1 | M o u l d i n g
BAB I
PENDAHULUAN
I.1. Latar Belakang
Saat ini, terjadi pertumbuhan yang sangat pesat pada penggunaan produk plastik di industri manufaktur karena sangat serbaguna dan memiliki nilai ekonomis yang tinggi. Dukungan ilmu pengetahuan dan teknologi sangat diperlukan khususnya untuk pemanfaatan dan pengolahan polimer, sehingga dapat dihasilkan produk plastik dengan kuantitas yang cukup tinggi dan kualitas yang baik. Salah satu teknik yang cukup efektif dan banyak dipergunakan untuk pengolahan bahan thermoplastic adalah injection molding. Injection Molding banyak dipilih karena memiliki beberapa keuntungan diantaranya :
kapasitas produksi yang tinggi, sisa penggunaan material (useless material) sedikit dan tenaga kerja minimal. Sedangkan kekuranganya, biaya investasi dan perawatan alat yang tinggi , serta perancangan produk harus mempertimbangkan untuk pembuatan disain moldingnya.
Pembuatan sebuah mould, tidaklah serumit dulu , karena telah banyak produsen yang menjual sebuah mould base , yang dapat memudahkan operator dalam mencapai efesiensi waktu dan memiliki kemudahan yang sangat menguntungkan.
I.2. Tujuan
Mengetahui fungsi Mould Base
Agar mengetahui standar-standar Mould Base yang ada atau tersedia di pasaran Sarana belajar moulding
2 | M o u l d i n g
BAB II
PEMBAHASAN
II.1. Pengertian Mould Base
Mould base digunakan dalam berbagai industri untuk jangka pendek dan aplikasi pencetakan.Mould base diproduksi dengan menggunakan bahan kualitas unggul seperti baja ringan dan baja karbon. Tersedia berbagai cetakan yang tersedia dalam berbagai ukuran, bentuk dan dimensi yang sesuai dengan berbagai jenis die casting dies.
II.2. Standar Mould Base
II.2.1. Standar Mould base dari Ashna
Standar. Standar dasar Mould umumnya digunakan dalam prototipe cetakan dan pendek berjalan. Cetakan ini menawarkan fleksibilitas untuk melakukan lebih banyak pekerjaan bernilai tambah, dengan penurunan yang signifikan dalam biaya dasar cetakan. Proses produksi terkonsentrasi pada penyediaan dasar cetakan berkualitas tinggi untuk
plastik.
Mould base / Mold Base
Material - C - 45 / As Per Customer requirement
S.N. 1 2 3 4 5 6 7 8 9 10 11 12
TYPE 2020 2025 2030 2035 2525 2530 2540 3030 3035 3040 4040 4045 CODE 1 AE 1 AE 1 AE 1 AE 1 AE 1 AE 1 AE 1 AE 1 AE 1 AE 1 AE 1 AE
3 | M o u l d i n g CODE 2 AE 2 AE 2 AE 2 AE 2 AE 2 AE 2 AE 2 AE 2 AE 2 AE 2 AE 2 AE CODE 3 AE 3 AE 3 AE 3 AE 3 AE 3 AE 3 AE 3 AE 3 AE 3 AE 3 AE 3 AE CODE 4 AE 4 AE 4 AE 4 AE 4 AE 4 AE 4 AE 4 AE 4 AE 4 AE 4 AE 4 AE
II.2.2. Standar Mould base dari Futaba
Specification/selection
Specification
2-plates
type 3-plates type
S series D/E
series F/G series H series
Standard specification Thickness selection Dimension A 〇 〇 〇 〇 Dimension B 〇 〇 〇 〇
4 | M o u l d i n g Dimension
U 〇 〇 〇 〇
Dimension
C 〇 〇 〇 〇
Mounting plate specification 〇 〇 〇 〇
Guide specification 〇 〇 〇
Ejector plate specification 〇 〇 〇 〇
Support pin specification 〇
Support pin length 〇 〇 〇
Puller bolt length 〇
Option specification Thickness selection Dimension R 〇 〇 〇 Dimension S 〇 〇 〇 〇
No screw hole for Eyebolt 〇 〇 〇 〇
No hole for Ejector rod 〇 〇 〇 〇
Material change 〇 〇 〇
Plate accuracy of mold base (template, ejector plate and the other plates)
* The surface roughness sign in the above figure is arithmetic mean roughness (Ra). Material
S50C(up to 25mm thick) S55C(30mm thick or more)
Dimensional allowance of T
L - dimension(mm) Dimensional allowance of T (mm)
5 | M o u l d i n g More than 300 and up to 600 +0.15 to +0.25
