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Plastic Injection Mold Standard__ 2007

Plastic Injection Mold Standard__ 2007
Plastic Injection Mold Standard__ 2007

CORPORATION

Benton Harbor, Michigan 49022 USA Plastics Injection Mold Standards

NOTE: THIS DOCUMENT IS INTENDED FOR THE EXCLUSIVE USE OF

WHIRLPOOL CORPORATION, ITS PLASTIC PARTS SUPPLIERS AND ITS

INJECTION MOLD SUPPLIERS. IT MAY BE REPRODUCED IN THE NORMAL

COURSE OF BUSINESS, BY THE ABOVE IDENTIFIED BUSINESSES FOR THE

SOLE BENEFIT OF WHIRLPOOL CORPORATION ONLY.

THIS MOLD CONSTRUCTION STANDARD WAS DEVELOPED AND PREPARED

BY A CORE TEAM OF WHIRLPOOL TOOLING ENGINEERS, STRATEGIC

MOLDERS AND PREFERRED TOOLMAKERS. THE GENERAL INTENT IS TO

PROVIDE A BASIC GUIDELINE FROM WHICH ALL INJECTION MOLDS ARE

TO BE QUOTED AND BUILT. FOR MORE SPECIFIC INFORMATION, PLEASE

REFER TO THE MOLD STANDARDS PROVIDED BY THE MOLDER.ALL

QUOTES FOR TOOLING SHOULD BE BASED ON THIS STANDARD.

DEVIATIONS WILL BE GRANTED UPON APPROVAL BY A WHIRLPOOL

TOOLING ADMINISTRATOR, THE BUYER OR A DESIGNATED WHIRLPOOL

REPRESENTATIVE. DEVIATIONS FROM THE STANDARD FOR ANY

INDIVIDUAL MOLD ARE TO BE IDENTIFIED IN WRITING.

Revisio n …F?

March 2007

MOLD STANDARDS REVISED by:

D. Dickey J. Fogelsonger J. Herweh B. Ruminer M. Waheed Strategic Molders

Preferred Mold Makers Procurement

STANDARD ACKNOWLEDGEMENT SHEET

By signing this sheet, as a supplier to Whirlpool, we acknowledge that we

have read and agree to the requirements for the entire Whirlpool Plastic

Injection Mold Standard – Rev F. The purpose of the Plastic Injection Mold

Standard is to make sure that Whirlpool receives the highest Quality Mold and

__________________________________________________________Page 1 of 16

any deviations have to be documented in writing to Whirlpool Tooling

Engineer or the Buyer. Any deviations to the standard can be implemented

only if there is a written acceptance from Whirlpool Tooling Engineer or the Buyer for only a specific project.

Supplier Responsible Person 1

Name: ___________________________

Title:_____________________________

Signature:_________________________

Date:_____________________________

Supplier Responsible Person 2

Name: ___________________________

Title:_____________________________

Signature:_________________________

Date:_____________________________

Supplier Responsible Person 3

Name: ___________________________

Title:_____________________________

Signature:_________________________

Date:_____________________________

Please send signed copy of this page with a minimum of 2 signatures

acknowledging you have read and agree with the entire tooling standard below to Malur Waheed NO LATER THAN MAY 1st 2007

Fax @ 269-923-6026

or e-mail scanned copy to malur_a_waheed@https://www.sodocs.net/doc/20443598.html,

INDEX

I MOLD DRAWING/DOCUMENTATIONS

1.MOLD DRAWINGS

1.1.Format and Ownership

1.2.Preliminary Mold Drawing Expectations

1.3.Final Mold Drawings and Documentation Package

2.MOLD 3D Data

3.OTHER MOLD RELATED DOCUMENTATIONS

II. MOLD DESIGN GUIDELINES

1PRODUCT DESIGN

2PLASTIC MATERIAL SELECTION AND SHRINK RATE

3REQUIRED MOLD FEATURES

4HANDLING AND MOLDING MACHINE INTERFACE

5PRE-HARD OR HARDENED MOLD STEEL

6MOLD BASE

7MOLD COMPONENTS

8MOLD ALIGNMENT

9COOLING

10SIDE ACTIONS

11MOLD INSERTS

12EJECTION

13INJECTION

14VENTING

15HYDRAULICS

16ELECTRICAL

17INDIVIDUAL MOLD IDENTIFICATION

18PLATING OR SURFACE TREATMENTS

19MOLD DOCUMENTATION AND DIMENSIONAL REPORTING

20WELDING

21STACK MOLDS

IV. AMENDMENTS AND EXCEPTIONS

1.LISTED DEVIATIONS FROM STANDARDS

Note: Please refer to …Whirlpool Policy, Procedure and Forms? documentation for responsibilities and forms required during different tool build stages

I. MOLD DOCUMENTATION GUIDELINES

NOTE:

1. Mold maker must submit final mold drawings, 3D mold data and other related documentation - IN AN ELECTRONIC FILE NAMED …Part#-t1.pdf (2D)and

Part#-t1.dwg (2D) and Part#-t1.igs (3D), (Part#-t2…if more than 1 tool for the same part?) to Whirlpool Tooling Engineer and the Molder before the final payment on the tool can be made.

