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An Injection Mold Designer's Typical Day

For those people that commonly deal with complex injection molds that have Lifters, Slides and require Ejector systems that seem to leave very little area for cooling lines. What are my options? Sure, I'd love to drill my 7/16" (11mm) diameter lines across the core block and place them fairly close to the part, let's say .150" (approx. 4mm) distance and in uniform rows so that the cooling will be uniform. But I can't navigate through the maze of components that restrict a straight path for a cooling line. So my cooling options now go to plan "B", perhaps dropping in a vertical "Bubbler" to cascade a single point of cooling in whatever area I can fit it in. Or maybe fit in a be copper insert to enhance thermal flow and try to get some water to it further away from the part geometry. Now I'm looking at the cavity side----Great! no ejectors, but the part geometry is curved, so I can't follow the cavity surface with a straight drilled cooling line, well, as long as I can get a few lines active, even though the cooling might not be balanced to the cavity of the part because the cooling line is more effective at the tangent/closest point to the part cavity. Oh! Now it becomes obvious that I have much greater cooling on the cavity side than the Core Side-----No problem, I can adjust the flow rate for each side until a good injection molding process is obtained, after all, I have designed the cooling lines for Turbulent Flow, so if I have enough water pressure/flow rate, I can make it happen. And now I am asked to calculate this cooling design!!!!

When you consider my example a tough job I can only think that the tooling you deal with is more basic. I can only say that the injection mold designs that are required for Telecommunication (2 Way radios and Cellphones) products are very typical of my description and have the most stringent surface requirements for cosmetics. After 4 decades and thousands of these injection molds built all over the globe I can assure you that the latest Analysis software is being used to support injection mold design functions. My point of the previous description was to punctuate the typical hardships that an injection mold designer is faced with when attempting to apply the proper cooling system in an injection mold of this type and that the final design is usually less than what you would like. Do you design the cooling system first and add the ejector system last?

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