Dies,Jigs,Fixtures

Dies and moulds: Types & Applications

Compression molds, injection molds, transfer molds, and blow molds are all examples of basic mold types used in plastic processing, and they are typically categorized according to the number of cavities they include.

Die Types:

1. Simple Die

One operation every press slide stroke characterizes a simple die, also called a single-operation die. This die style is more commonly employed for less substantial tasks in the business world. Producing lightweight metal components is one such application.

2. Compound Die

With a compound die, you can accomplish more than one thing at once, such cutting or punching. For more complicated blanking and piercing tasks, a compound die can complete the work more quickly. Instead of performing each step individually, the compound die may blank and pierce in one fell swoop. For mass-produced items, this is the best option.

3. Combination Die 

The combination die is functionally and aesthetically identical to the compound die. It's multitasking abilities mean it can process multiple requests simultaneously, so you get more accurate and timely responses. The combination die has additional utility as a cutting and shaping tool.

Mold Types:

1. Single –Cavity Mold 

One of the most fundamental mold concepts is this mold. Only one part at a time can be molded using this mold.

2. Dedicated Multiple Cavity Mold 

In order to mass-produce an item, factories will use specialised molds with several cavities. Because it is simple to regulate the plastic flow using this mold, it has found widespread use.

3. Family Mold 

Due to the short molding times, prototype molds benefit greatly from family cavity molds. Multiple cavities in a family injection mold allow for the simultaneous creation of several identical products within a single molding run.

4. Two-Plate Mold

When creating plastic components, a two-plate mold is employed. This sort of molding is extremely frequent because of how simple it is to execute.

5. Three-Plate Mold 

In three-plate molds, the runner is housed in the third plate, known as the striper. A double-action ejector mechanism ensures that the runner is not thrown out along with the component.

Dies And Moulds Meaning

Tools for making precise shapes include dies and molds. Sheet metal and other metal shapes can be shaped with dies. The automotive industry is a prime example of this type of use. In contrast, injection molding employs molds for the creation of plastic parts from liquid resin or metal castings from molten metal

In modern manufacturing, molds and dies are indispensable instruments for mass production. Molds are used in injection molding to form resin and in casting, while dies are used in stamping; both play critical roles in the production process. 

Modern methods allow for the creation of molds and dies with micron-order precision, facilitating the mass manufacture of products with consistent form and quality across many industries.

Mould And Die Design

1. Stacked mold Design 

The cavities in a stacked injection Dies & Moulds are arranged in rows and columns. This allows several cavities to be set up in a single device. By stacking four single cavities in an injection machine, for instance, four identical parts can be manufactured in a single cycle. 

As a result, the efficiency of the machine is increased. Injection molds are further classified as either Hot runner molds or Cold runner molds based on the feeding system.

2. Hot Runner mold design 

It is common practice for a hot runner mold system to include hot nozzles, temperature control boxes, manifolds, and accessories. An integral part of hot runner molds is the runner system, which is heated in advance by means of rods, coils, or heating components. In a three-plate mold, the runner system is contained within a stationary plate. 

Even if the part cools down, the runner system will keep it at a safe temperature. A runnerless mold is one in which the runner does not release the portion. There won't be a need to go through an extra step to get rid of the runner. 

Due of the necessity for a heating system to heat the runner, hot runner molds tend to be more costly. It also increases the price of the mold by adding an extra plate. It's also difficult to clean the runner system because the runners are hard to access due to being embedded in the mold.

 Hot runner molds are more difficult to run and keep in good condition than cold runner molds. Changing the material of the part requires extensive labor on the part of the mold.

3. Transfer Die Design 

Several tools can be operated with just one press using the transfer die. Using transfer dies has certain benefits, especially in mass production. To finish shaping a metal workpiece, it can freely transfer the work by adding shape.

 In the past, each step of these procedures was completed by hand, with the workpiece being transferred manually between separate presses and dies. Single-press efficiency is greatly improved by automating the transfer process.

