with the engineers of the professional heat channel company.
In our CAD system, our company has added the mold design standard database, and the mold designers only need to design molds according to the requirements.
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calculation assistance? in our CAD system,We have a database specifically designed for mold design, and maybe this is what you call design assistant
A good mold designer actually needs to know a lot of things!
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actually mold design need a complete database, including design standard, material,Mold standard parts and so on.
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there are many kinds of calculation assistance to help your mold design, as for how to choose, it depends on your company
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every mold company has it’s own experience in mold manufacturing
actually Database is a design assistance for every mould designer
For different product types and different mould company, they should have different design standards
as an excellent mold designer, maybe they knew how to do
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very important note! as a mold designer, I want to say your sharing will benefit many mold desiners
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A lot of design data has been integrated into CAD/CAM software
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Now CAD/CAM/CAE technology is more and more popular in mold industry, that kind of requirement is very easy to come true
in my opinion,The database is very important
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now in many professional CAD/CAM/CAE softwares, there are many specialized modules you can use, including mold design
yes! we need it:-)
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maybe different mold company has different calculation assistance in mold design
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that is an important process, calculation Assistance helps mold designers a lot
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every mold designer in our company has An uniform mold design handbook. yes! that is very important
I agree with you at all especially for fresh mold designers
yes! you are right! that is very important in mold design
actually every mold design need many Repeat calculations.
as a mould designer, I agree you at all
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Actually if you do secondary development for your design software, then it will completely meet your requirement
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our mold dsigners like your blog, always like to read and discuss
your suggestion is very good, also we do it like that
maybe our deisgn manual is what you said
Calculation assistance can promote your design efficiency
your suggestion is really useful for us
yes! we need it.
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I think calculation assistance should be a database
Calculation assistance is very important for a mold designer
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our mold designers agree your opinion
We can use all the deign dates to develop a small software, then our designers can use it easily
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yes! we need calculation assistance in our mold design.
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Your experience is right, we also do it like this
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as a mould designer, I do have calculation assistance at hand:-)
Yes, in our company, every mold designer has a mold design handbook
These datas are very flexible, every mold designer must be flexible to use
actually each company has it’s own design manual to guide designers
An experienced mold designers will know how to solve these problems
yes! these suggestions are very useful, I will recommend to our mold designers
a professional database really help your designers
Your experience has given a great enlightenment to us
Our company has a set of strict design rules, each mold designer must strictly implement
This blog should recommend to every mold company, it is very useful for them
This is why every new designer must be trained before working in a new mold company
your experiences are very useful for a mold designer, You must be a mold expert
You are exactly right, In our company, we also have our own experience parameters
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In fact, I feel it more like the use of empirical data
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Hello, as a beginner in mold design, these tips you mentioned will help me a lot, thanks a lot
Mold design requires designers have enough Flexibility
I think, for a senior mold designer, maybe he has an other saying:-)
for a senior mold designer, those datas are in their mind.
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The latest CAD/CAM integration software has a professional mold design module,Each mould company just set up their own database
Hi Your design concept has been ahead of ours, we should learn from you
every company develops their own calculation assistant according to their actual need
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I am in fact thankful to the owner of this website who
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