DFM English and design Principles

一．产品信息：Product information

1. 外观：Surface Appearance 2. 光洁度：Glossiness/gloss finish 3. 毛面：Matt finish/matt surface 4. 皮纹粒度：Grain

5. 特殊皮纹区域：Special area texture 6. 塑料色母: Master batch

7. 烫金/涂层/印刷/雾晕Hot stamping/ coating/

print/ haze 8. 仿皮革:leather cloak 9. 电火花纹：EDM

10. 光化学腐蚀法：Photochemical etching 11. 刷涂纹，拉丝纹Brushing 12. 激光雕刻：Laser engraving

二．浇口类型：Gate type

自动脱模浇口Automatic gate

1.潜伏式浇口：Submarine gate

2.香蕉形浇口：Cashew gate，banana gate 3.针点式浇口：Pin gate 4.热浇道口：Hot drop 5针阀浇口：Valve gate

13. 喷砂：Sand blasting

1. 设计版本: Design revision 2. 产品重量：part weight 3. 注射重量：Shot weight 4. 流道重量：Runner weight 5. 驻留时间：Resident time 6. 缩水率：Shrinkage

7. 最终外观：Cosmetic finishing: 8. 塑胶材料：Resin material 9. 塑胶等级：Resin Grade 10. 产品体积：part volume

手动整理浇口Manual gate

1.边缘浇口：Edge gate

2.凸耳浇口：Tab gate overlap gate 3.直接浇口：Sprue gate 4.隔膜浇口：Diaphragm gate 5.环形浇口：Ring gate 6.扇形浇口：Fan gate 7.薄膜浇口：Flash gate

8.过滤器瞟浇口：Filter Rowl gate

说明：illustrate

? 浇口进入位：Gate location ? 浇口大小：Gate size

? 转水口： Switching runner/gate ? 唧嘴口径：Sprue diameter

? 水口殘留最大0.1mm. The maximal residual gate is 0.1mm.Gates Vestige will be 0.1mm ? 此水口会用CNC铣平: The gate will be milled to flat by CNC. ? 此位会作凹陷Here will be recess.

? 浇口需要冲床机器二次加工来去除：Gates need 2nd process remove by stampingmachining ? 透明件不宜用香蕉浇口，易见流痕：The banana gate does not suite the transparent part. Flow mark is visible.

? 最终的进胶位置根据模流分析：Finally gate position according the mold flow analysis. ? 顶出后额外的墙被切掉: Extra wall to be cut away after ejection

? 是否可以添加一个小肋骨用来放潜水口,成型后再删除它如果必要的话：Is it possible to add one small rib to place sub gate, after molding remove it by operator if necessary

三．流道: runner

? 冷流道： Cold runner

1.唧嘴直流: Direct sprue gate 2.圆形流道：Round(full/half) runner

3.正圆形：Full Round （最有效）Most Efficient 4.梯形：Trapezoidal (有效）Good

? 冷料井— cold slug well

说明：illustrate

5.半圆形： Half Round （非有效）Not Good

? 热流道：Hot runner

1.热流道板：Hot manifold

2.热嘴转冷流道: hot sprue turn to cold runner 3.热流道转冷流道: hot tips turn tocold runner

? 单嘴阀针式热流道转冷流道: 1 drops valve nozzle to cold runner ? 单嘴尖点式热流道转冷流道: 1 drops tip nozzle to cold runner ? 单嘴开放式热流道转冷流道: 1 drops open nozzle to cold runner

? 2点针阀式直接进胶: Hot runner 2 drops valve nozzle direct to part ? 喷嘴Nozzle

设计原则：Design principles

? 根据模流分析结果最后确定浇口位置：Finally gate position according the mold flow analysis ? 检查流动长度在薄壁产品：check flow length in thin walled part

? 竖浇道太长了约有200mm長. 冷流道系统流动不均,推荐使用热流道以使流动较佳. The sprue will be too long if we use cold runner design. Its length is around 200 millimeters，Flow imbalance by cold runner，We recommend a hot runner system for better flow.