2. Molder must retain updated mold drawing check list, the final mold buyoff sheet and mold sampling sheet. These sheets should be made available if requested by Whirlpool before the final management fee is paid

3. For international tools the integrator must submit the international tool sampling sheet to Whirlpool and the Molder before the final mold shipment from overseas 1.MOLD DRAWINGS

1.1.All mold drawings will display “Property of Whirlpool” in Mold Maker

Standard Title block and the design will become property of the Whirlpool

Corporation. Mold designs to be in a metric unit of measure and to be

designed using a 3-D base format. All final 2D mold drawing must be

converted into DWG or IGES and PDF format and sent (in electronic

folder named …PART#-t1?) to Whirlpool and the Molder.

1.1.1.Exclusive of Patented Designs and/or processes that are the property of

the molder or mold builder.

1.1.1.1.The Whirlpool Tooling Administrator AND Buyer Must be

made aware of any and all situations where process, design or

component patents are owned by their direct or indirect

suppliers and may affect the continued production of any given

part or component for Whirlpool.

1.2.Preliminary mold drawings to include:

1.2.1.Mold material types and intended hardness of the blocks and mold

base must be stated.

1.2.2.Cavity and core plan views with steel blocks and mold base sizes

enough section views to define design intent

https://www.sodocs.net/doc/20443598.html,plete water layout

1.2.4.Location of venting

1.2.5.C lear definition of all “mold actions”– showing views actions in

both forward and back positions and view of machine daylight.

1.2.6.Detailed section view showing gate location, type and size

1.2.7.Preliminary hot-runner layout as it relates to cavity plan view

1.3.Molder?s can request for more info. before approving the initial tool

drawings

1.4.Final mold drawings to include:

1.4.1.All mold components listed in detail break-out sheets dimensioned,

as built. All individual details to include all plating, surface

hardening and heat treating processes with Rockwell hardness and

steel type.

1.4.

2. A complete water system schematic including inlets and outlets

numbered to match the mold

https://www.sodocs.net/doc/20443598.html,plete bill-of-materials

https://www.sodocs.net/doc/20443598.html,plete electrical circuit diagrams

1.4.5.Detail hot runner drawings for the molds with hot-runners with

manifold zone layout as it relates to the cavity plan view. Heat

expansion calculations for the manifolds and the drops

2.MOLD 3D DATA

2.1.All 3D mold data will also become Whirlpool property and must be

converted into IGES format (and put in same electronic file named

…PART#-t1.igs?) sent on a CD to Molder and Whirlpool.

3.OTHER MOLD RELETED DOCUMENTATION

3.1. A complete and accurate documentation package (in an electronic format

with the file named …part#-t1?) shall include:

3.1.1.1.The hot-runner and/or valve-gate system paper drawings

and manufacturers supplied booklet sent to Molder and the

design data in 2-D (.dwg or IGES) and PDF formats to

Molder and Whirlpool.

3.1.1.2.2-D (.pdf, .dwg or .igs) and 3-D (.igs) CAD files and .pdf

mold drawing files on CD

3.1.1.3.The manifold and mold drawings, in PDF format, shall be

sent in electronic format to the Molder and Whirlpool

during the preliminary and final designs as soon as they

come available

3.1.1.

4.All forms used thru the mold build, sampling and mold

revision process should be retained and should be made

available at request by Whirlpool. If the forms are

handwritten, a scanned .pdf file is to be included.

3.1.1.5.The mold design shall not be considered final until all

revisions have been made. It is required that any and all

mold adjustments and revisions be documented on the final

mold drawings and 3-D CAD files updated.

______________________________________________________________________________ II MOLD DESIGN GUIDELINES

NOTE: ANY THIN STEEL, HOTSPOTS, DIFFICULT TO VENT (DEEP RIB) CONDITONS NOTICED BY THE MOLD DESIGNER DURING THE INITIAL TOOL DESIGN STAGE AND NOT ADDRESSED DURING TOOL DRAWING REVIEW MUST BE BROUGHT UP IMMEDIATELY TO THE MOLDER OR WHIRLPOOL

1.PRODUCT DESIGN

1.1.The Product design will be supplied by Whirlpool in a 3-D format and when

available, 2-D dimensioned and toleranced part drawing will be provided.

1.2.The 3-D data will be considered the primary source of information. If the 3-D

data and part drawing do not agree, contact the Whirlpool product engineer.

The 2-D drawings should be used for part and/or mold tolerances.

1.3. A minimum of 3? should be used on all shut-offs unless Whirlpool

product engineering and tooling engineering have been notified and agree

to a lesser angle.

1.4.Surface finishes will be defined on the 2-D part drawings.

1.5.All parts of suitable size are to exhibit certain markings per the 2-D part

drawing. At a minimum these markings should include:

1.5.1.All markings, to the extent practical, should be on inserts.

1.5.

2.Whirlpool part number

1.5.3.Resin type and/or recycle logo – SPI

1.5.4.Supplier identification number or trademark should not be

included on the tool.

1.5.5.…pre-tooling launch meeting? is held before a final PO is issued

which will specify the requirement for the FSP (Factory Service

Part) symbol and date code to be included on the tool or not.

https://www.sodocs.net/doc/20443598.html,e DME, National Tool or Progressive Components date

code inserts with the year arrow replaceable from the face

of the tool.

1.5.6.In multi-cavity molds, a cavity number is to be imprinted in a non-

cosmetic surface of each cavity.

