Mold-Making Handbook - Buch.de · Mold-Making Handbook Günter Mennig Klaus Stoeckhert Hanser...

15
Günter Mennig K. Stoeckhert Mold-Making Handbook 3rd Edition

Transcript of Mold-Making Handbook - Buch.de · Mold-Making Handbook Günter Mennig Klaus Stoeckhert Hanser...

Page 1: Mold-Making Handbook - Buch.de · Mold-Making Handbook Günter Mennig Klaus Stoeckhert Hanser Publishers, Munich Hanser Publications, Cincinnati 3rd Edition. The Editors: Prof. Dr.-Ing.

Günter MennigK. Stoeckhert

Mold-MakingHandbook

3rd Edition

Page 2: Mold-Making Handbook - Buch.de · Mold-Making Handbook Günter Mennig Klaus Stoeckhert Hanser Publishers, Munich Hanser Publications, Cincinnati 3rd Edition. The Editors: Prof. Dr.-Ing.

Mennig, Stoeckhert Mold-Making Handbook

Page 3: Mold-Making Handbook - Buch.de · Mold-Making Handbook Günter Mennig Klaus Stoeckhert Hanser Publishers, Munich Hanser Publications, Cincinnati 3rd Edition. The Editors: Prof. Dr.-Ing.
Page 4: Mold-Making Handbook - Buch.de · Mold-Making Handbook Günter Mennig Klaus Stoeckhert Hanser Publishers, Munich Hanser Publications, Cincinnati 3rd Edition. The Editors: Prof. Dr.-Ing.

Mold-Making Handbook

Günter MennigKlaus Stoeckhert

Hanser Publishers, Munich Hanser Publications, Cincinnati

3rd Edition

Page 5: Mold-Making Handbook - Buch.de · Mold-Making Handbook Günter Mennig Klaus Stoeckhert Hanser Publishers, Munich Hanser Publications, Cincinnati 3rd Edition. The Editors: Prof. Dr.-Ing.

The Editors:Prof. Dr.-Ing. Günter Mennig,Technische Universität Chemnitz, Institut für Allg. Maschinenbau und Kunststofftechnik, Chemnitz, GermanyDr.-Ing. Klaus Stoeckhert (†)

Distributed in North and South America by: Hanser Publications 6915 Valley Avenue, Cincinnati, Ohio 45244-3029, USA Fax: (513) 527-8801 Phone: (513) 527-8977 www.hanserpublications.com

Distributed in all other countries by Carl Hanser Verlag Postfach 86 04 20, 81631 München, Germany Fax: +49 (89) 98 48 09 www.hanser.de

The use of general descriptive names, trademarks, etc., in this publication, even if the former are not especially identified, is not to be taken as a sign that such names, as understood by the Trade Marks and Merchandise Marks Act, may accordingly be used freely by anyone.While the advice and information in this book are believed to be true and accurate at the date of going to press, neither the authors nor the editors nor the publisher can accept any legal responsibility for any errors or omissions that may be made. The publisher makes no warranty, express or implied, with respect to the material contained herein.

Library of Congress Cataloging-in-Publication Data

Werkzeuge der Kunststoffverarbeitung. English. Mold-making handbook / [edited by] G?nter Mennig, Klaus Stoeckhert. -- 3rd Edition. pages cm ISBN 978-1-56990-446-6 (hardcover) 1. Plastics--Molds. I. Mennig, G?nter. II. Stoeckhert, Klaus, 1913- III. Title. TP1150.W4613 2012 668.4’12--dc23 2012027079

Bibliografische Information Der Deutschen Bibliothek Die Deutsche Bibliothek verzeichnet diese Publikation in der Deutschen Nationalbibliografie; detaillierte bibliografische Daten sind im Internet über <http://dnb.d-nb.de> abrufbar.

ISBN 978-1-56990-446-6E-Book-ISBN 978-1-56990-550-0

All rights reserved. No part of this book may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying or by any information storage and retrieval system, without permission in writing from the publisher.

© Carl Hanser Verlag, Munich 2013 Production Management: Steffen Jörg Coverconcept: Marc Müller-Bremer, www.rebranding.de, MünchenCoverdesign: Stephan RönigkTypeset: Manuela Treindl, FürthPrinted and bound by Kösel, KrugzellPrinted in Germany

Page 6: Mold-Making Handbook - Buch.de · Mold-Making Handbook Günter Mennig Klaus Stoeckhert Hanser Publishers, Munich Hanser Publications, Cincinnati 3rd Edition. The Editors: Prof. Dr.-Ing.

