Stichwortverzeichnis

Mold-Making Handbook

Herausgegeben von Günter Mennig, K. Stoeckhert

ISBN (Buch): 978-1-56990-446-6

ISBN (E-Book): 978-1-56990-550-0

For further information and order see

http://www.hanser-fachbuch.de/978-1-56990-446-6

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© Carl Hanser Verlag, München

Subject Index

Aabrasion 643abrasion resistance 277abrasive file 526abrasive stone 525ABS 361, 595, 659ABS-PP 287accessories 335accumulator 114ACES Injection Molding 589acid 567acid copper bath 167acidic range 448action plan 667adhesion 643adjustable pin 602adjustable wall 196adjustment sleeve 130agitated mold surface 147AIM cavity 599air bubble 86air ejector 73, 92air gap 33, 37, 50air gap insulating 369air oxidation 505air-permeable plate 143air pocket 327air trap 22, 23, 37alarm signal 634AlCuMg alloy 444AlCuTi 444alibrating blow pin 117alignment pin 62alignment wedge 72alkaline detergent solution 449alloy composition 442AlMg alloy 444

AlMgSi alloy 444AlSi alloy 444alternating electromagnetic field 399aluminum 70, 77, 121, 135, 143, 148, 161,

193, 201, 213, 233, 255, 271, 292, 297, 338, 424, 442, 571, 591

aluminum alloy 83, 296aluminum bronzes 467aluminum cast 123aluminum castings 131aluminum-ceramic precision casting 143aluminum-filled epoxy resins 514aluminum molds 294aluminum mold shells 163aluminum multi bronzes 461aluminum oxide stones 526aluminum particles 287aluminum prototype mold 473aluminum-wrought alloy 193AlZnMgCu alloys 444amorphous layer 656amorphous nickel phosphorus layer 559amorphous thermoplastics 384anatomical demonstration objects 166angle hand piece 524angle pins guide 337annealed state 534annealing 425annealing color 426anodic dissolution 645anodic stress corrosion cracking 646ante-chamber 29anti-body cleavage 646anti-static coatings 182arc welding 456argon 467artificial ageing 444

678 Subject Index

aspect ratio 267assembly injection molding 266, 303assembly seam 225assisting plug 138, 147, 149atomizing chamber 424austenite 425austenitising 547autoclave steaming 186autoclave technology 201automated tape laying 208automatic roll machine 149automatic switch over 625, 627automatic venting 638automobile industry 75auxiliary blow pin 133auxiliary parting plane 104

Bback blowing 195back feed behavior 457back-foaming mold 88, 516balancing 21, 22ball catch 13ball guides 263ball milling 465band heaters 376banding 578band-type formations 575barrier characteristics 112base body 643bath model 177beryllium copper 392beryllium free alloy 461biaxial orientation 112bimetal effect 518binder-forming molds 223biolactat 260Biot-number 385bismuth alloys 514blank 69, 76, 242blasting 507blind insert 263block mold 197blowhole formation 512blowing bell 152blow mold 458blow mold cooling 126blow molding 112, 290blow molding RTM process 235blow needle 117

blow pin 129blow up methods 117bobbin stand 238bonding strength 416bore holes 485, 491boriding 555boundary layer thicknesses 630brackets 167brass 123, 271, 498, 505, 571brass body 527breakage 667breakdown of costs 618bridge tooling 587brilliant surface 150, 532broken natural diamond 529bronze 72, 130, 271, 461, 597bronze alloys 460bronze bushings 192bronze infiltration 597brown wreaths 654brush plating 557brush units 376bubble bore holes 485buckling stability 446building parameters 586built-up edge 527, 531bulking force 182buoyancy force 358burn mark 665bushings 72butt welding 457bypass channel 61

CCAD 59, 295, 314, 472CAD/CAM 463CAD drawing 336Cadmould 8CAE program 9calibration 604calibration mandrel 117calibration station 113calottes area 355CAM 59carbide 271, 524, 540carbide formers 536carbide-tipped tool 70carbide tool 465carbon 655carbon content 425, 426