1.5.6.1.For subsequent, back-up or duplicate molds, the numbering

sequence will be a continuation of the preceding mold.

EXAMPLE: If mold #1 is an eight-cavity mold, the numbering

sequence will be 1 thru 8. For mold #2 the sequence will be 9

thru 16 and for mold #3, 17 thru 24 etc.

1.5.7.Generally, in single cavity molds, an identifying numeral will be

imprinted to signify that possibly more than one mold exists for the same

part starting with …1? for the first mold and …2? for the second mold etc.

1.5.8. A Whirlpool product design or tooling engineer will specify the

location and size of the above markings if not shown clearly on the

2-D part drawings during the …pre-tooling launch meeting?

2.PLASTIC MATERIAL SELECTION AND SHRINK RATE

2.1.The type and specifications of the resin will be supplied by Whirlpool

Engineering on the part drawing. The gating location and shrink rate will be

provided by the Molder

3.REQUIRED MOLD FEATURES

3.1.Unless specified by Whirlpool in writing, all Molds are required to have;

3.1.1. A Model # CVPL-100 PROGRESSIVE parting-line cycle counter

recessed and pocketed.

3.1.2.an interlocking feature between the cavity and core to prevent the

mold from shifting sideways during injection (side locks)

3.1.3.guided ejector system

3.1.

4.safety straps

3.1.5.eye bolt holes or lifting saddle to provide for balanced lifting

3.1.6.the rail or mold based stamped with Whirlpool required, mold

specific information and country of origin –

3.1.7.Mold cooling must be in the cores, cavities and slides whenever

possible

3.1.8.Steel moving against one another should be dissimilar and have a

hardness of at least 8-10 point Rockwell …C?

4.HANDLING AND MOLDING MACHINE INTERFACE

4.1.Unit of measure for eyebolts will be specified by the molder and the

identification must be stamped next to the eye bolt.

4.2.Eyebolt holes are to be drilled and tapped on all sides of the mold, and, if

size requires, in every plate that is 40lbs or higher. Eyebolt holes are to be

tapped along the center of gravity of the mold. Additionally, eyebolt holes

must be located in each half of the mold such that a single mold half will

hang straight if lifted by its self.

4.2.1.If the location of the holes on the top side would be in such a

location that the complete mold cannot be balanced, then a lifting

saddle must be provided

4.2.1.1.The saddle is to be mounted to either or both halves with

one screw at each end. One screw should be a shoulder

screw that allows the saddle to pivot out of the way during

normal operation. A riser may be required.

4.3.All molds to have a tie strap spanning across all parting lines on the

operator side. The tie strap should be painted yellow and have the mold

number stamped into it. These straps should have a screw thread to hold it

on the mold all the time. The strap shall be fastened to the mold with two

screws when the mold is in use as well as when the molds is not in the

machine.

4.4.Pry bar slots must be machined into all mold plates in a location where it

would not damage the mold.

4.5.When necessary, molds will be equipped with removable support legs

(risers) on the bottom. These risers will be of adequate height as to protect

any components that may be mounted on the bottom of the tool, such as

water lines/fittings, manifolds etc. These legs will be positioned such that

the assembled mold and or each mold half will stand by its self.

https://www.sodocs.net/doc/20443598.html,e DME style long lead locator rings as specified by the molder.

https://www.sodocs.net/doc/20443598.html,e SPE/SPI, inch standard knock-out patterns or as specified by the

molder.

5.PRE-HARD OR HARDENED MOLD STEEL

5.1.The type of steel used for each individual mold will be defined by Whirlpool or

the Molder on the tool specification sheet.

5.2.Only approved U.S. or European steel sources and their respective heat

treating services must be utilized for all steel used for Whirlpool tools. Mold

maker must provide certification of steel and heat treating upon request of

Whirlpool.

5.3.Cavities and cores may be made from a pre-hardened steel, this steel is to

be 28-34 Rockwell C. Examples of these materials are P20 or 4140.

https://www.sodocs.net/doc/20443598.html,rge tools, 1000 ton and up, should have the core and cavity

blocks made from a Pre-hardened materials like P-20.

5.4.Cavities and cores may be made from steel that require hardening. These

materials are not to exceed 46-48 Rc for the cavity and 42-44 Rc for the

core when practical. Examples of these materials are H-13 and S-7

5.5.Molds for corrosive materials, when specified by Whirlpool, are to be

made from stainless steel and hardened, not to exceed 46 Rockwell C.

6.MOLD BASE

6.1.Where possible, standard mold bases should be used.

6.2.Recognized mold base suppliers are: DME, National, Standard, LKM,

PCS and Hasco

6.3.Holder-block or mold base material is to be #2 steel of RHC of 28-32.

6.4.When Core cavity blocks are utilized, the inserts are to be standing proud.

The amount of relief will be based on the press tonnage and part shape

detail.

7.MOLD COMPONENTS

7.1.Molds should be designed to make use of standard mold components

readily available in the US. The unit of measure for these components will

be metric (if metric is not available then the English components can be

used but should be called out in the mold drw).

7.2.Approved sources for standard components are: DME, PCS, Progressive

and Hasco. Do not use substitutes or “equivalents” to standard mold

components

7.3.In the event standard components cannot be used, the mold builder is

expected to provide a notation on the stock list of recommended spare

parts for items which are considered perishable

8.MOLD ALIGNMENT

8.1.Leader-pins shall be configured in such a manner that there is only one

way the mold halves will fit together.