? 浇道系统应该有一个均衡的布局：Runner system should have a balanced layout ? 省料：Savings in material ? 周期短：Shorter cycles

? 浇口在最佳位置：Gates at the best position ? 压力降最小：Pressure losses minimized

? 人工系统流道平衡：Artificial balancing of the gate system ? 避免焊缝线: Avoidance of weld line ? 纤维取向: Fiber orientation

? 避免迟滯效应：Avoid the hysteresis effect ? 避免潜流：avoid underflow

? 所有的流道都要有冷料井：All runners are to have cold slug wells

? 多型腔模具浇口尺寸必须相同，平衡必须经过调整流道而不是调整浇口。 Gates in multi-cavity molds shall be the same size. Balancing shall not be done by differing gate sizes. Runners should be changed to balance mold filling and not gates ? 材料的弹性是否符合用潛澆口：material flexibility for sub gate

? 正確的流道尺寸能否滿足成型周期的要求：Runner sizes correct and adequate for required cycle time

? 阀针的顺序控制消除溶解线和变形：Valve gate sequence controlfor weld line / warpage

? 浇口设计在壁厚较厚的地方，方便胶料从壁厚较厚地方流到壁厚较薄的地方：The part and the gating should be designed , so the melt flows from the thicker section to the thinner section

四．产品排列Part Layout

1. 单穴：Single Cavity mold 2. 多穴：multicavity mold 3. 混合：Family mold

1. 轮辐式流道：Spoked runners

2. 自然平衡的流道：Naturally balanced runners 3. 流道平衡：Runners balancing 4. 不平衡： Unbalanced 5. 人为地平衡: Artificially balanced 6. 流道拉杆：Runner Lock Pin 7. 冷料井— cold slug well

常用名称：Common name:

1. 模具尺寸：moldbase size

2. 最大开距： maximum daylight;open daylight 3. 闭合高度 ： mould-shut height 4. 机台吨位：Machine Ton 5. 顶出行程：Ejecter Stroke 6. 流动平衡 : Flow balance

五．分型线：Parting line

1. 分模线不匹配：Parting line mismatch 2. 分模线飞边：Parting line flash

3. 产品特征保证分型线简单：Keep feature in the parting plane to simplify the part 4. 指定不匹配的分型线:Specify mismatch on the parting line 5. 可能不匹配：Possible mismatch 6. 合模插穿Shutoff

7. 足够的插穿角减小磨损和产生飞边：Draft at the shutoff will wear over time and develop flash 8. 垂直分型线：Vertical parting line， 9. 曲面分型线：curved parting line 10. 分型线红线所示: P/L is shown as red line.

设计原则：Design principles

1. P/L为简化模具结构: P/L for the tooling structure simplify ,

2. 如果空气被困在没有出路的分型线,建议在该地方发置销或镶件或顶针，气会逃脱通过销，镶件和孔之间

的间隙：If the air trapped with no way out to the parting line , it is advisable to place a venting pin or insert or ejector pin to permit the air escape through the clearance between pin and hole

六．滑块 Slider ，

1. 铲基：Locking bar，heel unit 2. 导轨：Slider Guide , slide base 3. 耐磨板：Wear Plates 4. 油槽：grease grooves 5. 压条，压板： Gib 6. 限位开关：limit switch

7. 斜销固定导套：angle pin housing 8. 液压拉出模芯：Hydraulic Core Pulls 9. 液压汽缸：Hydraulic Cylinder 10. 前模滑块：Cavity slider

设计原则：Design principles

1. 必须有至少三度角度差别在斜销针和滑块座斜孔之间：There must be a minimum of three degrees

difference between the angle pin and back wedge.

2. 当滑块的宽度超过150 mm长，需要设计两个斜销针并考虑加一个中心滑动导轨Two angle pins will

be required on any slide design that exceeds 150mm in length. Consider a center Slide Guide for all long slides

3. 滑块移动方向所有的插穿面要求最小3°：All shut-off surfaces must have a minimum of three degrees

draft in direction of slide travel.

4. There can be no ejection under the slide detail without written Customer approval. If the customer

accepts ejection under the slide detail, limit switches must register both forward and back movement of the ejector system.

5. 大面积的滑块必须有足够的运水Slides that mold large areas of part shape must have sufficient

cooling

6. 所有深肋必须制作镶件排气：All deep rib details must be sub-inserted for venting

11. 后模滑块：Core slider

12. 湾管滑块：Curved slider- the slide with angled

guides

13. 滑块内的滑块：The inner sliding block 14. 隧道滑块：ExploreTunnel slider 15. 延迟滑块：Delay the slider 16. 滑块开闭器： Slider retainer 17. 抽芯距： core-pulling distance 18. 抽芯力： core-pulling force

七．斜顶Lifter

1. 斜顶固定座：fixed lifter base

2. 带角度倒扣的斜顶：Angle lifter design for angled undercuts 3. 弹簧钢斜顶：Sprung core 4. 柔性弹簧钢斜顶： Flexible core 5. 双面弹簧钢机构：Double ejector core 6. 四面弹簧钢机构：Tulip ejector 7. 直顶：Vertical lifter block 8. 铜导套：Bronze bushing

设计原则：Design principles

1. 斜顶的顶部要低于产品0.01~0.03 以防铲伤产品：Provide a 0.01 to 0.03mm pad on top of the lifter to

prevent part “drag”.

