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The parts were 1.5 mm (.06") thick round chips, 19 mm (.75") in diameter with a 5 mm (.20") high wall running around their diameter. A copper chill-plate mounted on the back of the tool provided cooling to the cores. Four baffles on each side of the tool delivered water to the cavities. Both the A and B plates were cooled using ¼ NPT water lines configured in a single circuit around the perimeter of the tool. The cavity and core retainer plates were made from hardened H13 (R c54). The dynisco injection molders handbook registration#Registration of the cavities and cores was assured through the use of four mold side interlocks. Die springs and early return pins provided pre-return of the ejector plates and sleeves. Each sleeve had vacuum release hole to aid in part ejection. Parts were ejected using ion nitrided (R c 65-74) ejector sleeves at the parting line. The mold had four point guided ejection using bronze plated bushings. A DME straight-shot hot sprue bushing was used. The experiment used a geometrically balanced eight-cavity mold with edge gate. Tests were conducted as part of the ongoing long term wear study at Western Michigan University and were coordinated with the evaluation of other aspects of wear during the molding process. Uncoated copper alloys and standard tool steels were tested along with a variety of hard coatings and platings applied to the copper alloys. The focus of this research was the resistance of various mold materials to the wear forces applied by the part to the core during ejection. However, there has been the general perception that high thermal conductivity materials, specifically copper alloys lack the requisite wear resistance needed for longevity in high wear applications 2. Thus high thermal conductivity materials were shown to be the logical choice for cores and core like structures. Past research work has concluded that between 60% and 80% of all heat that must be given up by a molded part is transferred to the mold core 1. Surface hardness has either been achieved through a change in the type of steel, heat treatment, or by using a hard plating or coating. Second, increased mold surface hardness is a first line defense against wear of the surface. First, the polishing of smooth surfaces tends to decrease the amount of mechanical interlock between the molded part and the molding surface. The traditional approach for reducing wear of cores and certain cavity faces, has been twofold. In a normally cored part, the product tends to shrink onto the core, thus increasing the drag forces applied between the part and the core during ejection. This can be especially acute in areas of zero draft and in deeply cored areas, pins to provide holes for threaded fasteners. The molder and mold maker are faced with the knowledge that some parts can cause significant wear to the core and cavity faces. However, one of the major methods for the reduction of wear, lubrication, in most metal to metal systems is largely inappropriate by todays standards of part ejection. A mixture of shared experience and common sense stands as the basis for understanding ejection wear. Many of the things learned about sliding and rotating interfaces in metal to metal systems can be applied to the stripping and sliding interface that occurs between the mold and plastics products during the opening and ejection cycle. Both sliding interfaces such as pistons and cylinder bores and rotating interfaces including bushings and shafts, or anti-friction bearings are well understood. Much attention has been paid over the last century to the wear of metal-to-metal interfaces. The study of wear, or tribology predates injection molding. In addition, product geometry appeared to play a role in the wear process. Certain tool steels and copper alloys with hard coatings were shown to be significantly more resistant to this type of wear than others. This phenomenon has been largely undocumented, and was, in some cases, found to be aggressive. This research focused on wear that occurred on the metal core during ejection of glass filled plastic parts. Specifically, attention is paid to the wear between the pins, sleeves, blades, and the bores through which they pass. Philip Guichelaar, Western Michigan University, Kalamazoo, MI Michael Monfore, Johnson Controls Inc., Holland MI Abstractĭuring mold design, most consideration given to wear in the ejector system is focused on metal-to-metal interfaces. Undercutting Mold Performance: Ejection Wearĭr. |
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