8.1.1.One pin must be off-set.

8.1.1.1.The off-set or …0? corner will be the upper operator side.

8.1.1.2.All guide pin bushing holes will be adequately vented at the

bottom of the hole.

8.1.2.In all cases, guide-pins and/or leader-pins must enter their

respective guide bushings at least 25mm before any other mold

feature.

8.2.Except when specified by Whirlpool or Molder in writing, the mold

construction shall be such that the cavity and core have interlocking

features to prevent side movement during injection.

8.2.1.Pocketed and bolted in standard catalog mold interlocks (parting

line locks) may be used.

8.2.1.1.Preferred parting lock suppliers are: Progressive

Components, DME, Hasco and PCS

9.COOLING

9.1.In and Out locations

9.1.1.Unless otherwise noted, water lines should enter and exit the mold,

in order of preference, 1) opposite operator side, 2) operator side, 3)

bottom 4) top.

9.1.2.Each circuit is to be identified as “IN-1” and “OUT-1”, “IN-2” and

“OUT-2” and so on. The circuit identification numbers on the mold

should correspond with, and be found on the final mold drawings.

9.1.3.All water inlets and outlets ports to be furnished with quick

connector and are to be counter-bored for proper clearance for the

female connector. The specific type of connector will be specified

by the molder on mold specifications.

9.2. A limited number of loops or jumpers will be allowed in order to

maximize the volume of flow through the mold and to achieve a ?T of no

more than 5?F inlet vs. outlet.

9.3.The design of all water circuits must minimize the use of …O? rings.

9.3.1.All …O? ring applications will be reviewed and approved by a

Whirlpool tooling engineer

9.3.2.When …O? rings are to be employed, those surfaces that mate with

the …O?ring are to be plated unless they are made from a corrosion

resistant material.

9.4.All pipe plugs to be threaded NPT brass plugs . Press fit plugs will not be

allowed.

9.5.The water-channels are to be sized to the maximum diameter possible for

the specific mold size.

9.6.Water lines shall be laid out to cool the part uniformly and provide

maximum cooling with the core and cavity having similar (mirrored) flow

patterns or flow paths and will be scrutinized during the preliminary mold

drawing review.

9.7.Utilize turbo-baffles, spiral plugs, fountains/bubblers or heat transfer tubes

when required for cooling smaller cores. Water channels should be sized

to insure volumetric flow.

9.8.Heat pipes, water cascades and etc. should be used in the smallest cores

and where the cross-section or diameter is less than 1/2”. These circuits

should have the properly sized IN and OUT and should not be jumped

with other circuits.

10.SIDE ACTIONS

10.1.Where practical, all moving cores, cams, slides, lifters and mold locks are

to be made from hardened and stress relieved H-13 or S-7 steel except for

molds running corrosive materials.

10.2.Insert surfaces that mate with moving components such as slides and cams

with materials such as S-7, Lamina Bronze or Ampco Bronze.

10.2.1.Lubrication grooves will be machined into all wear surfaces.

10.2.2.Where possible, Zerk fittings should be installed for ease of

applying lubrication.

10.3.If at all possible, avoid the use of air or hydraulically actuated cores, slides

etc. A mechanically actuated means is preferred.

10.3.1.When any components are actuated by air or hydraulic cylinders

and are held in place by wedge-locks, the cylinder rod should be

connected to the mold component via a …T? slot. The slot should

have sufficient clearance to allow the rod to float and should

provide enough linear clearance as to let the wedge-lock seat the

core or slide etc. without causing any stress on the cylinder rod or

piston.

10.4.All slides, unless agreed upon by a Whirlpool tooling engineer, will be

equipped with a spring loaded return system to insure that they will be

held in the retracted position when the mold is open. The slides shall rest

against positive stops when retracted where practical.

10.4.1.Ball-notch detents are not acceptable. Use DME closes-pin locks or

Superior slide locks or Progressive slide locks

10.5.In most cases slides should have the capability of being removed while the

mold is in the machine.

11.MOLD INSERTS

11.1.Mold inserts can be fit into the mold base with the use of wedge lock (if

required) on the offset …O? corner

11.2.When practical, mold components should display a permanent mark, which

identifies the material and hardness from which the component was

manufactured.

11.3.Low Hard Mold Max (BeCu free) is to be inserted in areas of the mold

where heat is highly concentrated and is expected to dissipate poorly

and/or where the volume of available cooling water is inadequate to cool

the part properly. High Hard Mold Max must be avoided due to low

ductility and high possibility for it to crack. When HH Mold Max is used

there should be written approval from the Molder or Whirlpool

11.4.When possible, insert weak areas and difficult to maintain shut-off areas

for ease of maintainability. – For long, fragile or small cores that may warp

during heat treat, use PX5 from international mold steel

11.4.1.Dissimilar materials and/or hardness of 5-10 point Rockwell C

difference shall be used in these areas where galling is a concern.

11.4.2.Small cores or weaker areas shall be interlocked or pocketed to

avoid shifting and/or deflection.

11.5.Where practical, all-changeable or spare inserts must have the mold

number, part drawing number and raw part number imprinted on a non-

cosmetic surface of the respective insert.