More than 600 and up to 1150 +0.2 to +0.3 Uniformity of thickness (T)
0.008 per 100mm
Flatness of both faces of T
Dimensional – T (mm)
Dimensional - L (mm)
Up to 300 More than 300 and up to1150 5 or more and up to 10
More than 10 and up to 20 More than 20 up to 40 More than 40 up to 350 0.020 0.040 0.015 0.020 0.010 0.015 0.008 0.010
Squareness of reference plane 0.008 per 100mm
Spacer block
* The surface roughness sign in the above figure is arithmetic mean roughness (Ra). Material
SS400 or more than equivalent Uniformity of thickness of (T) 0.008 per 100mm
Variation of T in a pair of plates 0.02
6 | M o u l d i n g Mold base with three plates structure used for such as pin point gate
Feature Type Template size
High rigidity type which extend spacer block width High rigidity type 1518～2540
Standard type with extensive template sizes Standard type 1113～5070
Structure/Name
DA type DD type
Ejector pin ejects products.
Stripper plate ejects produts. No support plate.
7 | M o u l d i n g DB type DE type . DC type DF type . EA type
Stripper plate ejects products. Stripper plate ejects products b y m old opening m ovem ent
Ejector pin ejects products. No support plate. Stripper plate ejects products b y m old opening m ovem ent.
No support plate
Ejecter pin ejects products. No runner stripper plate.
EA t ype is m old base which elim inate runner stripper plate from DA type.
Sim ilarly, each t ype of EB/EC/ED is DB/DC/DD without runner stripper plate.
8 | M o u l d i n g Mold base with three plates structure which usable space is extended owing to the guide
by only support pin
Feature Type Template size
High rigidity type to extend spacer block width High rigidity type 1515～2540
Standard type with extensive template sizes Standard type 1113～5070
9 | M o u l d i n g FA type
FF type
This Type is what ejector pin is stuck out.
This type is what stripper plate is stuck out by mold opening movement.
FC type GA type
This type is what ejector pin is stuck out without backing plate. This type is what ejector pin is stuck out without runner stripper
FE type GC type
This type is what stripper plate is stuck out by mold opening movement. This type is what ejector pin is stuck out without runner stripper plate.
10 | M o u l d i n g Mold base with three plates structure to make pins etc. arranged at the four corners
Feature Type Template size
Standard for long mold with split mold and slide mechanism 2540～4070
11 | M o u l d i n g HA type
HC type
This type is what ejector pin is stuck out.
This type is what ejector pin is stuck out without backing plate.
HB type HD type
This type is what stripper plate is stuck out.
This type is what stripper plate is stuck out without backing plate.
12 | M o u l d i n g
13 | M o u l d i n g
II.2.3. Standar Mould base Hasco
HASCO Standard mould base (450*450~450*700)
Quick Details
Place of Origin: Guangdong, China (Mainland) Brand Name: JSM
Model Number: 45 seriesThree Plate Type System mold base Type: FAI~FCI, GAI~GCI,FAH-FCH,GAH-GCH
Size: 450*450~450*700
Shaping Mode: Plastic Injection Mould Product Material: Steel
Application: Household Product or Vehicle
Raw material:1050,P20,718,718H,738,8407,1.2311,1.1730,S50C Roughness: Ra 1.6
Thickness tolerance: +/- 0.05mm Vertical: 0.01/100mm
Packaging & Delivery Packaging
Details:
(1)Anti-rust oil (2)plastc film (3)white foam (4)pallet or wood box ,according to customer's request.
Delivery Detail:
14 | M o u l d i n g Specifications
1. professional manufacturers.
