CLASS 102 MOLD SPECIFICATIONS

CAVITY AND CORES

CLASS 102 MOLD SPECIFICATIONS

Cycles: Not Exceeding one million

Description: Medium to high production mold, good for abrasive materials and/or parts requiring close tolerances.
This is a high quality, fairly high priced mold.

GENERAL INFORMATION

Up to 1,000,000 lifetime cycles is expected from this mold

Mold must be constructed with valve gate or full hot runner design, assuming part configuration compatibility. No runners are desired, however sub-runners are allowed due to mold design or cost issues.

Mold spare parts shall be included in mold quotation package as a separate line item. Quote 25% spares for all unique non-standard mold components and details. Itemize spare parts quote.

Mold shall run full automatic cycle.

Mold shall produce acceptable parts at or below target estimated molding cycle as supplied by Tooling Engineer

Mold shall be built to produce 1.5 Cpk quality parts. On all critical print dimensions or additional dimensions noted by Tooling Engineer. Mold cavity dimensions must be held to within 10% of print tolerance to nominal. On all other print dimensions, mold cavity dimensions must be held to within 25% of print tolerance to nominal.

Approved shrink factors for the selected plastic molding material shall be supplied by Tooling Engineer and documented in writing.

Engineering shall supply IGES/CAD files for part dimensions, part prints, and approved title block upon release of purchase order.

Tooling Engineer shall supply molding machine platen layout and ejector KO pattern in writing. Preliminary mold design shall be approved by Tooling Engineer prior to start of mold construction.

Detailed mold design shall be supplied to after tool approval. Final mold designs must be updated with all mold changes prior to mold approval.

Mold shall have approved vendor cycle counter

All slides shall have wear plates with grease grooves. Prefer wear plate thickness of 1/4 inch. Wear plate material shall be Ampco or Lamina. Slides shall have positive stops and locking details.

All screws, bolts, leader pins/bushings, ejector pins, ejector blades, etc. shall be standard stock items wherever possible

MOLD BASE

Mold base steel shall be 280 BHN minimum

All mold base plates containing water cooling lines shall be Stainless Steel material or electoless nickel plated.

All steels moving atainst one another shall be of a dissimilar material and shall have a hardness differential of at least 4-7 Rockwell "C".

Straight parting line interlocks shall be on both sides of vertical and horizontal axis wherever possible. Size and location shall be approved by Tooling Engineer.

Eye bolt holes shall be located on all four sides and both halves of the mold base minimum. Individual plates shall have eye bolt holes located on all four sides. Eye bolt hole thread size shall be stamped near lift hole.

Mold base must have 4 inch diameter locating ring and 1/2 inch spherical radius sprue bushing, unless otherwise specified by tooling engineer.

All mold base plates to be chamfered approximately 1/16 inch X 45 degrees.

Mold base to have off-set Leader pin/Bushings and Return pins.

Mold to have ample support pillars with minimum of 1/8 inch clearance on pillar diameter.

Pry bar slots shall be located on all mold base plates. Pry bar slots to be 7/8 inch wide minimum by 3/16 inch deep minimum. Pry bar slots may be placed on corner of plates at 45 degree angle only if no room for preferred locations.

Multiple dowel pins shall be installed between plates to insure proper alignment of plates

Stamp "TOP" on top of mold, minimum 5/16 inch high

Leader Pins and Leader Pin Bushing shall be long enough to engage at least 1/2 inch prior to any other mold componenets. Bushings shall be self-lubricating.

Mold base shall have clamp slots in both halves of mold. Preferred dimension of clamp slot is 13/16 inch high X 5/8 inch deep where possible, 7/8 or 1 3/8 off top and bottom of mold. Direct bolting holes may be implemented if necessary.

CAVITY AND CORES

All molding surfaces shall be made of hardened tool steel and heat treated to a minimum of 48 Rockwell "C" hardness.