About the Book

The book uses European steel grades.

References for the comparison of US and European steel grades are available, for example, from Beuth Verlag (Marks, P., US Steels: A comparison of US and Euro-pean steel grades, German-English (2012), Beuth Verlag, Berlin, www.beuth.de) or at www.key-to-steel.com.

Page 7: Mold-Making Handbook - Buch.de · Mold-Making Handbook Günter Mennig Klaus Stoeckhert Hanser Publishers, Munich Hanser Publications, Cincinnati 3rd Edition. The Editors: Prof. Dr.-Ing.
Page 8: Mold-Making Handbook - Buch.de · Mold-Making Handbook Günter Mennig Klaus Stoeckhert Hanser Publishers, Munich Hanser Publications, Cincinnati 3rd Edition. The Editors: Prof. Dr.-Ing.

Contributors

Dipl.-Ing. (FH) Christopherus Bader (Chapter 5.2) PRIAMUS SYSTEM TECHNOLOGIES AG, Schaffhausen, Switzerland

Prof. Dr.-Ing. Thomas Bauernhansl (Chapter 1.9) Fraunhofer-Institut für Produktionstechnik und Automatisierung IPA, Stuttgart, Germany

Dr.-Ing. Joachim Berthold (Chapter 1.2) Gummersbach, Germany

André Brandt (Chapter 2.2) HASCO Hasenclever GmbH & Co. KG, Lüdenscheid, Germany

Dipl.-Ing. Otto Eiselen (Chapter 1.4) HECO Maschinen- und Werkzeugbau GmbH, Lohmar, Germany

Alfred Erstling (Chapter 3.2) Wuppertal, Germany

Dipl.-Ing. Thomas Eulenstein (Chapter 2.5 and 5.3) Kunststoff-Institut Lüdenscheid, K.I.M.W. NRW GmbH, Lüdenscheid, Germany

Prof. Dr. Ing. Andreas Gebhardt (Chapter 4.7) CP GmbH, Erkelenz and University of Applied Sciences Aachen, Aachen, Germany

Dipl.-Ing. Josef Gockel (Chapter 2.2) HASCO Hasenclever GmbH & Co. KG, Lüdenscheid, Germany

Ing. Rolf Hentrich (Chapter 1.6 and 4.3) Lahr, Germany

Dipl.-Ing. (FH) Felix Hinken (Chapter 2.1) Schneider Form GmbH, Dettingen/Teck, Germany

Dipl.-Ing. Udo Hinzpeter (Chapter 5.3) Kunststoff -Institut Lüdenscheid; K.I.M.W. NRW GmbH, Lüdenscheid, Germany

Page 9: Mold-Making Handbook - Buch.de · Mold-Making Handbook Günter Mennig Klaus Stoeckhert Hanser Publishers, Munich Hanser Publications, Cincinnati 3rd Edition. The Editors: Prof. Dr.-Ing.

VIII Contributors

Dr.-Ing. Frank Hippenstiel (Chapter 3.1) BGH Edelstahl Siegen GmbH, Siegen, Germany

Robert Hofmann (Chapter 1.11) Hofmann Modellbau, Lichtenfels, Germany

Prof. Dipl.-Ing. Peter Karlinger (Chapter 2.1) University of Applied Sciences Rosenheim, Rosenheim, Germany

Dipl.-Ing. (FH) Armin Klotzbücher (Chapter 4.1) KWO Kunststoffteile GmbH, Offenau, Germany

Dr. Ulrich Knipp (Chapter 1.3) Bergisch Gladbach, Germany

Günter Konzilia (Chapter 1.10) z-werkzeugbau-gmbh, Dornbirn, Austria

Stefan Krüth (Chapter 4.6) J. & F. Krüth GmbH, Solingen, Germany

Bernhard Mack (Chapter 4.2) Mack Erodiertechnik, Langenau, Germany

Dr. Udo Maier (Chapter 1.3) Pulheim, Germany

Prof. Dr.-Ing. Peter Mitschang (Chapter 1.8) Institut für Verbundwerkstoffe GmbH, Kaiserslautern, Germany