679 Subject Index

carbon fiber prototype mold 162carbon-fiber-reinforced polymer 204carbonitriding 543carburising 543, 551carrier film 574carrier foil 173carrier material 567carrying capacity 657cartridge heater 31, 32, 75, 376cascade-controlled multi-cavity mold 640cascade filling 36case hardened steel 58case hardening 216, 550case-hardening steel 338, 439, 543cashew gate 28cast alloy 443cast aluminum 98, 202cast elastomer 111casting 505casting molds 164casting process 457cast metal 120cast resin 120cast skin 516cast steel alloy 202cast zinc mold 127cathodic electron acceptance 645cavity evacuation 38cavity number 1cavity pressure 3, 622cavity stacks 269cavity temperature 379, 622cavity venting 37cementite 530centering 10, 93, 169, 264, 351centering ring 10centering sleeves 341central ejector 11, 67central mold storage 669centrifugal casting technique 111ceramic 271, 591, 593ceramic fiber file 532ceramic fiber sanding file 525ceramic injection molding 260CFK mold pocket 203changing mold inserts 295characteristics of costs 617checklists 612chemical corrosion 645chemical engraving 454, 567

chemical nickel 469, 653chemical nickel plating 167, 299, 437, 449chemical nickel-polytetrafluoroethylene 655chemical silver plating 503chimney effects 369chip braking 464chipping 531chip space 527chrome 652chrome carbides 652chrome plate 444chrome plating 299, 449chromium carbide 530chromium content 339, 438chromium layer thickness 59chromium nitride 256chromium plating 434circumferential application temperature

control 392clamp 507clamp force 125clamping 168clamping device 91clamping edge 138clamping force 2clamping frame 152clamping plate 361clamping pressure 242clamping unit 3, 182clamp stop 126Class A surface 69, 216cleaning concepts 278cleaning process 530clean room 268cleavage product 649CLI 584closed cell foam 179closed-control loop 638closed cooling circuit 154closed-loop control 627closing 168closing time 85cloth 531cluster nozzle 36CNC 135, 463CNC-milled production 123CNC-milled shell 163CNC milling 287coated mold surfaces 55coating 463, 469

680 Subject Index

coating technologies 649cobalt 504cocking 101CoCr 586CoCr-steels 591coextruded parts 124coextrusion 113co-injection technique 351cold fusion 644cold runner manifold 252cold runner system 49, 372cold welding 192, 654cold work mold steel 540collapsible core 343collective stress 643collision analysis 481collision function 477color change 31, 32color-coded sticker 671color pigment 646combination molds 160combinations of aluminum 449combined pressure/temperature sensor 625common loading chamber 64communication drawing 476complete system 33component height 499components for injection molds 332composite molds 458composite pins 347compressed air 415, 649compressed air hoses 91compression injection molding 267compression molding 52, 242compression shock 649computer simulation 108computing time 326concentration element 645condensate 191condensation 449, 652, 671conductive tip 30conformal cooling 592conformal cooling channels 462conical guide 243conical surface guide 342connected functionality 627connecting component 351connecting diagram 315consolidating roll 208contact corrosion 449

contact feed 167contact temperature 19, 402continuous fiber-reinforced thermoplastic

material 209continuously working press 210contour-adapted cooling 585contour-adapted cooling channels 584contour-close hardening process 535contour data 583contour-dependent temperature control 393contour elongation 510contour plate 227contour steel 339control technique 367convection heat loss 34conveyor belt 76conveyor system 90coolant 129cooled transfer pot 251cooling channel 39, 40cooling circuit 127, 640cooling fixture 130cooling line 195cooling phase 629cooling scheme 315cooling system 292, 308cooling time 6cooling tubing 127cooling water emulsion 466coordinate measuring machine 352copper 167, 188, 271, 494, 516, 571copper alloy 123, 144, 460copper-beryllium alloy 188copper cooling tubing 120copper plating 450copper reinforcement 502copper-steel composite 468copper tube 287copper tubing 83copy milling machine 59core 56, 67, 583core cooling 346core puller 17, 65, 189core strength 447core vents 191corner warpage 388correction 476correctional factor 616corrosion 159, 449, 644, 671corrosion element 645

681 Subject Index

corrosion inhibitor 653corrosion protection 154, 556corrosion protection cartridge 347corrosion resistance 193, 410, 429, 443,

