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Mould Cavities and Cores (2)

Posted by admin on Jun 21st, 2015

Inserts cavity and core plates

For moulds containing intricate impressions, and for multi-impression moulds, it is not satisfactory to attempt to machine the cavity and core plates from single blocks of steel as with integer moulds. The machining sequences and operation would be altogether too complicated and costly. The insert-bolster assembly method is therefore used instead.

The method consists in machining the impression out od small blocks of steel. These small blocks of steel are known, after machining, as inserts, and the one which forms the male part is termed the core insert and, conversely, the one which forms the female part the cavity insert. These are then inserted and securely fitted into holes in a substantial block or plate of steel called a bolster. These holes are either sunk part way or are machined right through the bolster plate.In the latter case there will be a plate fastened behind the bolster and this secures the insert in position.

For and against integer and insert-bolster methods

Both the integer and the insert-bolster methods have their advantages depending upon the size, the shape of the molding, the complexity of the mould, whether a single impression or a multi-impression mould desired, the cost of making the mould,etc. It can therefore be said taht in general, once the characteristics if themould required to do a particular job have been weighed up, the decision as to which desigh to adopt can be made.

Some of these considerations have already been discussed under various broad headings, such as coet, but to enable the reader to weigh them up more easily, when faced with a particular problem, the comparison of the relative advantages of each system is discussed under a number of headings.

Unquestionably for single impression moulds the integer design is to be preferred irrespective of whether the component form is a sinple or a complex one. The resulting mould will be stronger, smaller, less costly, and generally incorporate a less elaborate colling system than the insert-bolster design. It should be borne in mind that local inserts can be judiciously used to simplify the general manufacture of the mould impression.

For multi-impression moulds the choice is not so clear-out. In the majority of cases the insert-bolster method of construction is used, the ease of manufacture, mould alignment, and resulting lower mould coets being the overriding factors affecting the choice.

For components of very simple form it is often advantageous to use one design for one of the mould plates and the alternative design for the other. For example, consider a multi-impression mould for a box-type component. The cavity plate could be of the integer design to gain theadvantages of strength, thereby allowing a smaller mould plate, while the core plate could be of the insert-bolster design which will simplify machining of the plate and allow for adjustments for moud alignment.

Posted by Mandy Tang

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