I TECH MOULDS

06/01/2015

We manufacture the Plastic Products and Moulds in better way and within Scheduled Time.

08/08/2014

Reaction injection molding (RIM) is similar to injection molding except thermosetting polymers are used, which requires a curing reaction to occur within the mold.

Common items made via RIM include automotive bumpers, air spoilers, and fenders.

Process;
First, the two parts of the polymer are mixed together. The mixture is then injected into the mold under high pressure using an impinging mixer. The mixture is allowed to sit in the mold long enough for it to expand and cure.

If reinforcing agents are added to the mixture then the process is known as reinforced reaction injection molding (RRIM). Common reinforcing agents include glass fibers and mica. This process is usually used to produce rigid foam automotive panels.

A subset of RIM is structural reaction injection molding (SRIM), which uses fiber meshes for the reinforcing agent. The fiber mesh is first arranged in the mold and then the polymer mixture is injection molded over it.

The most common RIM processable material is polyurethane (known generally as PU-RIM),[2] but others include polyureas, polyisocyanurates, polyesters, polyphenols, polyepoxides, and nylon 6. For polyurethane one component of the mixture is polyisocyanate and the other component is a blend of polyol, surfactant, catalyst, and blowing agent.

08/08/2014

Two dies are used in die casting; one is called the "cover die half" and the other the "ejector die half". Where they meet is called the parting line. The cover die contains the sprue (for hot-chamber machines) or shot hole (for cold-chamber machines), which allows the molten metal to flow into the dies; this feature matches up with the injector nozzle on the hot-chamber machines or the shot chamber in the cold-chamber machines. The ejector die contains the ejector pins and usually the runner, which is the path from the sprue or shot hole to the mold cavity. The cover die is secured to the stationary, or front, platen of the casting machine, while the ejector die is attached to the movable platen. The mold cavity is cut into two cavity inserts, which are separate pieces that can be replaced relatively easily and bolt into the die halves.

07/08/2014

Cold-chamber die casting

A schematic of a cold-chamber die casting machine.
These are used when the casting alloy cannot be used in hot-chamber machines; these include aluminium, zinc alloys with a large composition of aluminium, magnesium and copper. The process for these machines start with melting the metal in a separate furnace. Then a precise amount of molten metal is transported to the cold-chamber machine where it is fed into an unheated shot chamber (or injection cylinder). This shot is then driven into the die by a hydraulic or mechanical piston. This biggest disadvantage of this system is the slower cycle time due to the need to transfer the molten metal from the furnace to the cold-chamber machine

07/08/2014

Hot-chamber die casting[edit]

Schematic of a hot-chamber machine
Hot-chamber die casting, also known as gooseneck machines, rely upon a pool of molten metal to feed the die. At the beginning of the cycle the piston of the machine is retracted, which allows the molten metal to fill the "gooseneck". The pneumatic or hydraulic powered piston then forces this metal out of the gooseneck into the die. The advantages of this system include fast cycle times (approximately 15 cycles a minute) and the convenience of melting the metal in the casting machine. The disadvantages of this system are that it is limited to use with low-melting point metals and that aluminium cannot be used because it picks up some of the iron while in the molten pool. Therefore, hot-chamber machines are primarily used with zinc, tin, and lead based alloys.

07/08/2014

Die casting is a metal casting process that is characterized by forcing molten metal under high pressure into a mold cavity. The mold cavity is created using two hardened tool steel dies which have been machined into shape and work similarly to an injection mold during the process. Most die castings are made from non-ferrous metals, specifically zinc, copper, aluminium, magnesium, lead, pewter and tin based alloys. Depending on the type of metal being cast, a hot- or cold-chamber machine is used.

The casting equipment and the metal dies represent large capital costs and this tends to limit the process to high volume production. Manufacture of parts using die casting is relatively simple, involving only four main steps, which keeps the incremental cost per item low. It is especially suited for a large quantity of small to medium sized castings, which is why die casting produces more castings than any other casting process. Die castings are characterized by a very good surface finish (by casting standards) and dimensional consistency.

FOLLOWING PICTURE "BMW 6-cylinder block Al-Mg"

07/08/2014

Tool materials
Tool steel or beryllium-copper are often used. Mild steel, aluminum, nickel or epoxy are suitable only for prototype or very short production runs.[1] Modern hard aluminum (7075 and 2024 alloys) with proper mold design, can easily make molds capable of 100,000 or more part life with proper mold maintenance.[19]

07/08/2014

Mold
Mold or die are the common terms used to describe the tool used to produce plastic parts in molding.

Since molds have been expensive to manufacture, they were usually only used in mass production where thousands of parts were being produced. Typical molds are constructed from hardened steel, pre-hardened steel, aluminum, and/or beryllium-copper alloy.[12]:176 The choice of material to build a mold from is primarily one of economics; in general, steel molds cost more to construct, but their longer lifespan will offset the higher initial cost over a higher number of parts made before wearing out. Pre-hardened steel molds are less wear-resistant and are used for lower volume requirements or larger components; their typical steel hardness is 38–45 on the Rockwell-C scale. Hardened steel molds are heat treated after machining; these are by far the superior in terms of wear resistance and lifespan. Typical hardness ranges between 50 and 60 Rockwell-C (HRC). Aluminum molds can cost substantially less, and when designed and machined with modern computerized equipment can be economical for molding tens or even hundreds of thousands of parts. Beryllium copper is used in areas of the mold that require fast heat removal or areas that see the most shear heat generated.[12]:176 The molds can be manufactured either by CNC machining or by using electrical discharge machining processes.

07/08/2014

Injection moulding (Injection molding in the US) is a manufacturing process for producing parts by injecting material into a mould. Injection moulding can be performed with a host of materials, including metals, glasses, elastomers, confections, and most commonly thermoplastic and thermosetting polymers. Material for the part is fed into a heated barrel, mixed, and forced into a mold cavity where it cools and hardens to the configuration of the cavity.[1]:240 After a product is designed, usually by an industrial designer or an engineer, moulds are made by a mouldmaker (or toolmaker) from metal, usually either steel or aluminum, and precision-machined to form the features of the desired part. Advances in technology now also allow for 3D printing of injection moulds for certain applications, using photopolymer plastics which do not melt during the injection process. Injection moulding is widely used for manufacturing a variety of parts, from the smallest components to entire body panels of cars.

24/07/2014

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We manufacture the Plastic Products and Moulds in better way and within Scheduled Time.

08/06/2014

basically the split cavity is same as 2 plate standard mold, but the cavity have split block to make undercut product or external threads.

this type of mold use when the slider is not enough to make the undercut or the threads. the disadvantages of this mold is when use for little parts, the construction will difficult.

07/06/2014

3 Plate mould layout