All mold details such as slides, heel blocks, gibs, wedge blocks, etc. shall be made of hardened tool steel.

Hardened Satinless Steel cavities, cores, and core pins shall be used wherever possible if selected plastic resin is highly corrosive

Cavities, cores, core pins, and all other molding survaces shall be flash chrome or TIN plated wherever possible if selected plastic resin is highly abrasive. Tooling Engineer to specify type and thickness of plating.

Leader pins shall be long enough to engage at least 1/4 inch before core details engage cavities.

All core pins shall be full-through hardened.

All part undercuts must be formed with mechanical, hydraulic, or pneumatic slides, lifters, etc.

All shut-off angles to be minimum of 3 degrees with a minimum 1/10 inch step, (assumes part design allows). Preferred shut-off angle is 5 degrees for all matching surfaces.

All insert pockets shall have appropriate lead-in to assist in assembly.

Excellent venting is required and shall be in accordance to plastic resin specifications. Last to fill areas must always have appropriate venting to insure ease of processing. Deep pockets must be vented wherever possible.

Potential high breakage areas shall be inserted design for ease of replacement.

All cavity and core details to have steel type and harrdness stamped into recessed pockets wherever possible.

COOLING

Water lines shall be in both mold halves and in cavities, cores, and slides wherever possible to allow for optimized molding cycles.

Water inlet and outlet locations shall be positioned so as not to interfere with molding machine tie bars and mold clamp slots.

All water inlets and outlets shall be stamped and identified on mold base. Indentify inlets as "IN 1", "IN 2"l, etc. Identify outlets as "OUT 1", "OUT 2", etc. All water inlets and outlets must also be identified by their appropriate level on mold base.

Water inlets and outlets shall be recessed and installed below the mold base surface wherever possible.

Water lines shall be 7/16 inch diameter or larger wherever possible

Bubblers and baffles shall be stainless steel (preferred), or brass. Plastic bubblers and baffles are not acceptable. Baffles shall be keyed in place and secured with a set screw wherever possible.

Spiral baffles shall be used wherever possible for turbulent flow.

Air and vacuum fittings shall be different from water fittings to prevent misconnection and for ease of installation.

Mold shall be deisgned with "O" ring installations such that "O" rings do not shear or become damaged during proper mold assembly.

Water channels to be flash chromed when using steel other than 420 (or stainless).

EJECTION

Ejector plates shall run on guided bushings. Recommend four pins and bushings wherever possible.

Bushings shall be self-lubricated.

Ejector plates shall have one off-set return pin.

Ejector plate travel must be sufficient for full part ejection and consistent automatic molding cycle operation.

Ejector pins and sleeves shall be through hardened. Ejector sleeves shall be nitrided on all inside and outside surfaces.

Ejector pins and sleefves shall be industry standard sizes wherever possible. All exceptions must be noted and approved by Tooling Engineer in writing.

Contoured ejector pins located flush with core surfaces must be keyed into place to maintain core contour alignment.

Cavity cores shall have ejector pin clearance of 1/64 inch larger than ejector pin diameter. Land distance shall be sized to optimize mold wear and fit characteristics.

Ejector pin clearance holes in "B" plate shall be 1/32 inch larger than ejector pin diameter wherever possible.

Ejector pin holes shall be 1/8 inch minimum from core side wall whereer possible.

Knock-out clearance holes shall be 1.25 inch diameter. Tapped holes for knock-out pins/adapters shall be 1/2 inch-13 thread size. Knock-out adapters shall be flush with back half of mold.

Standard SPI knock-out patterns shall be used. Multiple KO is preferred. Tooling Engineer to provide mold supplier appropriate KO pattern to match molding machine configuration.

All ejector plates shall have return springs where mold design and mold operation allows. Springs shall be standard sizes, and not cut to length. Springs shall have standard diameter counter bore holes wherever possible. Springs to be installed around return pins or have separate pins in the event breakage occurs.