2. High quality, low price.
3. Advanced machinery and equipment.
4. Meet European standard.
Product's Details:
Standard: DME, HASCO, JIS, LKM
Design Software: UG, CAD
Life Time: 300,000 shots
lead Time: 7 days
Manufacture Experience: 15 years
Certification: ISO9001
Processing Machinery: CNC, Grinding, Milling, lathe, polishing Terms Of Delivery: By sea or By air
Surface Treatment: Sparkerusion and polished
place an order: your own design or choose our design
Terdapat 3 standar, di antaranya: I. K – Standards
K 3600 /… Small series mould
Order No. material No.
K3660/3670/156x156/1.1730 2048822 K3660/3670/156x156/1.2312 2048823 K3660/3670/190x246/1.1730 2048824 K3660/3670/190x246/1.2312 2048825 K3660/3670/246x296/1.1730 2048826 K3660/3670/246x296/1.2312 2048827 K3660/3670/296x396/1.1730 2048828 K3660/3670/296x396/1.2312 2048829 Ejector assembly K3660/3670
15 | M o u l d i n g K /… round
Order No. material No.
K 15/156X 22/1.1730 11142 K 15/196X 22/1.1730 11231 K 15/246-3X 27/1.1730 114880 K 15/246X 27/1.1730 11304 Clamping plate K 15 K /… square
Order No. material No.
K 10C/095X095X 22/1.1730 2009292 K 10C/095X095X 22/1.2085 2009293 K 10C/095X095X 22/1.2312 2009294
Clamping plate K 10C
K 2500 /… Split Mould Kit
Order No. material No.
K 2500/100x130x 16 589546 K 2500/100x130x 20 589547 K 2500/100x130x 25 589548 K 2500/100x130x 32 589549 K 2500/100x130x 40 589550 K 2500/156x156x 20 589551 K 2500/156x156x 25 589552
Split mould kit K 2500
K 3500 /… Quick-change Mould System
Quick changeable mould K 3500
Order No. material No.
K 3500/156x196x46x46/1.2085 2001233 K 3500/156x196x46x56/1.2085 2001234 K 3500/156x196x 46x 56/1.2312 589071 K 3500/156x196x 46x 46/1.2312 589070
16 | M o u l d i n g K 3500/156x196x56x46/1.2085 2001235 K 3500/156x196x56x56/1.2085 2001236 K 3500/156x196x 56x 46/1.2312 589072 K 5000 /… Mouldbase 75x75mm Cavity plate K 5121
Order No. material No.
K 5121/075X075X 40/1.2083 2007853 K 5121/075X075X 40/1.2085 2006804 K 5121/075X075X 40/1.2343 2006805 K 5121/075X075X 50/1.2083 2007855 K 5121/075X075X 50/1.2085 2006808 K 5121/075X075X 50/1.2343 2006809 K 5121/075X075X 60/1.2083 2007857 K 5121/075X075X 60/1.2085 2006812 K 5121/075X075X 60/1.2343 2006813 KR /… Insert-Modular-System Bloster plate KR 25
Order No. material No.
KR 25 /246X246X 36/1.1730 589902 KR 25 /246X246X 36/1.2085 589903 KR 25 /246X246X 36/1.2312 589904 KR 25 /246X246X 46/1.1730 589905 KR 25 /246X246X 46/1.2085 589906 KR 25 /246X246X 46/1.2312 589907 KR 25 /246X246X 56/1.1730 589908 KR 25 /246X246X 56/1.2085 589909 KR 25 /246X246X 56/1.2312 589910 II. P – Standards
F /… precision flat steel
17 | M o u l d i n g K / 500 X 63 X 1000 / 1.1730 K / 500 X 50 X 1000 / 1.1730 K / 500 X 40 X 1000 / 1.1730 K / 500 X 32 X 1000 / 1.1730 K / 500 X 30 X 1000 / 1.1730 K / 500 X 25 X 1000 / 1.1730 K / 500 X 63 X 1000 / 1.1730 K / 500 X 50 X 1000 / 1.1730
Precision ground flat stell F
P /… riser ring
Order No. material No.