八．冷却水路： Cooling

1. 螺纹运水芯：Spiralwater core 2. 螺旋隔水片：Spiral baffle boards 3. 隔水片：Plug baffle

4. 喷泉管：Junction tube， cooling pipes 5. 转接件：Diverting element 6. 止水栓：Cooling circuit plugs 7. 密封带：Sealing tape 8. 密封圈： O ring

9. 水路接头：Connecting nipple 10. 加长水路接头：Extension nipple 11. 螺塞：Sealing plug 12. 弯头:Elbow

13. 筒式加热器：Cartridge heaters 14. 热电偶感温线Thermocouples 15. 隔热板：Temperature insulator 16. 铍铜: Beryllium copper

设计原则：Design principles

1. 建议新增单独水路：Add individual cooling channel to adjust warpages.， 2. 添加单独冷却通道以调整变形：Add individual cooling channel to adjust warpages 3. 统一的模具温度降低翘曲：Uniform mold temperature reduce theeffect of warp page 4. 短的冷却通道, 确保温度之间的差异和出口不超过5°度 : Short cooling channels to ensure

temperature difference between in and outlet do not exceed 5o

5. 避免盲点或气泡在冷却回路: Avoid dead spots and or air bubbles in cooling circuits

6. 铍铜合金转移热量是碳钢2倍，不锈钢的四倍：Beryllium copper transfer twice much heat as carbon

steel and four times as stainless steel

7. 铍铜合金不推荐材料,需要高模具温度,因为他们允许传热：Beryllium copper is not recommend for

material that require high mold temperature as they allow so much heat transfer.

8. 铍会运行一些薄壁部分要快得多：Beryllium will run some thin walled part significantly faster 9. 使產品有均勻的冷卻：Make the product has uniform cooling 10. 避免遲滯效應：Avoid the hysteresis effect

九．出模角度分析Draft angle information

1. 倒扣：Undercut 2. 金刚砂 Emery

3. 纹面的深度模式：Texture deep pattern

设计原则：Design principles

1. 所有的面都要有出模角,不然产品面上会拉伤，粘后模，前模，滑块，斜顶：Draft on all surface，

Otherwise there will be scratch on plastic product surface, sticking on core , cavity , slider or lifter 2. 根据纹面的最小出模角要求，检讨产品的出模角是否满足要求。the part will texture and must least

draft angle

3. 公模仁拔模修改到一度The draft of core is modified to one degree.

4. 根据纹面的0.03深度模式，需要大约5o出模角才不会拉伤产品This illustration indicates that this 0.03

deep pattern would require approximately 5 odraft。

5. 根据产品纹面的深度给出最小出模角的要求，检查产品的出模角是否满足要求. According to the

minimum angle of the requirements in depth in texture, check out the product draft Angle whether meet the requirements of the product texture 。 6. 产品顶出需要有出模角：Draft is required for release

十．壁厚：Thickness

1. 平滑逐渐过渡：The gradual transition 2. 薄铁：Weak steel

3. 此处胶位太薄不易入胶：This material is too thin to shot. 4. 应力集中：Stress concentration

5. 突然冷却的差别: Abrupt cooling difference 6. 凸起的： Rasied 7. 凹陷的： Recessed 8. 台阶：Step

设计原则：Design principles

1. 筋骨的壁厚是产品对应位置壁厚的60% ：Rib thickness of 60% wall thickness

2. 防止壁厚不均匀,会导致应力的部分: Prevent uneven wall thickness that will cause hate on part 3. 基本壁厚应该保持统一：The basic wall of the part should be kept uniform

4. 壁厚统一会提供流动的熔体在注射甚至冷却和收缩过程中控制部分弯曲和减少成型压力和减小缩

痕 :This provide for even flow of the melt during injection even cooling and shrinkage that controls part warpage and reduce molded in stress and avoid sink marks

5. 壁厚的逐渐过渡避免应力集中和突然冷却的差异The gradual transition avoids stress concentration and

abrupt cooling differences

6. 肋的壁厚太厚会在肋的对面产生缩痕：The wall thickness is too thick can resultSink on the wall opposite

the rib

7. 最大肋高度H = 3 x名义壁厚,深肋变得难以填充,也可引起贴模具Maximum rib height H =3X nominal wall

thickness, Deep rib become difficult to fill, may stick on the mold on ejection

8. 因此厚部分需要很长时间来冷却相比薄的区域,这种微小冷却率差别会导致扭曲等问题,失真,孔隙和缩影。

Hence thicker sections take a longer time to cool compared to thin regions. Such differential cooling rates can cause problems like warping, distortion, voids and sink marks.