Dipl.-Ing. Dirk Paulmann (Chapter 2.3) HASCO Hasenclever GmbH & Co. KG, Lüdenscheid, Germany

Dipl.-Ing. Norbert Reuber (Chapter 1.7) Kurtz GmbH, Kreuzwertheim, Germany

Dipl.-Ing. Manfred Sander (Chapter 2.3) Iserlohn, Germany

Dipl.-Ing. (FH) Dietmar Schäffner (Chapter 4.2) Viscoch GmbH, Widnau, Switzerland

Prof. Dr.-Ing. Alois K. Schlarb (Chapter 1.8) University Kaiserslautern, Kaiserslautern, Germany

Prof. Dr.-Ing. Ralf Schledjewski (Chapter 1.8) Montanuniversität Leoben, Leoben, Austria

Prof. Dr.-Ing. Friedhelm Schlößer (Chapter 5.1) KION Group AG, Wiesbaden, Germany

Page 10: Mold-Making Handbook - Buch.de · Mold-Making Handbook Günter Mennig Klaus Stoeckhert Hanser Publishers, Munich Hanser Publications, Cincinnati 3rd Edition. The Editors: Prof. Dr.-Ing.

IX Contributors

Edgar Seufert (Chapter 3.3) Schmelzmetall Deutschland GmbH, Steinfeld-Hausen, Germany

Dipl.-Ing. Peter Schwarzmann (Chapter 1.5) Illig Maschinenbau GmbH & Co. KG, Heilbronn, Germany

Claudia Steiner (Chapter 4.4) NOVAPAX Kunststofftechnik Steiner GmbH & Co. KG, Berlin, Germany

Prof. Dr.-Ing. Paul Thienel (Chapter 2.4) University of Applied Sciences Südwestfalen, Iserlohn, Germany

Uwe Thiesen (Chapter 5.4) Plastics Germany GmbH & Co. KG, Lohne, Germany

Peter Vetter (Chapter 4.5) Buderus Edelstahl GmbH, Wetzlar, Germany

Dipl.-Betriebsw. Oliver Wandres (Chapter 1.6) Maus GmbH, Karlsruhe, Germany

Prof. Dipl.-Ing. Peter Wippenbeck (Chapter 1.1) Steinbeis-Innovationszentrum Kunststofftechnik, Aalen, Germany

Klaus Zoller (Chapter 1.9) Freudenberg Sealing Technologies GmbH & Co. KG, Weinheim, Germany

Page 11: Mold-Making Handbook - Buch.de · Mold-Making Handbook Günter Mennig Klaus Stoeckhert Hanser Publishers, Munich Hanser Publications, Cincinnati 3rd Edition. The Editors: Prof. Dr.-Ing.
Page 12: Mold-Making Handbook - Buch.de · Mold-Making Handbook Günter Mennig Klaus Stoeckhert Hanser Publishers, Munich Hanser Publications, Cincinnati 3rd Edition. The Editors: Prof. Dr.-Ing.

Editor’s Preface to the 3rd edition

When this book was first published in Carl Hanser Verlag in 1965 in German, edited by K. Stoeckhert, a market gap was filled, because a second edition was already required after four years, this time in collaboration with H. Domininghaus. The third edition came eleven years later (1980), which already had almost twice the number of pages. It was translated and became the 1 st English edition. Due to the personnel change in the editorship, it then took 15 years until the next edition was published with a slightly altered title in English and German. In addition a Chinese edition was launched for the first time. Again it took some 15 years for the now presented 3rd edition (the 5th in German) to be published.

The present edition is not only updated, but modernized and renewed. This is also indicated by the fact that only six of the “old” authors are still involved, and there are new chapters such as micro injection molds, molds for the rubber industry, or rapid prototyping, while others are no longer applicable. Otherwise, as it was already stated in the preface of the 4th German edition, it still applies that this compilation does not intend to serve as a textbook for the detailed design of an injection mold or to replace the catalogue of a manufacturer of standard mold units, and it is also not the long version of a lecture manuscript either. Rather, the brief description of the basic facts and the latest state of the art for the individual mold types and their manufacture allow a direct comparison in a compact form.

The book still addresses both, the reader who is looking for an introduction to a key area of plastics processing as well as the pronounced specialist to enable quick reading into related technical areas, which can result in ideas for their own work. Each chapter is self-contained; the proposed synergistic effect is achieved especially when the reader not only reads “his” chapter, but is willing to “look outside the box” of his own specialist field.

