Car door panel is an important part of car interior parts. It is located on the inside of car door. It is divided into front, rear, left and right. It varies according to car series, usually two-door and four-door. These parts are collectively called door panel series. This article takes left rear door panel of a car as an example to explain key points and experience in designing injection molds for car door panels.
Tag: injection mold design
Automobile plastic parts generally have complex structures and require high surface roughness and dimensional accuracy. Left/right support bracket of a certain car is shown in Figure 1. According to UG software query, the overall dimensions of support bracket are 171.93 mm * 117.34 mm * 127.79 mm, the overall wall thickness is 3.5 mm,volume of left support bracket is 130 039 mm3, volume of right support bracket is 133 307 mm3, and molding material is PP+30%GF. Left/right support bracket is larger in size and has a complex overall shape, with many characteristic structures and side holes, side recesses, etc. Left support bracket has 2 more side holes in structure than right support bracket, and the other structures are symmetrical. Plastic parts are difficult to part and form.
Mould: 13 setsManufacturing cycle: 4 weeks for first mold trial1 project manager; 2 project engineers; 4 mold design engineers; more than 20 manufacturing technicians jointly completed 13 sets of molds. According to customer's 2D/3D inspection-Product's appearance requirements, size, function-Is there any interference in assembly gap? Is gap reasonable?-Does product have a draft angle and is … Continue reading Design for Spotlight
Cavities 6 for 6 changable styles from 180-420mm size Cavities 6 for 3 changable styles from 220-260mm size Cavities 10 for 5 changable styles from 180-160mm size Cavities 12 for 4 changable styles from 80-140mm size
Mold Information CAD and Part Information Mold Base Information Cavity Insert Size Information Cavity Cooling Layout Core Insert Information Cavity Insert Size Information Core Cooling Layout Core Insert Information Runner Information Mold Layout – Parting lines Parting Line Information Slide Action Information Ejection Layout Information Draft Analysis Information Part Thickness Analysis Surface (Grain) Finish Information … Continue reading Design Structure for Manufacture of Gud Mould
Base is similar to a semi-enclosed box-shaped piece. Coil is installed inside box surrounded by vertical ribs. Outer side where vertical ribs are located and B and C surfaces are exterior surfaces. No push rod marks or obvious parting lines are allowed. End surface where height of vertical rib is located is mating surface with upper shell. Try to avoid setting flat push rods. Side A is installation surface. Bottom surface must be horizontal, a push rod or parting surface can be set. In order to realize two functions of contactor rail installation and screw installation, this plastic part is designed with 2 dovetail grooves and 4*φ5.2mm through holes. In order to be consistent with installation dimensions of other models of contactors, distance and position of 4*φ5.2mm holes cannot be changed, resulting in 2*φ5.2mm holes penetrating dovetail groove that needs to be formed by side core pulling. This is a difficulty in mold design. Material of plastic part is reinforced flame-retardant nylon. Vertical ribs have a large area, a high height, and a thin wall thickness of only 1.2 mm. Allowable draft angle is small, plastic part is easy to stick to mold and trap air during molding. φ14mm hole and fan-shaped side hole are heat dissipation holes, which are located on appearance surface and need to be formed by side core pulling. How to ensure smooth forming and demoulding of vertical ribs and side holes, while ensuring that there are no push rod marks or obvious parting lines on appearance, is also a difficult point in mold design. 3.0, 9.3, and 12.8mm slots are clamp installation slots and require side core-pulling molding.
At present, most of exterior parts of household appliances are obtained by injection molding. During injection molding process, defects such as weld marks, air marks, and deformation are prone to occur; high-gloss traceless molds can solve above defects. Let's take a look at ten elements of high-gloss, traceless injection mold design.
Frame material of decorative strip is PP-GF20, and the overall dimensions are 955mm*62mm* 130mm. It is a non-appearance part. Product is long and arcuately curved, and there are a large number of reinforcing ribs on the surface to ensure strength of product. Decorative strip skeleton and another cover are pre-assembled, installed and fixed on instrument panel assembly in the form of components. There is a space for placing wiring harness on one side of product, forming multiple undercut shapes. Mold adopts a 4-cavity structure. Design difficulties are as follows: ① Product has a large number of undercuts and requires design of more core-pulling mechanisms; ② There are a total of 36 sets of designed slide blocks and 4 sets of hydraulic cylinder core pullers, all of which are easy to disassemble and assemble; ③ Mold has a large number of sliders, inclined push structures and hydraulic cylinder core-pulling mechanisms. Design must be verified by geometric methods to avoid interference from movement of mold parts.
Remote control front and bottom shell products are shown in Figure 1. Maximum outer dimensions of face shell product are 100.00 mm * 50.00 mm * 10.00 mm; average glue thickness of plastic parts is 1.50 mm, plastic part material is ABS, shrinkage rate is 1.005, and weight of face shell plastic parts is 10.55 grams. Technical requirements for plastic parts are that there must be no defects such as peaks, underfilling, flow lines, pores, warping deformation, silver streaks, cold materials, jet lines, etc. and they must comply with ROSH environmental requirements.
N93 mobile phone mid-case product is shown in Figure 1. Maximum outer dimensions of product are 98.10 mm * 49.06 mm * 9.85 mm; average glue thickness of plastic parts is 0.70 mm, plastic part material is PC+ABS, shrinkage rate is 1.004, and plastic part weight is 5.36 grams. Technical requirements for plastic parts are that there must be no defects such as peaks, underfilling, flow lines, pores, warping deformation, silver streaks, cold materials, jet lines, etc. and they must comply with ROSH environmental requirements.
Gud Mould 