4. Progressive Die Design 

A progressive die can do numerous operations at once, but it does so in stages at different machines. The progressive die is superior because of the increased productivity that comes from working quickly while using less force. 

The progressive die makes it simpler to achieve peak punching efficiency in a multi-station layout, despite the fact that its management is more complex than that of a single-station device. 

To mass produce complex components like those used in automobiles and electronics, engineers employ progressive dies.

Difference Between Mould And Die

Die

• A die is a specialized piece of machinery utilized in the industrial sector for cutting and/or forming materials into the desired form. A die is used to shape only two of a part's three dimensions, as opposed to a mold, which shapes the item from start to finish. Other process variables determine the third dimension, which is typically thickness or length.
• Tool steel, a special type of carbon steel and alloy steel, is commonly used in the production of dies and other types of tooling such as cutting tools and hand tools.
• High strength, wear resistance, plus impact toughness at both room temperature and higher temperatures are the hallmarks of tool steels' unique alloy composition. Dies are helpful because of the volume of material they can cut.

Mold 

• A mold is a tool used in manufacturing that is designed to create objects of a specific design and dimensions. Materials can be shaped into components or finished goods by applying pressure using specialized tools that are mounted on the press as part of the manufacturing process.
• A mold is used to create a complete three-dimensional plastic item during plastic manufacturing. Metal-plastic forming molds, mold injection molds and Casting molds are just a few examples of the many categories of molds, but their common purpose is obvious.
• Blow molding, reaction injection molding, thermoforming, and Injection molding, are all mold-based plastics processing techniques.

Die And Mold Industry

1. Overview 

From 2020 to 2025, the Indian dies and molds market is forecast to expand by USD 1.47 billion, representing a compound annual growth rate (CAGR) of 9%.

2. Trends and Challenges 

As far as we can tell, the expansion of the market before, during, and after the COVID-19 era was unaffected. Growth in the dies and molds market in India is being propelled by new possibilities in aluminum metal injection molding, but the market could be stymied by issues including a shortage of competent workers in the industrial sector.

 The researchers have analyzed past data to identify the leading market drivers and the consequences of the COVID-19 pandemic for India's dies and molds sector. In order to deduce objectives and fine-tune advertising campaigns to get an advantage over the competition, a comprehensive analysis of the drivers is required.

3. Key Players

• Godrej & Boyce Manufacturing Co. Ltd.
• Alfa Plast Mould, Classic Die Tools 
• Hindustan Die Castings 
• Sankalp Engineering & Services Pvt. Ltd.
• NAGATA AUTO PARTS Co. Ltd.
• JPM Group
• DIETECH INDIA (P) Ltd.

Conclusion

Plastics, resin, and metal casting are common uses for molds. A die is a tool used for cutting and shaping metal into a specific profile. Commonly, the same alloys were used for both dies and molds. However, a durable mold manufactured from high-strength metals isn't always necessary, especially for smaller applications. After that, we may switch to using materials like plastic, silicone, and wood to create molds.

FAQs: Dies and moulds

Q. What are the top Die And Mould Manufacturers in India?

Ans. Here are the top manufactures:

• Godrej & Boyce Manufacturing Co. Ltd.
• Hindustan Die Castings
• Sankalp Engineering & Services
• Greatoo Intelligent Equipment Inc.

Q. Types of Moulds And Dies.

Ans. Here are some basic types:

• Simple Die
• Compound Die
• Transfer Die
• Single Cavity Mold
• Dedicated Multiple Cavity Mold
• Two plate mold
• Three Plate mold
• Cold Runner mold 

Q. How to start Dies and Mould in India.

Ans. Here are the steps:

• Find a niche and focus
• Plant Layout
• Warehousing for injection molding 
• Required molding machine 
• Select the equipment

Q. Applications of Dies and Mould

Ans. Die cutters and molds serve the same function in the manufacturing industry. Metal sheet and other shapes can be formed using dies. Fabricating car bodies is a common use case. Conversely, injection molding, which can be done with molten resin or metal, requires the usage of molds.