505, 511, 658corrosion-resistant plastic mold steel 437corrosion-resistant steel 338, 542, 570cost control 662cost element methodology 616cost formula 616cost function term 618cost of distribution 616cost ratio 615cost saving 641CO2 temperature control 395counter body 643counter-casting 589counter mold 153, 224counter pressure filling 182, 184counter sunk area 388coupling layer 287cover fluxes 457crack filling process 184crack formation 644crack susceptibility 456crater overlay 492critical shear rate 117cross-linking 241cross-linking polymer 1cross steaming 186crust 159cryogenic treatment 540crystal-clear part 147crystalline layer 656crystallinity 381CuBe alloy 461cube technology 46cubing model 471CuCoBe 356CuCoBe alloy 354cup grade 188cure time calculator 249curing phase 249curing position 85curing process 207curing time 53curved kerb 337curved tunnel gate 28cusing 592cutter heads 483

cutting bushing 118cutting data 452, 467cutting edge 124, 257, 451, 463cutting edge corrections 484cutting geometry 452cutting plate 156, 465cutting sleeve 117cutting speed 464, 510cutting unit 197CVD 469, 648CVD coating 560cycle time 158, 379, 658cycle time reduction 462

DDam Gate 102data acquisition 627data feedback 474data model 325data plane 474data quality 475dead water zone 253decade switch 371decarburising 544decentralized mounting 344decorating plastic product 172Decoupled Molding 630deep bore hole 466deep-drawing operation 519deep etching 454deep hole drilling 485deep slot 599defect-free part 634deflashing 125deflecting area 528deflection aid 127deflection angle 22deflection bar 389deflection element 346degassing 283degradation product 650degrees of forming 214delamination 205demoldability 161, 276demolding 6, 10, 50, 54, 145, 150, 171,

177, 183, 187, 238, 505, 570demolding aid 89, 92demolding air volume stream 145demolding concept 308demolding element 343

682 Subject Index

demolding force 382, 410, 658demolding principle 375demolding procedure 19demolding unit 319density 123, 442deposit formation 659depositor 418deposit table 76deposit welding 457depth-hardened steel 338depth of etching 567design 471design draft 314design drawing 334designer product 569Design of Experiment 630design process 318design rules 8design rules slider molds 15detour hotrunner 25development phase 609dew point 129diamond 70, 271diamond dressing file 525diamond grain 528diamond-like layer 656diamond ring 525diamond turning 271diaphragm forming 217diaphragm gate 24dielectric fluid 490dielectric measurement 234die ring 116diesel effect 37, 263, 416, 649, 665die-sinking ED 532die-sinking EDM 491differential pressure 281diffusion barrier 97diffusion welding 593digital control signal 627digital switch over 627dimensional accuracy 503, 510, 622dimensional inspection 485dimensioning 305dip blow molding 112, 133direct-coating model 506direct cooling 39direct gate 86, 103direct production 582direct tooling 586

disassembly 662discharge energy 492displacement cavity 244displacement stress 644dissipation 246distortion 186distributor head 116DLC 656DLC layer 561DLP projector 589documentation 309, 619dosed molding 53dosing 248dosing unit 373double bath model 178double-threaded spiral core 390downholder 215downtime 662draft angle 92, 145, 192, 231, 569drag plate 104draping 216draping aid 225draping behavior 214drawn brass 506drilled cold runner 253drilled cooling channel 127drilling 465drop box 159drop-in system 33drying cycle 235dry-run 653dullness 406dwell time 278dwell-time length 64DXF 584Dynamic Feed 36

Eeddy currents 221eddy currents develop 399edge chipping 465edge lifting 553edge rounding 647edge weakness 511edge webbing 152EDM 59, 454, 490, 532eectric valve gate system 366effective bounding volume 614effective cost volume 615eggshell effect 469

683 Subject Index

ejecting 166ejecting unit 336ejection 10, 263ejection pin 344ejector box 11ejector elements 654ejector half 9ejector pin 624ejector pins 12, 56, 73, 101, 347, 367ejector plate 73ejector position 311ejectors 96, 376, 654ejector type 375elastic deformation 446elastic mat 205elastic modulus 382elastic strip-off 18elastic strip-over 19elastomer mold 49elastomers 241, 291, 640electrical discharge 490electrical heating cartridge 211electrically conductive 221electrically insulating separating agents