11.5.1.All changeable inserts, slides, core, etc., must be shipped in a

custom made wooden box or crate that is suitable for shipping and

as a permanent storage container. The part and Whirlpool tool

numbers shall be painted on the top and one side of the box.

11.5.2.Shipping/storage boxes are to be lined with a non-abrasive non-

moisture absorbing material to protect the contents.

12.EJECTION

12.1.In all molds the ejector system will be equipped with a minimum of six (6)

stop or rest buttons to avoid full contact between the ejector and back up

plates when the ejector system is fully retracted.

12.2.The ejector plate in all molds will have a minimum of four (4) guide rods

and will be equipped with bronze plated bushings with lubrication grooves

and Zerk fittings for ease of lubricate introduction. (guided ejector system)

12.2.1.One guide rod will be off-set at the …0? corner.

12.3.Ejector systems will include four properly calculated return springs.

12.4.Ejector systems will be fitted with PKO pucks or bushings in four (4)

places and will be flush with the back side of the mold for positive ejector

system pull back. The specific KO pattern will be specified by the molder.

12.4.1.To the extent practical, a second KO pattern should also be

installed.

12.5.Ejector systems that are actuated by a singular rod in the center of the

mold are not acceptable unless constrained by mold size.

12.5.1.1.Documented approval by molder is required.

12.6.Unless otherwise specified, all ejector pins shall be adjusted to provide a

flush to +.1 mm surface with respect to the mold surface.

12.6.1.Stepped ejector pins are required for all ejector pins that are ≤ 3

mm diameter

12.6.2.Ejector pins shall not be placed under moving cores or slides

unless approved by the tooling engineer and mechanical, hydraulic

or electrical early returns are incorporated.

12.6.3.All ejector pins with the part shape that are not flat must be locked

in place to prevent any rotation.

12.7.Avoid ejector blades to the extent practical.

12.8.The ejector stroke must be of sufficient length as to completely eject the

part from the mold.

12.8.1.All molds should be designed to allow the part to be removed by an

automatic part extractor (an up and out robot).

12.9.The combined total projected area of the support pillars must be equal to

or greater than 50% of the cavity projected area. Elector clamp plates to

ejector retainer plate are to be doweled. Rails to be doweled in place and

identified for mounting location. All pillars to be identified with

corresponding location to clamp plate.

13.INJECTION

13.1.Cold Runner

13.1.1.When possible use DME “B” series sprue bushings with 3/4”

radius.

13.1.1.1.Unless otherwise stated, the sprue-bushing radius shall be

3/4”.

13.1.1.2.Orifice sizes greater than 3/16” must be reviewed with the

Molder.

13.1.2.The cross-sectional area of all cold runner systems shall comply

with the resin manufacturer?s specifications.

13.1.3.Unless otherwise specified, all cold runners shall have a full-round

style cross-section

13.1.3.1.Break all sharp corners by 1mm, minimum, and blend the

transitional points of all cross-sectional size reductions

13.1.3.2.All runners shall be polished to a SPI/SPE B-3 surface

finish.

13.1.3.3.All runners will have cold slug wells machined at the end

of each run and will have proper venting

13.1.3.3.1.Detail Gate info will be provided by the molder

13.1.3.3.2.In all cases, material should impinge on an

opposing wall or steel as it enters the cavity to avoid

jetting.

13.1.3.4.Molds that will be running corrosive or abrasive materials

shall be equipped with replaceable runner-bars.

13.1.3.5.Multi-cavity mold to have runner shut offs to enable

production without any one cavity.

13.2.Hot Manifold and Valve gates

13.2.1.At this time, Mold Master and Synventive systems are approved.

13.2.2.Purchases Orders from Tool manufactures to the system

manufacturers of all hot runner systems “MUST” indicate

Whirlpool Corporation as the end-user of the specified system.

13.2.3.The System manufacturers must be notified when specifying hot

runners and valve-gates systems for use with PVC and/or corrosive

resins.

13.2.4.The runner system in all multi-cavity molds must be balanced.

13.2.5.Replaceable gates and tips should be designed and implemented

into all systems where practical.

13.2.6.Mold maker must verify the heat expansion calculations for the

manifold and the drops on hot runner drawings hot and cold.

13.2.7.Hot-runner molds must have a depression of such depth so as to

leave the gate-vestige sub-flush to the part surface, whenever the

part design and aesthetics permit.

13.2.7.1.In most cases, the surface of the mold, which is opposite

the gate, must have a mirrored detail in order to maintain

wall thickness.

13.2.8.Attach manufacturer tags and the manifold Zone Plaque to the

mold base.

13.2.8.1.The mold should be designed to float the …A? plate to the

…B? p late, in press, using cap screws from the parting line,

to facilitate cleaning or changing the tips. The guide pins

are to be in the manifold and bushings in t he “A” plate. The

guide pins are to be longer than the longest tip. The Guide

pins must be installed from the B-Side of the mold.

13.2.9. Unless otherwise requested, all valve-gate systems will be air

actuated.

14.VENTING

14.1.All molds will be vented per the molders specifications

14.2.Venting to be shown on preliminary and final mold drawings.

14.3.“Porcerax” may be used in selected areas for difficult to vent applications

and may be used as a molded part surface.

14.4.Self cleaning vent pins must be used whenever possible

15.HYDRAULICS

https://www.sodocs.net/doc/20443598.html,e only reputable cylinder manufacturers that have replacement parts

readily available in the US. Verify cylinder selection with a Whirlpool

tooling Engineer or molder before purchasing.

