5/31/2019 Undercut Process
Undercut Process
In this chapter you will learn about the process for an undercut part.
Undercut refers to the convex or concave area of part. When removing the part from the mold, you need some device so that the part of the mold which contacts to the undercut can be moved to remove the part from the mold
since the part will not be removable directly without the device.
This process is called Undercut process.
Undercut process uses different methods depending upon whether the undercut is outside or inside the part.
Here are some examples of parts with undercut.
Push-pin Grip of a driver Grip of a cup
Now, let's learn about external slide core method, internal slide method, and hydraulic cylinder method of undercut process.
External Slide Core Method
The external slide core method is usually used for the process of outer undercut.
Working along with the open / close movement of a mold, this method slides the slide core to process the undercut.
The hydraulic cylinder method is also available, which will be explained in detail later
Slide Core Body Unit
The portion where the undercut process is performed linked along with the movement of mold opening. The amount of movement of the slide core and the angle and the length of the angular pin are key factors to this unit.
The locking block installed to the cavity plate receives the pressure from the injection when closing the mold. Upon opening of the mold, the slide core moves backward by the force from the angular pin and the spring,
thus releasing the part.
As the hole will be misaligned and the angular pin will not be inserted if the slide core moves too far backward, a core stop block needs to be installed.
This correlation is illustrated below.
(Click each name in the figure to display the description.)
The relief distance and the tilt angle of the angular pin are as follows :
S : Undercut amount
S1 : Slide stroke amount
a : Tilt angle of slide core
b : Tilt angle of angular pin
S1 = S + 5mm up
a = b +(2 - 5 )
b 20
In order to prevent the slide core and the locking block from intervening with each other in mold opening and closing, make the tilt angle of the angular pin
smaller than that of the locking block.
Also, a gap of 0.5mm is added to the hole for angular pin for errors occurring at processing.
View Animation
Push Back Spring
The mass when the slide core is sliding varies depending on the direction of sliding.
<Example>
Suppose you install a 5kg slide core on the side parallel to the ground. How long should the spring be? The stroke is 20mm.
D : Spring diameter
L : Spring free length (see a catalog by each manufacturer)
E : Spring close length (see a catalog by each manufacturer)
F : Stroke
G : Length of shrinkage by slide weight
K : Spring constant (see a catalog by each manufacturer)
W : Slide weight
If using light load [K = 0.6kgf / mm] for spring:
<Example of Catalog>
Spring constant ( K ) Free length ( L ) Max. deflection ( F + G ) Outer diameter ( D ) Usage count
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0.6kg/mm 65mm 32.5mm 16mm 350,000 times
To figure out the slide mass, it is 1.5 times the weight of the slide core because the slide core slides parallel to the ground:
W = 5*1.5 = 7.5kg
As the length of shrinkage due to the weight of the slide mass is: G = W / K :
G = 7.5/0.6 = 12.5mm
As the free length of the spring is : L = E + F + G :
L = 32.5 + 20 + 12.5 = 65. Referring to the catalog,
Use the spring with L = 65.
Answer D = 16 L = 65mm
Internal Slide Method
If there is an undercut area inside the part, process the undercut by the following method.
Loose Core Method
Adapted when there is a small bulge or dent inside the part. The slide unit is installed to the ejector plate and the slide unit is linked to the loose core by the slide rod.
As the ejector plate moves forward, the loose core moves to the side pushing the part to remove the undercut.
This mechanism employs extremely strong force at an especially fragile part of the mold; therefore, you must be extremely cautious about the mechanism design and
material accuracy.
(Click each name in the figure to display the
description.)
View Animation
If there are more than two loose cores, be cautious not to have them collide with one another. If they collide, the loose cores can not be used.
Slide Stroke and Tilt Angle
B : Undercut amount
a : Tilt angle of slide rod
Relief distance A = B + 3mm to 5mm
<Example>
If stroke h = 150mm, B = 8.1mm, relief = 5mm:
A = 8.1 + 5 = 13.1mm
What is the tilt a of the slide rod?
As a = (A / h),
a = (13.1 / 150)
0.0873
a 5
(Click each name in the figure to display the description.)
View Animation
Also, if the tilt angle is larger than 15 , a support rod needs to be installed.
Method to push out undercut
Used for the part which has a side boss inside.
The method in which parts are pushed by the block and slid to the side by hand.
(Click each name in the figure to display the description.)
View Animation
Internal Slide Core Method
Applied when the part has an inner channel or a rib inside.
The method in which a slide core is moved using an angular pin .
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5/31/2019 Undercut Process
(Click each name in the figure to display the description.)
View Animation
Hydraulic Cylinder Method
The undercut process utilizing the hydraulic cylinder method is not related to the opening / closing movement of a mold, and is able to move independently.
This is used when undercut must be processed before mold opening when the undercut is on the cavity plate side.
Movement of Hydraulic Cylinder
The method in which undercut is processed by the external power of a hydraulic cylinder. In this figure, the oil pressure cylinder is installed to the cavity plate and a hole is made.
(Click within the circle in the figure to display the animation.)
Calculation of Hydraulic Cylinder
The calculation that determines the size of an hydraulic cylinder based on the size of undercut. Figure out the pressure required for the hydraulic cylinder to calculate the inner diameter of the hydraulic cylinder.
D : Cylinder inner diameter( )
a : Cylinder thrust coefficient 0.8
k : Working pressure (generally 60 - 70kgf/ )
P : Resin pressure 500(kgf/ )
S1 : Area to receive resin pressure( )
S2 : Contact area( )
W : Slide mass (kgf)
*The value of k varies depending on molding machine.
The values S1, S2 , W are calculated as follows:
First, the area that receives resin pressure (cross section of product) S1 is:
Then, the contact area (slide core cross section - cross section of product) S2 is:
[Detail of Undercut]
Slide Mass (the mass of the part attached to hydraulic cylinder) W is:
[Hydraulic Cylinder: Left Side and Front]
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[Profile of Undercut]
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