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AMTS07 Mold Construction 7-107.10 The following guidelines will be used for waterline design and connectors: 7.10.1 The mold will be fitted with male, quick-disconnect waterline connectors. 7.10.2 The connector orifice size will be equal to the waterline size to eliminate any flow restriction. 7.10.3 Waterline fittings will be mounted below the surface of the mold in a counter bored hole. The diameter of the hole should allow for easy connection and disconnection of the mating connector. Teflon tape will be used as a sealant for the connectors to prevent leakage under normal operating pressures. 7.10.4 The diameter of the waterline will be sized to allow sufficient flow. See the chart in section 7.10.6.4. 7.10.5 The mold is to be fitted with a drain groove connecting each counter bored waterline fitting to direct any leakage away from the core and cavity surfaces. 7.10.6 Waterlines are to be located to produce even cooling throughout the part in both the core an cavity. These ideal locations should be determined through thermal finite element analysis. Where finite element analysis is not practical, the waterlines are to be placed within three waterline diameters of each other and within 2.5 waterline diameters of the part surfaces. 7.10.6.1 It is recognized that ideal cooling patterns are not always possible, due to part and mold design. Every effort should be made to insure even thermal cooling of the part and avoid creating areas in the mold that create uneven heat exchange. 7.10.6.2 The ideal locations for waterline inlets and outlets are on the bottom of the mold. It is preferred that the top of the mold be avoided as a location to place waterline connections. The sides are preferable to connections on the top. 7.10.6.3 Waterline acts as the heat exchange mechanism that cools the part. Waterline size and efficiency play a critical role in determining the production rate of the tool and therefore the part cost. The waterlines should be sized to obtain the maximum efficient heat exchange ability in the mold. When feasible, they should employ computer modeling to get the best balanced heat exchange waterline placement. Efficient waterlines promote turbulent flow of the water. Turbulent flow is enhanced through two conditions: the first are sharp transitions. Waterlines should have sharp turns in the internal circuits instead of smooth turns. The second way to assure turbulent flow is with the speed of flow. Many waterlines are straight-through circuits. Turbulent flow increases with increased flow thorough the circuit. Turbulent flow will be achieved when the Reynold number is in excess of 10,000. The mold cooling circuits should be designed and the mold tested to achieve the following flow rates whose Reynold number has been calculated to be above 10,000. 7.10.6.4 The table below is based on some specific assumptions of initial pressure and pressure loss through the circuit. Long water circuits inherently have a significant pressure drop. Ideally, the water line circuits should be as short as possible. If, due to the geometry of the design, inadequate flow is achieved, booster pumps should be considered to improve the flow. The design should extrapolate the diameter to the minimum flow rate and publish this as part of the waterline diagram.
7.11 When required, the mold will be fitted with valves that can be locked in a set position to thermally balance the flow. When specified, the mold will be fitted with flow meters to assure proper flow can be monitored through the cooling circuits. 7.12 In situations where cooling is required in areas unattainable with waterlines, baffles may be used to achieve proper cooling. Baffles should be used in place of bubblers. Plastic baffles should be avoided. The baffles must be held securely in position with a key way, set screws, and teflon tape as a sealant. 7.13 All plates in the mold base system pertaining to the part, with the exception of the clamp plates should be fitted for water lines. 7.14 Each hydraulic circuit is to be fitted with connectors according to the machines’ hydraulic system which will be provided at the program start. A male connector will be attached to the forward position port and a female connector will be attached to the return position port. Miller cylinders should be used at all times. Confirmation of the movement of the hydraulic system will be monitored with confirming either electrical or fluid sensing devices. The devices must conform to the full forward and full return position of the moving member. 7.15 A competent licensed electrician will install all electrical mechanisms, including but not limited to: limit switches, cavity pressure sensors, hot runner circuits, motor drive circuits, etc. according to electrical wiring standards. All circuits will be wired with grounded connections. All circuits are to be housed in an approved housing and adequately labeled as to the power requirements. All wires are to be insulated with a material sufficient to provide appropriate electrical insulation for its prescribed application, (i.e., environmental, chemical, and temperature resistance). 7.16 All electrical boxes will be of the following make and model: They are Amphenol-Tuchel Components. The Hood or housing part number C146-10F024-001-1, Female receptacle part number is C146-10B024-102-1 and the Male plug part number is C14610A024-102-1. These can be ordered thru Allied at 1-800-433-5700. Allied’s part numbers are as follows: Hood SKU:246-5086, Female SKU:246-5245 and the Male is SKU:246-5215. These are to be the only components to be used on CEP molds. 7.17 The following specifications are to be used when designing and building mold bases/cavity pre-load: 7.17.1 Cavity inserts or the core and cavity will be pre-loaded to stand .0010” to .0015” higher than the overall parting line, and extend .250” to .500 “. The remainder of the parting line is to be cleared .050”. 7.18 The size of the mold base will be large enough to hold the core, cavity, leader pins, slides, and other mechanisms with additional mold base material to provide sufficient strength for the mold to prevent distortion or shifting during continued operation. The chosen material for the mold base will be determined by the type of mold and the projected life cycle. The material chosen must be approved by Argo Mold. Mold shut-height will be sufficient so that the mold clamps and/or other mechanisms do not interfere with each other during installation or operation. Standard mold base and mold components are preferred to custom items. The mold design will include in the plan view, platen layout showing the location of the recommended machine tie rods and mounting hole locations to insure the mold will fit in the machine and it can be mounted easily and safely. The side view will show the location of the clamps so that the installation of waterlines will not interfere with clamps. 7.19 The parting line height should surround the guide pins to allow for the pre-load to exert pressure on the parting line, but not be crushed by the clamp pressure. Standoff pads are to be of sufficient area to avoid crushing the pre-load shutoff at maximum clamp pressure. |
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