9. 尖角也可能被替换为适当保持均匀的壁厚: Sharp corners may also have to be replaced with appropriate

to maintain uniform wall thickness

10. 尖角,材料收缩,也可能导致高压力,因此可能需要适当圆角过渡: Sharp corners, upon material shrinkage,

may also cause high stresses and hence may have to be appropriately filleted or rounded.

十一.顶出机构：Ejection

1. 顶针：Ejector pin 2. 丝筒针：Ejector sleeve

3. 扁顶针：Ejector blade，Flat ejector pin 4. 气阀：Air valve 5. 推块：Blow off strip 6. 推嘴：Blow off nozzle 7. 气顶：Air ejection 8. 阀门顶出：Valve ejection 9. 拉料杆： Sucker pin 10. 顶块： Stripper bar 11. 顶环：Stripper ring

12. 推板: Stripper plate 13. 加速顶: Accelerated ejection 14. 脱模距：Stripper distance 15. 推件环：Stripper ring

16. 使用推板/推块顶出:Use the stripper plate /

ejector block to eject this part.

17. 推板加气顶顶出: Stripper Plate and gas

ejection

18. 二次頂出: Double Ejection

19. 此位做頂針：The location of ejector is here 20. 反向顶出：Reverse Ejection

21. 三次顶出机构：three-step ejection mechanism

设计原则：Design principles

1. 把模具表面变为毛面为了减少可能粘问题, 当成型软材料：To reduce possible sticking problems , a

matted surface finish on mold is preferable , when molding the softer grades 2. 顶针排布在产品壁厚厚的位置：Ejector pin act on the thickest section of the part

3. 因为塑胶收缩时抱紧凸模芯，所以顶出力的作用点应当尽量靠近凸磨芯：The action point of the ejection

force shall be near the core as much as possible, since the plastics part would enclasp the core when contracting

4. 模具顶出的顺序：Tooling ejection sequence

5. 强制脱模的机制：the mechanisms of forced demoulding 6. 外观要求： appearance require

7. 如果产品设计多个薄壁部分,应当采用两级弹射：

If the part design required multiple thin-walled sections, two-stage ejection shall be used.

十二：注塑缺陷 Injection defect analysis,

1. 缩痕: Sink mark 2. 翘曲: Warpage/warped

3. 打不满: Short shot/short molding 4. 变形: Distortion 5. 熔接线 : Weld line 6. 变色: Discoloration 7. 飞边: Flashing

8. 段差： mismatchdiscrepancy 9. 银丝纹：Snake marks, streak 10. 困气: Air trap

11. 气泡：Bubbles / Vacuoles

12. 制品表面的光泽差异：Variations in gloss on the

surface of the molded article 13. 变黑：Blackening 14. 白斑 : White spots

15. 剥落：Flaking 16. 冷流痕cold flow marks 17. 水泡：blisters 18. 应力痕：stress marks 19. 喷射：jetting 20. 霜雾：Frosting 21. 光泽：Gloss 22. 裂纹：cracks 23. 银条：Sliver steraks 24. 烧焦：Burn Marks 25. 黑条：Black streaks 26. 拉伤：scratch

27. 涂色区域会产生缩水： The colored area will be

shrinkage.

十三: 模具设计理念：Tool concept :

1. 互换镶件:Interchangeable inserts 2. 拿出镶件：Carrier inserts，traveling insert 3. 包胶模：Overmolding/ Insert_Molding 4. 双色模：Double color

5. 多色成型_多射成型: Multishot 6. 薄壁模: Thin wall molding 7. 感应加热模:Induction molding

8. 蒸汽急冷急热注塑：FHKP

9. 水辅助注塑：Water assisted injection molding 10. 低压注塑：Low-pressure injection molding 11. 硅胶注塑：Injection molding of liquid silicone

rubber

12. 粉末注射成型：Powder injection molding 13. 倒装模:Reverse injection tools

14.模内装饰IMD--- 镶片注塑/模内转印 IML/IMR Inmold decoration--- Inmold lamination / Inmold release 14. 气辅助注塑：Gas-assisted Injection Molding

15. 微发泡注塑：MuCell technology for injection molding / Microcellular molding