P/ 156X098X 36/1.1730 34886 P/ 156X098X 46/1.1730 34894 P/ 156X098X 56/1.1730 34908 P/ 156X098X 76/1.1730 34916 P/ 196X132X 46/1.1730 36919 P/ 196X132X 56/1.1730 36927 P/ 196X132X 76/1.1730 36935 P/ 196X132X 96/1.1730 36943 P/ 246X168X 56/1.1730 39144 Plate P P /… riser segments
Order No. material No.
P/ 095X020X 22/1.1730 31674 P/ 095X020X 27/1.1730 31682 P/ 095X020X 36/1.1730 31690 P/ 095X020X 46/1.1730 31704 P/ 116X029X 36/1.1730 32913 P/ 116X029X 46/1.1730 32921 P/ 116X029X 56/1.1730 32930 Plate P
Order No. material No.
P/ 095X 6/1.1730 30996 P/ 095X 6/1.2162 31003 P/ 095X 6/1.2312 31011
18 | M o u l d i n g P/ 095X 6/1.2767 84662 P/ 095X 9/1.1730 31038 P/ 095X 9/1.2162 31046 P/ 095X 9/1.2312 31054 P/ 095X 9/1.2767 84670 P/ 095X 12/1.1730 31070 P /… round Plate P P 1100 /… square Order No. P 1100 / 218X296X17 / 1.2162 P 1100 / 218X296X17 / 1.2312 P 1100 / 218X296X17 / 1.2311 P 1100 / 218X296X66 / 1.2767 P 1100 / 218X296X66 / 1.2312 P 1100 / 218X296X66 / 1.2311 P 1100 / 218X296X76 / 1.2311 P 1100 / 218X296X76 / 1.2162 P 1100 / 218X296X76 / 1.2085 P 1100 / 218X296X76 / 1.1730 Machine plate P 1100 P 8000 /… round steel
Order No. material No.
P 8000/006X100/1.2210 2032215 P 8000/006X200/1.2210 2032216 P 8000/006X400/1.2210 2032217 P 8000/006X500/1.2210 2032218 P 8000/006X650/1.2210 2032219 P 8000/006X800/1.2210 2032220 P 8000/008X100/1.2210 2032221 P 8000/008X200/1.2210 2032222
19 | M o u l d i n g
P 8000/008X400/1.2210 2032223
Round steel P 8000
PR /… inserts, square
Order No. material No.
PR/ 40X 50X 20/1.2767 235962 PR/ 40X 50X 20/3.4365 278262 PR/ 40X 50X 25/1.2767 235970 PR/ 40X 50X 25/3.4365 278270 PR/ 40X 50X 32/1.2767 235989 PR/ 40X 50X 32/3.4365 278289 PR/ 40X 50X 40/1.2767 235997 PR/ 40X 50X 40/3.4365 278297 PR/ 40X 70X 20/1.2767 236004 Precision insert PR III. Z – Standards
Z1 General mould Components
Order No. material No.
Z 12 /12X 40 194646 Z 12 /12X 56 194654 Z 12 /18X 45 194662 Z 12 /18X 56 194670 Z 12 /18X 71 194689 Z 12 /30X 56 194697 Z 12 /30X 75 194700
20 | M o u l d i n g Z2 General tool component
Arrow insert Z 484
Order No. material No.
Z 484 / 6 232009 Z 484 / 8 232017 Z 484 /12 232130 Z 484 /16 232149 Z 484 /20 232157 Z3 Ejection Air valve Z 491
Order No. material No.
Z 491 / 8/ 6 73199 Z 491 /12/ 8 73210 Z 491 /16/10 73237
Z4 Demoulding
Adapter Z 1696
Order No. material No.
Z 1696 /22 92908
Z 1696 /25 171913
Z 1696 /32 19909
21 | M o u l d i n g
Filter cartridge Z 109
Order No. material No.
Z 109 /14 X 45/0,7 143987 Z 109 /20 X 45/1 278181 Z 109 /25 X 50/1,2 278190 Z7 measuring technology
Bracket Z 1455
Order No. material No.