15.2.Hydraulic cylinders used for any application shall;

https://www.sodocs.net/doc/20443598.html,e magnetic proximity type switch internal limit switches when

practical unless otherwise specified by molder

https://www.sodocs.net/doc/20443598.html,e NPT ports for hydraulic fittings.

15.2.3.Be pre-plumbed to male and female fittings (refer to the specific

molders specifications)

15.2.4.Have a manifold if multiple cylinders are on the same circuit

15.3.Hydraulic ports must be identified by their function

15.4.If a Hydraulic cylinder is to be used for slide actions - Calculation required for

the pressure for the cylinder must be indicated on the tool drawings

15.5.3000Psi rated cylinder must be used unless specified by the molder

16.ELECTRICAL

16.1.If a mold has electrical components, the mold builder is required to supply

these components wired to connectors, adjusted and ready to be installed

in the molding machine. Please refer to the specific molders mold

standards for all limit switch, electrical wiring and connector requirements.

Use the following as a minimum requirement:

16.1.1.All limit-switches are to be mounted for easy access

16.1.2.All electric wiring are to be mounted on top of the mold, or on the

upper half of the non-operator side of the mold in such a manner as

to avoid or eliminate the possibility of accidental contact with

cooling water or hydraulic fluid spills or leaks.

16.1.3.A detailed electrical schematic shall be included in the final mold

drawings.

16.1.4.Hot runner and hot sprue connectors are to be DME type and not to

exceed 15 amps per circuit.

16.1.4.1.An accurate detailed Schematic of all heater circuits and

zones must be included in the final mold design.

16.2.Thermocouples and Heaters

16.2.1.1.All thermocouple s are to be “J” type unless otherwise

stated.

16.2.1.2.All heaters will be standard, readily available is the US

and rated @ 240 VAC

17.INDIVIDUAL MOLD IDENTIFICATION:

17.1.Certain Identification marks are to be permanently attached to, or formed into an

outer surface of the mold, typically on or in the operator side of ejector riser or

the holder block.

17.1.1.The mold must be stamped “Property of Whirlpool”

17.1.2.ASSET TAGS are to be provided by Whirlpool at time of PO and should

be attached to the mold.

17.1.3.The name, address and telephone number of the mold builder

17.1.3.1.The name, address and telephone number of the mold Integrator

17.1.4.Part Drawing number

17.1.5.The Whirlpool mold number

17.1.6.Date of manufacture

17.1.7.The weight of each mold half is to be stamped on the operator side of the

corresponding mold half.

17.1.7.1.The weight of the complete mold is to be stamped below the

single half weight on both mold halves.

18.PLATING/COATING

18.1.Plating of any kind will only be used when it is specified by a Whirlpool

tooling engineer. Armoly or titanium nitride coating must be used for any

Glass Filled resin tools.

18.2.PVC molds should be stainless steel: however, if they must be plated, hard

nickel should be used on the core and cavity surfaces. Electrolysis nickel

coating process should be used on surfaces that interact with the PVC resin.

19.MOLD DOCUMENTATION AND DIMENSIONAL REPORTING

19.1.Written progress reports are to be submitted to the project leader and/or

tooling administrator as requested.

19.2.Mold tolerances to follow the current ASTM tolerance requirements.

19.3.An inspection of the mold steel must be generated by the mold maker of

all “Boated” or critical characteristic dimensions and the overall width and

length of part and shall be available to Whirlpool or Molder upon request.

19.4.Where practical all the critical dimensions on the parts must be measured

by the molder before the tool is shipped from the tool maker.

20.WELDING

20.1.Welding is totally unacceptable unless approved by a Whirlpool tooling

engineer. This includes part maintenance, new tool release, and

refurbishment.

21.STACK MOLDS

21.1.When possible, stack molds should be designed so that the leader-pins support

the third member, eliminating the need for tie-rod supports or out-riggers.

21.2.Stack molds, three-plate molds and molds that, in any way, have the

moving and stationery plates tied together must have over-stroke

protection provided and/or must have prominently tagged and displayed

cautions that specify the maximum safe-open distance.

IV. AMENDMENTS AND EXCEPTIONS

1.

1.1.

1.2.

1.3.

1.4.

2.

2.1.

2.2.

2.3.

2.4.

3.

3.1.

3.2.

3.3.

3.4.

4.

4.1.

4.2.

4.3.

4.4.

5.

5.1.

5.2.

5.3.

5.4.

