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The cooling water design of a plastic mold is critical for ensuring efficient and effective cooling during the injection molding process. The cooling system’s design should meet several conditions to achieve optimal cooling and improve the overall productivity and quality of the molded parts. Here are the key conditions that the cooling water design of a plastic mold should meet:
- Sufficient Cooling Capacity: The cooling system should have enough capacity to remove heat from the mold efficiently. It should be able to maintain the desired mold temperature throughout the production cycle.
- Uniform Cooling: The cooling water design should ensure uniform cooling across the entire mold surface. Uniform cooling helps prevent warping, sink marks, and other molding defects.
- Balanced Cooling: The cooling system should be designed to achieve balanced cooling in multi-cavity molds. Each cavity should receive the same amount of cooling to ensure consistent part quality.
- Proper Placement of Cooling Channels: The cooling channels should be strategically placed to target areas of the mold that require more cooling. Channels should be located near thick sections or areas prone to shrinkage.
- Avoidance of Dead Spots: Dead spots are areas in the mold where the cooling water flow is limited or blocked. The design should minimize dead spots to ensure effective cooling in all areas.
- Adequate Water Flow Rate: The cooling water flow rate should be sufficient to carry away the heat generated during the molding process. An adequate flow rate prevents overheating and maintains a stable mold temperature.
- Proper Cooling Water Temperature: The cooling water temperature should be regulated to match the required mold temperature. The temperature should be controlled to prevent under or overcooling of the mold.
- Corrosion Resistance: The materials used in the cooling system should be corrosion-resistant to prevent deterioration and prolong the life of the cooling channels.
- Easy Maintenance: The cooling system should be designed for easy maintenance and cleaning to prevent clogging or scaling of the cooling channels.
- Compatibility with Molding Materials: The cooling system materials should be compatible with the molding materials to avoid any adverse reactions or contamination.
- Energy Efficiency: The cooling water design should aim to be energy-efficient by minimizing water usage and optimizing cooling efficiency.
- Safety Considerations: Proper safety measures should be in place to prevent water leakage and protect operators from potential hazards.
By meeting these conditions, the cooling water design of the plastic mold ensures effective cooling, improves productivity, reduces cycle times, and enhances the quality of the molded parts. Regular monitoring and maintenance of the cooling system are essential to ensure its optimal performance throughout the mold’s lifecycle.
1、 The edge distance between water conveyance and product material level shall not be less than 10MM generally, and shall be designed between 10MM and 12MM as far as possible; Alloy die is generally 25MM;
2、 The design of water transport margin and insert needle, thimble, ejector sleeve, insert material level margin is as follows:
① The edge distance between the water conveyance edge and the insert pin, thimble, barrel and insert material level of the internal mold less than 200MM shall not be less than 3.5MM:
② For the internal mold larger than 200MM – 400MM, the distance between the water carrying edge and the level of insert pin, thimble, barrel and insert shall not be less than 4MM;
③ For the internal mold larger than 200MM – 400MM, the distance between the water carrying edge and the level of insert pin, thimble, barrel and insert shall not be less than 4MM;
④ For the internal mold larger than 400MM – 600MM, the distance between the water carrying edge and the level of insert pin, thimble, barrel and insert shall not be less than 5MM;
⑤ . For internal formwork larger than 600 mm, the distance between the water carrying edge and the inserted pin, thimble, barrel and insert material level shall not be less than 8 mm;
3、 The water conveyance, gas cap and oil pressure circuit shall not be less than 8MM;
4、 The water carrying edge and the air avoiding edge of the pump mouth shall not be less than 8 mm:
5、 The water conveying edge and internal mold edge shall not be less than 10MM;
6、 Distance design in the same direction of water transportation and water transportation:
① . When two pipe joints are in the same direction, the nearest distance between centers shall not be less than 38MM;
② . When the pipe joint and the throat plug are in the same direction, the nearest distance from the center shall not be less than 25MM;
③ . When two throat plugs are in the same direction, the nearest distance between centers shall not be less than 20MM;
④ . When the area of large mold level is large, the water transportation distance in the same direction is generally taken as 60MM;
7、 The distance between groove edges of water separator rubber ring shall not be less than 2MM; The distance between the laryngeal plugs shall not be less than 5MM;
8、 Generally, no more than 8 spacers are connected in series for each water conveyance circuit (American fisherman customers require no more than 6 spacers connected in series;)
9、 When the insert is designed with cooling water, the nearest distance between the water delivery and the insert material level shall be 5MM; Water delivery and insert edge shall not be less than 3.5mm.