Z 1455 /20/ 6,5 383724 Z 1455 /20/ 8 383732 Z 1455 /20/ 8,2 383740 Z 1455 /20/10 557943 Z 1455 /24/12,2 383759 Z 1455 /30/18,2 383767 Z8 Cooling system
Order No. material No.
Z 803/9x9,4 2038497 Z 803/9,4x9 2038498 Z 803/13x13,5 2038499 Z 803/13,5x13 2038500 Adapter coupling Z 803
22 | M o u l d i n g
II.2.4. Standar Mould base LKM
23 | M o u l d i n g
26 | M o u l d i n g
II.2.5. Standarisasi Mould Base Hoppt
Mould Base & Mould Base Components
Standard, semi-complex and finishing mould bases of more than 2,000 combinations of different dimensions
Pins and bushes to support every customer's needs
We also sell various components such as:
Guide Pin, Guide Bush, Support Pin, Support Pillar, Ejector Guide Pin, Ejector Guide Bush, Return Pin
* Steel Grade JIS S50C-Plain Carbon Steel
* Applications: Plastic Injection Moulds
* Composition (%) C 0.50 Si 0.25 Mn 0.70 * Equivalent: - AISI 1050 - DIN C55W5 - WERKSTOFF 1820 - ASSAB 760 - BSS EN 43 * Our quality Mould Bases are
precision machined to close tolerance
* Material used is JIS S50C which is highly recommended for Plastic Injection Moulds. To cater, other materials are available upon request * Our prices are very competitive * Quick delivery service
* "hoppt®" Mould Bases are made in Singapore
* We also accept special or customized Mould Base orders according to customers'
specifications All enquiries are welcomed
30 | M o u l d i n g
II.3. MOLDING PLASTIC INJECTION
Injection molding adalah proses manufaktur yang paling umum digunakan untuk pembuatan plastik. Berbagai macam produk yang diproduksi menggunakan injection molding, yang sangat bervariasi dalam, kompleksitas aplikasi mereka ukuran, dan. Proses injection molding memerlukan penggunaan mesin injection molding, bahan baku plastik, dan cetakan. Plastik meleleh di mesin injection molding dan kemudian disuntikkan ke dalam cetakan, di mana mendingin dan membeku ke bagian akhir. Langkah-langkah dalam proses ini dijelaskan secara lebih rinci dalam bagian berikutnya.
Injection molding
Injection molding digunakan untuk menghasilkan berdinding tipis plastik untuk berbagai macam aplikasi, salah satu perumahan paling umum plastik yang. Perumahan plastik adalah kandang berdinding tipis, sering
membutuhkan banyak tulang rusuk dan bos pada interior. Ini perumahan digunakan dalam berbagai produk termasuk peralatan rumah tangga, elektronik konsumen, alat-alat listrik, dan dashboard seperti otomotif. Umum
31 | M o u l d i n g Proses Siklus
Siklus proses untuk injection molding sangat pendek, biasanya antara 2 detik dan 2 menit, dan terdiri dari empat tahapan sebagai berikut:
1. Clamping - Sebelum injeksi bahan ke dalam cetakan, dua bagian cetakan
pertama harus aman ditutup oleh unit klem. Setiap setengah dari cetakan terpasang pada mesin injection molding dan satu setengah diperbolehkan untuk slide. Unit penjepit hidrolik mendorong cetakan bagian bersama-sama dan mengerahkan kekuatan yang cukup untuk menjaga aman cetakan tertutup sementara bahan yang disuntikkan. Waktu yang diperlukan untuk menutup dan klem cetakan tergantung pada mesin - mesin yang lebih besar (orang-orang dengankekuatan menjepit lebih besar) akan membutuhkan lebih banyak waktu. Kali ini dapat diperkirakan
dari waktu siklus mesin kering.
2. Injeksi - Bahan baku plastik, biasanya dalam bentuk pelet, dimasukkan ke
dalam mesin injection molding, dan maju ke cetakan oleh unit injeksi. Selama proses ini, bahan yang meleleh oleh panas dan tekanan. Plastik cair kemudian disuntikkan ke dalam cetakan sangat cepat dan penumpukan kemasan tekanan dan memegang materi. Jumlah bahan yang disuntikkan disebut sebagai tembakan. Waktu injeksi sulit untuk menghitung secara akurat karena aliran kompleks dan berubah dari plastik cair ke dalam cetakan. Namun, waktu injeksi dapat diperkirakan dengan volume
menembak, tekanan injeksi, dan kekuasaan injeksi.