Amendments and Exceptions Accepted

Whirlpool Tooling Engineer Date Molder Date

塑料成型工艺及模具设计考试期末试题

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(勤奋、求是、创新、奉献) 2006 ~ 2007 学年第一学期考试试卷 主考教师:廖秋慧 学院材料工程班级 _0511031__ 姓名 __________学号 ___________ 《塑料模设计》课程试卷A答案 (本卷考试时间 120分钟) 一、填空(本题共10小题,每空1分,共20分) 1.顶出推板与凸模(型芯)在安装时应采用锥面配合,其目的是辅助定位, 防止偏心溢料。 2.螺杆式注塑机与柱塞式相比,其优点在于__螺杆式注塑机剪切塑化能力强, 塑化量大_。 3.调湿处理是针对吸湿性塑料而言,具体方法是将制品放在热水中处 理。 4.压制成形与压铸成形均可用于热固性塑料,二者在模具结构上的主要差别在 于压铸模具有浇注系统,而压制成型没有。 5. ABS属于高强度塑料,在注塑成型前需要预先干燥,而且成型时的流动 性也稍差。 6.在斜抽芯机构中锁紧楔的楔角一般比斜导柱的倾斜角大。主要是为了模 具开模时防止造成干涉。

7.塑件允许的最小壁厚与塑料品种和塑件尺寸有关。 8.塑料模的基本结构都由动模和定模两大部分组成。 9.型腔气体的排除,除了利用顶出元件的配合间隙外,主要靠分型 面,排气槽也都设在分型面上。 10. 塑件尺寸精度的影响因素有很多,在计算时需考虑的主要有:成型零部件 的制造误差、成型零部件 的磨损和塑料的成型收缩。 11. 当分流道设计的比较长时,其末端应留有冷料穴,以防前锋冷料阻塞浇 口或进入模腔,造成充模不足或影响制品的熔接强度。 12. 适用于要求自动切除浇口凝料的注塑模浇口方式是潜伏式浇口。 二、判断正误(本题共10小题,每题1分,共10分) 1. 厚壁塑件不容易产生表面凹陷和内部缩孔。 (×) 2. 当模具采用脱件板脱模机构时,可以采用Z形拉料杆与冷料井匹配。(×) 3. 冷却系统的通道要尽量避开塑件的熔接痕部位,以免影响塑件的强度。( √ ) 4. 斜导柱侧抽芯机构中的滑块导滑长度有一定的要求,完成抽拔后,滑块留在导滑槽中的长度不应小于 滑块长度的3/2。 (×)

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2010-2011学年下学期期末考试 《模具设计与制造》补考试卷答案 一、选择题(每题1分,共20分) 1 、冲裁变形过程中的塑性变形阶段形成了 ___ A ________ 。 A 、光亮带 B 、毛刺 C 、断裂带 2 、模具的合理间隙是靠 ___ C ________ 刃口尺寸及公差来实现。 A 、凸模 B 、凹模 C 、凸模和凹模 D 、凸凹模 3 、落料时,其刃口尺寸计算原则是先确定 ____ A_______ 。 A 、凹模刃口尺寸 B 、凸模刃口尺寸 C 、凸、凹模尺寸公差 4 、对 T 形件,为提高材料的利用率,应采用 _____ C______ 。 A 、多排 B 、直对排 C 、斜对排 5 、冲裁多孔冲件时,为了降低冲裁力,应采用 ___ A___ 的方法来实现小设备冲裁大冲件。 A 、阶梯凸模冲裁 B 、斜刃冲裁 C 、加热冲裁 6 、冲裁件外形和内形有较高的位置精度要求,宜采用 _____ C ______ 。 A 、导板模 B 、级进模 C 、复合模 7 、导板模中,要保证凸、凹模正确配合,主要靠 ______ B____ 导向。 A 、导筒 B 、导板 C 、导柱、导套 8 、在导柱式单工序冲裁模中,导柱与导套的配合采用 _____ C _____ 。 A 、 H7/m6 B 、 H7/r6 C 、 H7/h6 9 、精度高、形状复杂的冲件一般采用 _____ A _____ 凹模形式。 A 、直筒式刃口 B 、锥筒式刃口 C 、斜刃口 10 、弹性卸料装置除起卸料作用外,还有 _____ C_____ 的作用。 A 、卸料力大 B 、平直度低 C 、压料作用 11 、中、小型模具的上模是通过 ______ B ____ 固定在压力机滑块上的。 A 、导板 B 、模柄 C 、上模座 12 、小凸模冲孔的导板模中,凸模与固定板呈 _____ A_____ 配合。 A 、间隙 B 、过渡 C 、过盈 13 、能进行三个方向送料,操作方便的模架结构是 ____ B______ 。 A 、对角导柱模架 B 、后侧导柱模架 C 、中间导柱模架 14 、凸模与凸模固定板之间采用 __ A __ 配合,装配后将凸模端面与固定板一起磨平。 A 、 H7/h6 B 、 H7/r6 C 、 H7/m6 15 、表示板料弯曲变形程度大小的参数是 ___ B _____ 。 A 、 y/ρ B、r/t C、 E/σS 16 、弯曲件在变形区内出现断面为扇形的是 ____ B____ 。

