Appendix

193 Appendix Appendix 1: Suggested Contents of a Mold Manual Description (possibly a photo) of the mold Date of building Serial number, size, weight List of patents applying to the mold. List of third-party trade marks of components used. Table of contents 1. Safety of operation 2. Specifications: What is required to operate the mold: Molding machine type, space, plant floor, hoist capacity, air supply, cooling water, lubricants, power, etc. 3. Safe handling of the mold 4. Installation, startup, and operation 5. Troubleshooting 6. Mold storage 7. Mold maintenance (frequency and procedures) 8. Setup guide from the original testing of the mold 9. Mold drawings and bill of materials Assembly drawing(s) Detail drawings of stack components Detailed drawings of all other mold parts, optional Drawings or specifications of special, commercial products used in the mold (valves, heaters, seals, etc.) 194 Appendix Appendix 2: Mold Set-up Guide Blank Mold Wizard Inc. SET UP GUIDE Customer: _____________________ Mold No: __________________ Job No.: _________________ Project Engineer: _____________________ MOLDED PART Part Description: _____________________ Tested by: __________________ Part Wt (g): __________________ Date: _________________ Shot Wt (g): _________________ Overall Cycle: ___ (sec) ___ (shots/min) Avg Wall Thick.: ______________ Flow Length: _________________ MATERIAL Type: _________ Manufactured by: __________________________ Pre-Dry Temp & Time: ________ Number: _________ Batch No: _________ Color: _________ % Concentrate: ________ MOLD No. of Cavities: Nozzle Bushing: __________ __________ Shut Height (mm): Locating Ring (mm): __________ __________ Type: Single Face Stack Mounting Bolts: Metric Inch Ejection System: __________ Ejector Stroke (mm): __________ Runner System: ______________ MOLD PROCESS TEMPERATURES AND PRESSURES Core: _____ (°C) _____ (°F) Cavity: _____ (°C) _____ (°F) Gate Pad: _____ (°C) _____ (°F) Pressure in (psi): _____________ Pressure out (psi): _____________ Air Pressure (psi): _____________ Flow Rate: ___________________ (US gal/min or Litres/min) Cooling Tonnage Required: __________________ MACHINE Type: Serial No.: ______________ ______________ Extruder Dia. (mm): Inj. Pot Dia (mm): ______________ ______________ Clamp Stroke (mm): No. of Accumulators: ______________ ______________ Auxiliary Equipment: ______________________________________________________________________________ HEAT PROFILE Machine S/Point Mold Start Auto NOZ DIS1 DIS2 ___ °C ___ °C ___ °C ___ °F ___ °F ___ °F N/T1 N/T2 N/T3 ___ °C ___ °C ___ °C ___ °F ___ °F ___ °F S/P2 S/P1 B/HD EXT6 ___ °C ___ °C ___ °C ___ °C ___ °F ___ °F ___ °F ___ °F N/T4 S/BAR X/MA H/R1 ___ °C ___ °C ___ °C ___ °C ___ °F ___ °F ___ °F ___ °F EXT5 EXT4 ___ °C ___ °C ___ °F ___ °F H/R2 H/R3 ___ °C ___ °C ___ °F ___ °F EXT3 EXT2 EXT1 ___ °C ___ °C ___ °C ___ °F ___ °F ___ °F H/R4 ___ °C ___ °C ___ °C ___ °F ___ °F ___ °F NOTES (For different zone temperatures and/or special start-up procedures see notes below) Appendix 2: Mold Set-up Guide Blank 195 CLAMP CLAMP CLOSE Timer(s) Clamp Tonnage Set Points (mm) Close (%) (t) (%) (t) Velocity (%) Mold Break (mm) Clamp Pos. (mm) CLAMP OPEN Timer(s) Open Set Points (mm) Velocity (%) Mold Pos. (mm) Mold Protection Pressure (%) Set Point (mm) EJECTOR & AIR HYD. EJECTOR AIR FUNCTION Set Set Point (mm) Set Timer (t) Hyd. Ejec. Start S/P (mm) 1 Hyd. Ejec. Back (mm) 2 Hyd. Ejec. Stroke (mm) 3 Hyd. Ejec. Fwd. Timer 4 Hyd. Ejec. Counter 5 6 7 8 9 10 196 Appendix INJECTION FILL Pull Back Shot Size Cycle Time(s) Inj. Time(s) Set Points (mm) Velocity (%) Trans. Time(s) Injection Pressure (%) (psi) Piston Pos. (mm) TRANSITION Time (s) Position (mm) Cavity Press (psi) Inj. Pres. (psi) HOLD SCREW Hold Time (t) Back Press. (%) (psi) Speed (%) (rpm) Current (amp) CARRIAGE EXTRUDER Hold Press. (psi) Fwd. Set P. Stroke Back Pos. (%) TIMERS & COUNTERS CLAMP Mold Close Timer Mold Open Timer Hyd. Ejec. Fwd Timer Hyd. Ejec. Stroke Ctr. PRODUCT HANDLING Index Conveyor Counter Parts Drop Off Delay Tilt Forward Time Set INJECTION Set Exc. Inject. Timer Exc. Cycle Timer Hold Zone #3 Timer Hold Zone #2 Timer Hold Zone #1 Timer Shooting Pot Pack Time Extended Decompression Shut-off Noz. Del. Tmr. VALVE GATE Delay Valve Gate O/Tmr. Ext. Valve Gate O/Tmr. Appendix 3: Example of Light-Weighting a Product and Increasing Productivity 197 Appendix 3: Example of Light-Weighting a Product and Increasing Productivity A 2 ´ 4 stack mold for DVD cases (Fig. A1) is a good example of the results of clever product design, weight reduction by thin-walling, and using advanced mold and handling technology. Amongst other good design features, this mold is using 2 valve gates per cavity located on the spine of the DVD case. The productivity has increased enormously, and reduced the product cost considerably. Box and cover are now one unit.After ejection into a high-speed side-entry robot, the two case halves are flipped closed and are then held in a buffer storage to control shrinking and warping. Figure A2 shows the side entry robot.The tooling arms entering the mold take a total of 0.75 s to enter, grab the products, and retract. The mass of the product has been reduced from the original 84 g, which amounted to 75% of the product cost,to 60 g.At the same time, by selecting a stack mold, the number of cavities has been increased from 2 to 8. Cycle time is now 6 s, for a production of 4,800 cases per hour, or more than 34 million per year. As a result of redesigning (light-weighting) the product and getting better molds, the product cost has been reduced by 40%. While the mold cost is considerably higher than before and the handling equipment was added, the capital cost per unit molded amounts to only a few percent of the total piece price. These products run continuously for 5 years, using the best quality molds with high cavitations, resulting in the lowest product cost. ... - tailieumienphi.vn