3. Pendinginan - Plastik cair yang ada di dalam cetakan mulai dingin segera
karena membuat kontak dengan permukaan cetakan interior. Seperti plastik
mendingin, itu akan memperkuat ke dalam bentuk bagian yang diinginkan. Namun, selama pendinginan beberapa bagianpenyusutan dapat terjadi. Kemasan bahan dalam tahap injeksi memungkinkan material tambahan untuk mengalir ke cetakan dan mengurangi jumlah penyusutan terlihat. Cetakan tidak dapat dibuka sampai waktu pendinginan yang diperlukan telah berlalu. Waktu pendinginan dapat diperkirakan dari sifat termodinamika beberapa plastik dan ketebalan dinding maksimum bagian. 4. Ejeksi - Setelah cukup waktu telah berlalu, bagian didinginkan dapat
dikeluarkan dari cetakan oleh sistem ejeksi, yang melekat ke bagian belakang cetakan. Ketika cetakan dibuka, mekanisme yang digunakan untuk mendorong bagian dari cetakan. Angkatan harus diterapkan untuk mengeluarkan bagian karena selama pendinginan bagian menyusut dan melekat pada cetakan. Dalam rangka memfasilitasi pengusiran bagian, agen pelepas cetakan dapat disemprotkan ke permukaan rongga cetakan sebelum injeksi material. Waktu yang dibutuhkan untuk membuka cetakan dan mengeluarkan bagian yang dapat diperkirakan dari waktu siklus mesin kering dan harus mencakup waktu untuk bagian yang jatuh bebas dari cetakan. Setelah bagian tersebut dikeluarkan, cetakan bisa menjepit ditutup
untuktembakan berikutnya untuk disuntikkan.
Setelah siklus injection molding, beberapa pengolahan pasca biasanya diperlukan. Selama pendinginan, bahan dalam saluran cetakan akan memperkuat melekat pada bagian. Ini materi berlebih, bersama dengan flash yang telah terjadi, harus dipangkas dari bagian, biasanya dengan menggunakan pemotong. Untuk beberapa jenis bahan, seperti termoplastik, bahan memo bahwa hasil dari pemangkasan dapat didaur ulang dengan ditempatkan ke dalam penggiling plastik, juga disebut regrind mesin atau granulators, yang regrinds bahan bekas menjadi pelet. Karena beberapa degradasi sifat material, regrind harus dicampur dengan
32 | M o u l d i n g bahan baku dalam rasio regrind yang tepat untuk digunakan kembali dalam proses injection molding.
Injeksi dibentuk bagian
lainnya berdinding tipis produk meliputi berbagai jenis wadah terbuka, seperti ember. Injection molding juga digunakan untuk memproduksi beberapa barang sehari-hari seperti sikat gigi atau maperalatan medis, termasuk katup dan alat suntik, diproduksi menggunakan injection molding juga.
II.3.1 Injection Mould Mitsumi
Mold Related Dimensions of Plastic Injection Molding Machines (1) Category : Standard Specifications
While a mold for plastic injection molding is used by installing it in an injection molding machine, at present the specifications for installing the mold in the molding machine are different for different molding machines. On the other hand, in JIS, the recommended standard specifications have been stipulated regarding the "Mold related dimensions of plastic injection molding machines" (JIS B 6701-1992). From now on, these standards are considered to be referred to for the general injection molding machines manufactured in Japan. These standards will be discussed for several courses beginning with this course.
There is only one point that has to be paid attention to and that is, in the actual design of a mold, as the final information for judgment, giving first priority to the mold installation specifications of the injection molding machine that is scheduled to be used. Since JIS standards are only recommended standards, depending on the individual features of the injection molding machine, it is possible that the contents of the standards have been changed, and hence it is necessary to keep this point in mind.