Chemnitz, April 2013 Günter Mennig

Page 13: Mold-Making Handbook - Buch.de · Mold-Making Handbook Günter Mennig Klaus Stoeckhert Hanser Publishers, Munich Hanser Publications, Cincinnati 3rd Edition. The Editors: Prof. Dr.-Ing.
Page 14: Mold-Making Handbook - Buch.de · Mold-Making Handbook Günter Mennig Klaus Stoeckhert Hanser Publishers, Munich Hanser Publications, Cincinnati 3rd Edition. The Editors: Prof. Dr.-Ing.

Contents

About the Book . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V

Contributors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VII

Editor’s Preface to the 3rd edition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . XI

1 Molds for Various Processing Methods. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.1 Injection Molds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

P. Wippenbeck1.1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.1.2 Injection Molding Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.1.3 Design of the Molded Part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71.1.4 Basic Mold Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91.1.5 Types of Ejection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101.1.5.1 Products without Undercuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101.1.5.2 Products with External Undercuts . . . . . . . . . . . . . . . . . . . . . . . . 131.1.5.3 Product with Internal Undercuts . . . . . . . . . . . . . . . . . . . . . . . . . . 171.1.5.4 Products with Internal Threads . . . . . . . . . . . . . . . . . . . . . . . . . . . 191.1.6 Gate Technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211.1.6.1 Gate Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211.1.6.2 Solidifying Runner, Remaining at the Molded Part . . . . . . . . . 231.1.6.3 Automatically Separated Runner . . . . . . . . . . . . . . . . . . . . . . . . . . 261.1.6.4 Pass Through Channels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291.1.6.5 Hotrunner Molds. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311.1.6.6 Hotrunner Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341.1.7 Venting of the Cavity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 371.1.8 Temperature Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 391.1.9 Special Designs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411.1.9.1 Stack Molds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411.1.9.2 Injection-Compression Molds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 431.1.9.3 Multi-Component Technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Page 15: Mold-Making Handbook - Buch.de · Mold-Making Handbook Günter Mennig Klaus Stoeckhert Hanser Publishers, Munich Hanser Publications, Cincinnati 3rd Edition. The Editors: Prof. Dr.-Ing.

XIV Contents

1.1.9.4 Outsert Technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 481.1.9.5 Molds for Thermosets and Elastomers . . . . . . . . . . . . . . . . . . . . . 49

1.2 Compression and Transfer Molds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52J. Berthold1.2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 521.2.2 Compression Molds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 531.2.2.1 General Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 531.2.2.2 Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 551.2.2.3 Components of a Compression Mold . . . . . . . . . . . . . . . . . . . . . . . 561.2.3 Transfer Molding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 561.2.3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 561.2.3.2 Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 571.2.3.3 Structure of a Transfer Mold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 571.2.4 Making Compression Molds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 581.2.4.1 Machining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 591.2.5 Mold Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 591.2.5.1 Types of Molds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601.2.5.1.1 Small-Series Mold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601.2.5.1.2 Test Mold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601.2.5.1.3 Standard Mold Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601.2.5.1.4 Conventional Compression Mold . . . . . . . . . . . . . . . . . . . . . . . . . . 621.2.5.2 Structural Mold Designs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 621.2.5.2.1 Positive Mold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 621.2.5.2.2 Positive Mold with Lands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 631.2.5.2.3 Multi-Cavity Mold with a Common Loading Chamber. . . . . . . 641.2.5.2.4 Multi-Cavity Mold with Individual Loading Chambers . . . . . . 641.2.5.2.5 Mold with Lateral Core Puller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 651.2.5.2.6 Split Mold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 661.2.5.2.7 Hinged Split-Cavity Mold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 661.2.5.2.8 Mold with Inserts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 671.2.5.2.9 Unscrewing Mold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 671.2.5.3 General Aspects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 681.2.6 Sheet Molding Compound (SMC)-Molds . . . . . . . . . . . . . . . . . . . 691.2.6.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 691.2.6.2 Mold Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 701.2.6.2.1 Mold Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 721.2.6.2.2 Ejector Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 731.2.6.2.3 Undercuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 741.2.6.2.4 Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 751.2.7 GMT/LFT Molds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 751.2.7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75