Standard |
MCA 231 – Mold Design
II
Continuation of Mold Design I in the selection of mold steels, machining methods, heat treatments, polishing, construction theory of molds, and the design of die cast molds. Topics include: selection of mold base steels, machining methods, heat treatments, polishing of molds, theory in the construction of a mold base, heating and cooling of molds, and design and operation of die cast molds and rubber molds.
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Competency
Areas |
Hours |
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Selection of Mold Base Steels |
Class |
5 | |
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Machining Methods |
D. Lab |
0 | |
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Heat Treatments |
P. Lab/O.B.I. |
0 | |
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Polishing of Molds |
Credit |
5 | |
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Theory in the Construction of a Mold Base |
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Heating and Cooling of Molds |
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Design and Operation of Die Cast Molds and Rubber Molds |
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Prerequisite/Corequisite: |
MCA 230, MCA 235 | ||
Course Guide |
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Competency |
After completing this
section, the student will: |
Hours | ||
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Class |
D.Lab |
P.Lab/
O.B.I. | ||
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SELECTION OF MOLD BASE
STEELS |
5 |
0 |
0 | |
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Steel |
Describe the type of steel recommended for each mold component and explain why that particular type of steel is used. |
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Describe the impact of a particular molding operation on the types of steel used in making a mold. |
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MACHINING METHODS |
5 |
0 |
0 | |
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Types of machines |
Identify CNC and EDM machines. |
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Describe pressure casting processes. |
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Describe how "hobbing" a casting works. |
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Discuss the processes the different machining methods make possible. |
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HEAT TREATMENTS |
10 |
0 |
0 | |
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Methods & processes |
Describe the different methods used in heat treating materials. |
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Describe the processes/stages of heat treatment. |
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Describe the methods used when testing materials for hardness. |
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POLISHING OF MOLDS
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10 |
0 |
0 | |
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Polishing methods |
List the methods available to polish molds both mechanically and by hand. |
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Grit |
Describe grit and screen size of grits and polishing compounds. |
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Finish |
Explain polishing procedures to obtain a given finish. |
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THEORY IN THE CONSTRUCTION OF A MOLD
BASE |
10 |
0 |
0 | |
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Cutting |
Cut metal with torch. |
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Guide pin holes |
Explain procedure for locating, measuring, and marking guide pin holes and number plates. |
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Provide for the location and machining of pockets. |
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Drill holes |
Discuss hole drilling techniques for guide pins, return pins, ejector pins, water channels, and assembly screws. |
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HEATING AND COOLING OF MOLDS |
5 |
0 |
0 | |
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Introduction |
Explain necessity for heating or cooling molds. |
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Temperature control |
Describe mold temperature regulation during production using permanent molds. |
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Explain temperature control in plastic molding processes. |
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Describe a closed die casting machine set up, heat the dies, and cast parts. |
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DESIGN AND OPERATION OF DIE CAST MOLDS AND RUBBER
MOLDS |
5 |
0 |
0 | |
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Die cast molds |
Describe zinc die cast mold and aluminum die cast mold use. |
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Discuss the effect of a die cast mold design on operation. |
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Describe process for entering material in a die cast mold. |
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Rubber molds |
Describe rubber mold design. Describe rubber mold operation. |
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Suggested Resources |
Allyn, E. (1987). Mold design I: For plastic injection.
Woodstock, NY: Allyn Air.
Bhattacharya. (1987). Metal-filled polymers: Properties and
applications. New York: Dekker.
Birley, A. W., et al. (1988). Plastics materials: Properties and
applications (2nd ed.). New York: Chapman & Hall.
Brown, R. L. (1980). Design and manufacture of plastic parts.
New York: John Wiley & Sons.
Calvert, E. (1980). Injection moulding. Philadelphia:
Trans-Atl Phila.
Chkeremisinoff. (1989). Handbook of polymer science and technology:
Performance properties of plastics and elastomers (Vol. 2). New York:
Dekker.
DuBois, J. H., & Pribble, W. I. (1987).
Plastics mold design engineering
handbook (4th ed.). New York: Van Nos Reinhold.
Dym, J. B. (1987). Injection molds and molding (2nd ed.).
New York: Van Nos Reinhold.
Epstein, G., & Schwartz, S. (Eds.).
(1985). Mold design and moldmaking for
plastics products. New York: T-C Pubns CA.
Gastrow, H., & Stoeckhert, K. (1983). Injection molds: One hundred two
designs. New York: Oxford University Press.
Glanvill, A. B., & Denton, E. N. (1965).
Injection-mould design fundamentals.
New York: Industrial Press.
Isayev, I. A. (1987). Injection and compression molding
fundamentals. New York: Dekker.
Johannaber, F. (1983). Injection molding machines: A user's
guide. New York: Oxford University Press.
Menges, G., & Mohren, P. (1986). How to make injection moulds. New York:
Oxford University Press.
Nyborg, R. L. (1990). Plastic injection molding made easy.
Provo, UT: Regal Pubns.
Robinson, J. S. (Ed.). (1981). Plastics molding: Equipment, processes, and
materials. Lake Mary, FL: Polymers and Plastics Tech
Pub.
Rosato, D. V., & Rosato, D. V. (1985). Injection molding handbook. New York:
Van Nos Reinhold.
Rosato, D. V., & Rosato, D. V. (Eds.).
(1989). Blow molding handbook. New
York: Macmillan.
Schwartz, S., & Goodman, S. (1982). Plastics materials and processes. New
York: Van Nos Reinhold.
Society of Plastics Engineers Staff. (1985).
Tooling challenges for the 80's:
Injection molding tooling: Design, materials, methods. New York: Bks Demand
UMI.
Sors, L. (1981). Plastics molds and dies. New York: Van
Nos Reinhold.
Sors, L., & Balazs, I. (1989). Design of plastic moulds and dies. New
York: Elsevier.
Stoeckhert, K. (1983). Mold-making handbook: For the plastics
engineer. New York: Oxford University Press.
T-C Pubns CA. (1981). Proceedings of SPE Pactec '81, August 25-27,
1981, Los Angeles, California. New York: Author.
T-C Pubns CA. (1983). Foams: Molding thermosetting and
thermoplastic structural foam. New York: Author.
T-C Pubns CA. (1983). Injection molding-plastics. New York:
Author.
T-C Pubns CA. (1984). Injection molding machinery and accessories,
1976-January 1985. New York: Author.
T-C Pubns CA. (1984). Injection molding of plastics. New York:
Author.
T-C Pubns CA. (1984). Mold release agents for rubbers and
plastics, 1973-1986. New York: Author.
T-C Pubns CA. (1984). Reaction injection molding of polymers.
New York: Author.
T-C Pubns CA. (1985). Machining processes and properties of
plastics and elastomers, 1973-April 1985. New York:
Author.
Tobin, W. J. (1985). Quality control manual for injection
molding. New York: T-C Pubns CA