33 | M o u l d i n g ＜JIS B 6701-1992＞
"Mold related dimensions of plastic injection molding machines"
These specifications stipulate the mold installation dimensions, etc. of plastic injection molding machines with a mold clamping force of 196 to 7845 kN (20 to 800 tf). Explanation:
The names of the different parts of the injection molding machine are as shown in the figure below. (These names are merely the names used in the explanation of this standard, and do not indicate the shape or the structure of the different parts.)
35 | M o u l d i n g In specific terms, the following items have been stipulated.
1. Spacing of the tie bar 2. Mold mounting bolt
3. Placement of the holes for mold mounting
4. Placement of the hole for the push rod (ejector rod) 5. Shape of the tip of the injection nozzle
6. Shape of the hole for the locate ring
II.3.2. Injection Machine Toshiba
Highest basic performance and achievement of high productivity and steady molding
The EC-SX series is a high performance all electric injection molding machine that achieves"Precise aand steady molding"and"High productivity" by great improvement of the basic performance given by newly developed mold clamping unit and injection unit. The machine satisfies customer's various needs with "Five kinds of new technologyh"we propose and molding technology accumulated over many years.
Product Introduction
1) New mold clamping unit (Solid Clamp)
The device transforms uniform clamping force to the mold with newly designed toggle mechanism and improved rigidity, enabling molding by lower clamping force than conventional device. Moreover the device achieves high speed cycle of the industry-leading class.
1. New toggle mechanism: link line toggle + high rigidity platens
- Minimizes mold deflection and achieves uniform clamping force distribution.
- Enables molding even by clamping force lower than conventional unit and contributes to improve product quality and mold maintenance reduction.
36 | M o u l d i n g 2. Dynamic acceleration/deceleration control (Patent pending)
- Adopts acceleration/deceleration control to reduce shock at mold opening/closing. - Enables maximum accelerate from an arbitrary position achieving high speed cycle molding.
3. High response ejection
- Sharp movement shortens ejection time. 4. Grease-less tie rod
- Grease-less tie rods eliminates grease adhesion onto mold or product and maintains clean environment.
- Standard rust proofing on hopper inlet prevents mixing of rust or refuse into product 5. SFC (high-speed mold open/close) specification (option)
- Shortens dry cycle time further and achieves molding at higher speed cycle. 6. High rigidity frame
- Level pads to facilitate installation or relocation is available as option. 7. Built-in hydraulic core puller (option)
- The unit is stored inside the machine to be installed at the clamping unit end. 2) New injection unit S-Cube (Simple, Steady, Smooth)
Takes over powerful filling performance in high speed and high pressure range and achieves steady molding by smooth movement.
1. Friction-free drive
- Suppresses slide resistance to the utmost limit and contributes to precise and steady molding by stable injection characteristic.
- Smoothes leading response of injection and improves charging stability. - Reduces variation among molding machines.
2. Control accuracy improvement in injection pressure and back pressure
- Absorbs inherent characteristic of pressure detector by linearize correction control, to lose machine difference to the utmost limit. This improves control accuracy of injection pressure and back pressure and achieves one up steady molding.
3. Space-saving injection unit
- The structure of the injection unit was optimized to shorten the overall length of the machine.
4. Hold pressure strength improvement
- Hold pressure strength was improved to enable heavy load injection molding. 5. 2-stage charge deceleration device: high torque and medium rotation (option)
- Handles high viscosity resin
3) High performance controller (INJECTVISOR-V50)
Achieves high productivity and precise stability by great improvement in control performance.
1. High performance HMI (Human-Machine Interface)
- 15-inch large-scale panel facilitates visualization and improves operability. *Takes over the function of INJECTVISOR-V30.
- Enables data browsing or printing on the personal computer by means of USB thumb drive or iPAQET LiTE.
37 | M o u l d i n g 2. Wide split screen
- Displays information necessary for the process on a split screen independent of the setting screen. This minimizes the changing of setting screen.
3. Signal customizing function
- Enables arbitrary selection of output signal to peripheral equipment. - Allows each selection of output condition or output form.
4. Remote monitor/managerial system "iPAQET"
- Monitors and manages multiple molding machines in real time by using LAN line. Enables centralized management on wide range of information including the monitoring of
operational condition of the machine and resin lot in addition to the monitoring of production state or the accumulation analysis function of product quality data.