Injection molding is an intricate process that involves several critical components, including the cooling system. The cooling water design of plastic molds plays a crucial role in the plastic injection molding process. Proper cooling system design is vital to facilitate efficient and effective mold cooling, which leads to high-quality products and increased productivity.
When Cooling a Mold Which Method of Cooling is Best?
The most effective method of cooling a mold is through a uniform and consistent cooling system. One such system is the water cooling system, which involves the passage of cooling water through channels of the mold. Water cooling is the most efficient, cost-effective, and versatile method of cooling a mold.
What are the Cooling Requirements for Injection Molding Machines?
Injection molding machines require water with a constant flow of between 2 and 5 liters per minute (LPM) for every millimeter of channel depth. Water pressure ranges at between 100 and 500 Kpa for optimal performance. To achieve this, the cooling channel design should match the required flow rate and pressure to ensure adequate cooling capacity.
What are the Challenges in Designing Cooling Channel in Injection Mould?
The cooling channel is a critical part of the cooling system, and its design plays a crucial role in the overall performance of the mold. The challenges involved in designing the cooling channel include maintaining mold stability during operation, uniform cooling of the mold, maintaining proper channel flow and pressure balance, and reducing mechanical stress caused by thermal expansion and contraction.
What is the Cooling Process in Molding?
The cooling process in injection molding involves the passage of cooling water through the channels of the mold. The cooling water absorbs heat from the molten plastic, which exits the mold as a solidified product with the desired shape. The temperature of the cooling water should be maintained at room temperature or lower to facilitate efficient cooling.
What Temperatures and Conditions do Molds Prefer?
Molds prefer lower temperatures, as high temperatures can cause warping, shrinkage and weaken the structural integrity of the mold. The ideal temperature range for molds is between 30°C and 70°C. Optimal mold cooling results when the cooling water temperature is within five degrees of the molded product’s melt temperature.
What are the Proper Cooling Methods?
The proper cooling methods in injection molding involve the use of water cooling systems. There are different types of cooling systems available, including baffle, spiral, and parallel, all designed to facilitate efficient cooling of molds during the injection molding process. Water cooling through channels within the mold itself is the preferred standard cooling method.
Conclusion
The cooling system design is a critical component of injection mold, with water cooling being the most effective, cost-effective, and versatile method. The water cooling system should meet the cooling requirements for injection molding machines to ensure adequate cooling capacity. Designing the cooling channel can be challenging due to several factors such as maintaining mold stability during operation, uniform cooling of molds, and reducing thermal expansion and contraction stresses. Molds prefer lower temperatures; hence the temperature of the cooling water should be maintained at less than room temperature. The proper cooling method involves utilizing water cooling through channels within the mold itself. Accurate control of the cooling water design of plastic molds is necessary, ensuring efficient cooling, high-quality products, and increased productivity in the plastic injection molding process.
The cooling system design is a crucial component of injection mold in which water cooling is the most effective and versatile method. Additionally, the cooling channel design and the flow rate of cooling water play a crucial role in the overall performance of the mold. Molds prefer lower temperatures, which should be achieved by maintaining the temperature of cooling water at less than room temperature. Proper cooling methods include using water cooling through channels within the mold that will ensure efficient cooling, high-quality products, and increased productivity during the plastic injection molding process.
