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David O. Kazmer
Injection Mold Design Engineering
Preface
6
Contents
8
Nomenclature
16
1 Introduction
22
1.1 Overview of the Injection Molding Process
22
1.2 Mold Functions
24
1.3 Mold Structures
25
1.4 Other Common Mold Types
30
1.5 The Mold Development Process
34
1.6 Chapter Review
36
2 Plastic Part Design
38
2.1 The Product Development Process
38
2.2 Design Requirements
41
2.3 Design for Injection Molding
49
2.4 Chapter Review
56
3 Mold Cost Estimation
58
3.1 The Mold Quoting Process
58
3.2 Cost Drivers for Molded Parts
60
3.3 Mold Cost Estimation
64
3.4 Part Cost Estimation
81
3.5 Chapter Review
87
4 Mold Layout Design
88
4.1 Parting Plane Design
88
4.2 Cavity and Core Insert Creation
95
4.3 Mold Base Selection
98
4.4 Mold Material Selection
105
4.5 Chapter Review
110
5 Cavity Filling Analysis and Design
112
5.1 Overview
112
5.2 Objectives in Cavity Filling
113
5.3 Viscous Flow
115
5.4 Validation
123
5.5 Cavity Filling Analyses and Designs
125
5.6 Chapter Review
138
6 Feed System Design
140
6.1 Overview
140
6.2 Objectives in Feed System Design
140
6.3 Feed System Types
144
6.4 Feed System Analysis
153
6.5 Practical Issues
171
6.6 Chapter Review
179
7 Gating Design
182
7.1 Objectives of Gating Design
182
7.2 Common Gate Designs
184
7.3 The Gating Design Process
196
7.4 Chapter Review
203
8 Venting
206
8.1 Venting Design Objectives
206
8.2 Venting Analysis
207
8.3 Venting Designs
213
8.4 Chapter Review
218
9 Cooling System Design
220
9.1 Objectivesin Cooling System Design
220
9.2 The Cooling System Design Process
222
9.3 Cooling System Designs
240
9.4 Chapter Review
253
10 Shrinkage and Warpage
254
10.1 The Shrinkage Analysis Process
256
10.2 Shrinkage Analysis and Validation
268
10.3 Warpage
273
10.4 ChapterReview
278
11 Ejection System Design
280
11.1 Objectives in Ejection System Design
282
11.2 The Ejector System Design Process
286
11.3 Ejector System Analyses and Designs
299
11.4 Chapter Review
317
12 Structural System Design
320
12.1 Objectives in Structural System Design
321
12.2 Analysis and Design of Plates
327
12.3 Analysis and Design of Cores
346
12.4 Fasteners
353
12.5 Review
361
13 Mold Technologies
364
13.1 Introduction
364
13.2 Coinjection Molds
364
13.3 Insert Molds
371
13.4 Injection Blow Molds
376
13.5 Multi-Shot Molds
379
13.6 Feed Systems
385
13.7 Mold Wall Temperature Control
393
13.8 In-Mold Labeling
399
13.9 Ejection
402
13.10 Review
409
Appendix
410
Appendix A: Plastic Material Properties
411
Appendix B: Mold Material Properties
415
Appendix C: Properties of Coolants
419
Appendix D: Statistical Labor Data
420
Appendix E: Unit Conversions
423
Appendix F: Advanced Derivations
426
Bibliography
430
Subject Index
434
The Author
445
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