5. Enables plug-in of peripheral and rationalization equipments and facilitates integrated management including rationalization equipments.
4) Molding control (DST: Dynamic Self Tuning)
Automatic correction function is added to molding control. This contributes to reproducibility of high-precision molding and long-term steady molding.
1. DST-Press (clamping force correction)
- Does not generate sink mark or short shot (influence of gas vent) as a result of clamping force fluctuation.
- Automatic correction made during molding does not influence operation cycle while maintaining steadybr molding.
2. DST-Fill (molding condition correction)
- Conducts automatic change of molding conditions and maintains steady molding, against the variation of molded product quality that takes place in a long period of operation as a result of resin lot change, crushed material ratio change or molding environment change. 3. Abundant molding controls
- A variety of function are installed, such as VHI (virtual hydraulic injection) circuit, high sensitivity mold protection and ejection torque monitor.
5) Screw variation
Screw variation matched to diversified resin types is available.
Screw name Resin
DBG screw (standard) General purpose
SDB screw For olefin series resin
DBC screw Hard vinyl chloride
6) Package specification
Satisfies customer's various needs.
38 | M o u l d i n g
o Vinyl chloride spec/fluorine spec/core back and injection compression/gas injection/light guide plate spec/MuCell spec
II.3.3. Injection Molding Machine (MZ1180F)
Basic Info.
Model NO.:MZ1180F
Type:Injection Blow Molding Export Markets:Global Additional Info.
HS Code:8477101090
Production Capacity:30/Month Product Description
Injection molding machine
1. Two oil tanks, one tank for cycle the injection part, another tank for cycle the clamping part. In this case, the oil temperature will not increase too much when oil press through the valves. Machine is more stable and longlife.
2. Three safety protector(hydraulic, mechanic, electric)
3. Adopt bearing in the moving platen. The connection between the surface and the bearing is only one touchable line, so it is more quick response than normal block design.
4. Machine clamping force is bigger than the model name. So you don't afraid of reach high peak of this machine
5. Machine has the auto-back-pressure setting in the PLC. Whatever you want to adjust the backpressure for different products and material, just click the keyboard, very convenience. 6. Machine is more stronger design with thick platen. All the material we'r using is endurable.
SPECIFICATION TABLE SPECIFICATION MZ1180F INJECTION UNIT A B C screw diameter mm 110 120 130 screw l/d ratio L/D 24 22 20 shot volume cm 3 5037 5994 7035 injection weight g 4634 5515 6472
injection pressure Mpa 181 152 129
injection rate g/sec 647 770 904
39 | M o u l d i n g CALMPING UNIT
clamp tonnage KN 11800
toggle stroke mm 1250
min mold height mm 450
max mold height mm 1200
space between tie brs mm 1220*1220
ejector tonnage KN 240
ejector stroke mm 350
ejector number pc 21
OTHERS
max pump pressure Mpa 16
heater power kw 60
motor power kw 45+45
oil box volume L 2000
machine dimension(L*W*H) M 12.3*2.6*307
40 | M o u l d i n g
BAB III
KESIMPULAN
Dipasaran banyak sekali macam-macam jenis dan harga dari berbagai produsen mouldbase,kita dapat membeli atau menyesuaikan harga dan tujuan yang kita inginkan dengan tersedianya bnyak variasi di pasaran.
Mould base digunakan dalam berbagai industri untuk jangka pendek dan aplikasi pencetakan.Mould base diproduksi dengan menggunakan bahan kualitas unggul seperti baja ringan dan baja karbon. Tersedia berbagai cetakan yang tersedia dalam berbagai ukuran, bentuk dan dimensi yang sesuai dengan berbagai jenis die casting dies.
Dalam membuat sebuah moulding , ada beberapa aspek penting yang harus
diperhatikan , diantaranya adalah biaya, wkatu, dan pengefesiensian alat-alat yang ada. Hal, ini akan berpengaruh dalam ketertarikan konsumen dalam memesan hasil produksi kita.
41 | M o u l d i n g