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《冲压模具设计与制造》期末总复习题 一、填空题: 1、在冲压工艺中,有时也采用加热成形方法,加热的目的是 ---提高塑性, -------- ,增加材料在一次成型中所能达到的变形程度;----降低变形抗力-------提高工件的成形准确度。 2、.冲裁件的切断面由圆角带、光亮带、剪裂带、毛刺四个部分组成。 3、按工序组合程度分,冲裁模可分为----单工序模、级进模、复合模--等几种。 4、材料的塑性--越好, ---,塑性变形的稳定性越强,许可的最小弯曲半径就--越小--。 5、工件上有多个弯曲角时,一般应该先弯外角,后弯内角。 6、拉深件的壁厚 ----不均匀------。下部壁厚略有--减薄----,上部却有所增厚---。 7、冷冲模是利用安装在压力机上的模具对材料施加变形力,使其产生变形或分离,从而获得冲件的一种压力加工方法。 8、胀形变形区内金属处于双向拉伸的应力状态,其成形极限将受到拉伸破裂的限制。 9、一般常用的金属材料在冷塑性变形时,随变形程度的增加,所有强度硬度指标增加,塑性指标降低,这种现象称为加工硬化。 10、在弯曲变形区内,内层纤维切向受压而缩短,外层纤维切向受受拉而伸长。 11、对于弯曲件上位于变形区或靠近变形区的孔或孔与基准面相对位置要求较高时,必须先弯曲,后冲孔。 12、缩口变形区由于受到较大切向相对弯曲半径的作用,易产生切向失稳而最小弯曲 半径,所以失稳起皱是缩口工序的主要障碍。 13、拉深系数是表示拉深后圆筒形件的直径与拉深前毛坯(或半成品)的直 径之比,用式d/D表达。 14、最小相对弯曲半径是指在保证毛坯弯曲时外表面不发生开裂的条件下,弯曲件内表面能够弯成的最小圆角半径与毛坯厚度的比值,用r /t来表示。 min

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模具设计与制造期末复习题与答案 一、填空题: 1在冲压工艺中,有时也采用加热成形方法,加热的目的是------- ,增加材料在 一次成型中所能达到的变形程度; -------- 提高工件的成形准确度。 2、.冲裁件的切断面由-------- 、----------- 、---------- 、---------- 、 四个部分组成。 3、按工序组合程度分,冲裁模可分为 -------- 、 --------- 和--------- 等几种。 4、材料的塑性----- ,塑性变形的稳定性越强,许可的最小弯曲半径就------------- 。 5、工件上有多个弯曲角时,一般应该先弯 -------- ,后弯 ---------- 。 6、拉深件的壁厚------- 。下部壁厚略有 ------------ ,上部却有所——。 7、冷冲模是利用安装在压力机上的对材料施加变形力,使其产生,从而获得冲件的一种压力加工方法。 8、一般常用的金属材料在冷塑性变形时,随变形程度的增加,所有强度硬度指标 ------- ,塑性指标 ------------- ,这种现象称为加工硬化。 9、在弯曲变形区内,内层纤维切向 ---------- ,外层纤维切向受--------------- 。 10、对于弯曲件上位于变形区或靠近变形区的孔或孔与基准面相对位置要求较高时,必须先-------- ,后--------------- 。 11、拉深系数是表示拉深后圆筒形件的----------- 与拉深前毛坯(或半成品)的直径 之比,用式---------- 表达。 12、最小相对弯曲半径是指在保证毛坯弯曲时外表面不发生开裂的条件下,弯曲件内表面能够弯成的 ---------- 与 ---------------- 的比值,用rmi n/t 来表示。 13、在拉深过程中,毛坯受凸模拉深力的作用,在凸缘毛坯的径向产生-------- , 切向产生----------- 。在它们的共同作用下,凸缘变形区材料发生了塑性变形, 并不断被拉入凹模内形成筒形拉深件。 14、与冲裁模相比,拉深凸、凹模的工作部分不应具有锋利的刃口,而应具有一定的 -------- ,凸、凹模间隙略-------------- 料厚。 15、有弯曲、拉深等成形工序的零件,采用级进冲压时,位于成形变形区上的孔,应安排在 -------- 冲出,落料或切断工位一般安排在----------------- 工位上。 16、当弯曲件的折弯线与纤维方向时,材料具有较大的拉伸强度,不易拉 17、金属塑性变形时物体主要是发生形状的改变,体积变化------- ,其表达式可写成

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塑料成型的方法很多,有压缩、压注及注射等。 塑料一般是由_高分子合成树脂_和_添加剂_组成。 塑料按合成树脂的分子结构及热性能分为热塑性塑料和热固性塑料两种。 注射成型一般用于热塑性塑料的成型,压缩模塑主要用于热固性塑料的成型。 塑料按性能及用途分为通用塑料、特殊塑料、工程塑料。 在挤出模塑中,塑件的形状和尺寸基本上取决挤出机头和定型模。 注射模塑工艺的条件是温度、压力和时间。 铸造方法可分为砂铸和特种两大类。 弯曲件最容易出现影响工件质量的间题有弯裂、回弹、和偏移等。 拉深模中压边圈的作用是防止工件在变形过程中发生起皱。 冲模的制造精度越高,则冲裁件的精度越高。 按工序组合程度分,冲裁模可分为单工序模、级进模和复合模等几种。 在压力机的一次行程中,只完成一个冲压工序的冲模称为单工序模。 在条料的送进方向上,具有两个或两个以上的工位,并在压力机的一次行程中,在不同的工位上完成两个或两个以上工位的冲压工序的冲模称为级进模。 在压力机的一次行程中,在模具的同一位置上,完成两个或两个以上的冲压工序的模具,叫复合模。 由于级进模生产率高,便于操作,易实现生产自动化,但轮廓尺寸大,制造复杂,成本高,所以一般适用于批量大、小尺寸工件的冲压生产。 全部为冲裁工步的级进模,一般是先冲孔后落料。先冲出的孔可作为后续工位的定位孔,若该孔不适合定位或定位要求较高时,则应冲出工艺孔作定位用。 冲裁过程中落料件的外形尺寸等于凹模尺寸,冲孔件孔的尺寸等于凸模尺寸。

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