449electrically non-conductive materials 221electrical switchboxes 66electric discharge machining 486, 490electric field 492electric heater 53electric needle drives 363electro-chemical corrosion 650electrochemical process 555electrode material 272electrodes 486electro forming 275electroless nickel 555electrolyt 504, 645electrolytic application 450electrolytic corrosion 645electromagnet 363electromagnetic drive 36electromagnetic system 366electron beam 590electron beam welding 468electronic mold storage management 672electronic parts 52electroplated hard chromium 449electroplated mold 165, 173, 175electroplated molding 161, 167

electroplating 275, 502electroslag remelting 424electrostatic charge 268embossing unit 267emery cloth 531encapsulation material 419encapsulation of insert 417encircling channel 392encrustation 647end mills 483energy balance 24energy consumption 31engraving 126, 599Enterprise Resource Planning 669EPE 181epoxy 280epoxy laminate 518epoxy resin 167, 177, 201, 287epoxy resin coating 96epoxy resins 505, 589EPS 180equipment designer 475erosion 646erosion wire 498erosive turning 273ESR 424estimated value technology 614etch-grainability 429etch-graining 438etching 126, 270, 470, 507, 568etching depth 570etching test 578etching trial 571ethernet interface 628evacuation 415evaporation 40evaporation/condensation process 390evaporation enthalpy 187evaporation of alloying elements 467excess air 149excessive weight 630exchange of electrons 645exothermic heat 83exothermic reaction 79, 234expandable contour skin 228expandable polyethylene 181expandable polyethylene-copolymer 181expandable polymethyl methacrylate 181expandable polypropylene 181expandable polystyrene 180

684 Subject Index

expanding 184expanding core 665explosive films 273exposure time 261, 567external inductor 413external undercuts 10, 13extrusion blow molding 112extrusion process 595

Ffactory-wide network 636failure modes and effects analysis 667fairing lines 175family mold 21, 36, 350, 638fasteners 507fastening of inserts 93fast tool making 582fatigue 644feasibility study 475feedback 476felt 531felt body 523FEM 80female mold 54female side 190FEM calculation 400ferrite phases 530ferritic structure 524fiber-filled coupling layer 289fiberglass laminate 506fiberglass technology 513fiber orientation 148, 578fiber-reinforced materials 200fiber-reinforced thermoplastics 329FiFo principle 114file structure 314filler content 646filling 86filling behaviour 546filling gates 191filling injector 183, 193filling pattern 323filling pressures 110filling simulation 40, 629filling time 632filling unit 182film gate 86, 232, 375final inspection 315final part quality 622fine tuning 633

finishing 494finishing electrode 527, 533first in, first out (FiFo) principle 115fission products 167, 649five-axis milling machine 484fixed half 9fixed stripping nozzle 220fixture 129flame harden 77flame hardened 71flame hardening 548flame retardants 649flash 68, 124, 132, 159, 243, 257, 647, 665flash cooling 124flash formation 375, 417flash-free product 254flashing 4flash pocket 125flash relief 125flat centerings 10flat guides 264, 342flat temperature control 387flexible 83flexible heating elements 75flexible integral skin foams 105flexible mold concepts 599flexible PUR foams 93flexible sealing elements 417flexible tubular heaters 368flex-poli 523floating manifold 32, 33Flotek-process 177flow anomalies 117flow channels 244flow channel thickness 326flow fronts 327flow lines 407flow marks 70flow molding process 76flow path 382, 573, 629flow path length 647flow pattern 669flow pattern method 327flow patterns 109flow resistances 242fluid core 44flux density 557fluxes 456FMEA 667foam 236

685 Subject Index

foam brakes 87foaming molds 190foam molds 458foam pressure 186, 196foam structure 88foil feeding 674Fo number 128force 54force shunt 623forged aluminum 121format frame 153format parts 139forming vacuum 154foundry sands 591fountain cooling system 346fountain flow 4, 44fracture-resistance 429free chrome content 652free-form surface 325free jet 101free jet simulation 326free-standing domes 585freezing effects 398fretting 654fretting of ejectors 642frictional heat 57friction coefficient 450, 656front-flush 626fuel tank 116, 122fully electric injection molding machines

366fume extraction 467functional costs 613functional principle 625functional tests 489Fused Deposition Modeling 595fusing 183, 184fusion 186fuzzy logic 370

Ggalvanic electrolyte 504galvanic element 348galvanic hard chromium plating 437galvanic insert 502galvanized mold 502galvanized mold surface 55gas flushing 457gas injection 361, 638gas nitriding 553

gas permeability 190gate 262gate area 40gate cross-section 21gate design 21gate manifold 375gate position 22, 327gate region 7gate system 308, 311gating 101, 105gear rack 20gear rack drive 68generative manufacturing 582generative manufacturing procedure 292generative mold making 598generative process 582glass fiber 646glass-fiber-reinforced polymer 204gliding behavior 147globular particles 647gloss 381, 406, 530gloss differences 647gloss grad 171gloss level 573GMT 52, 69, 75, 556grabbing mechanism 113gradient materials 585grained surfaces 145, 406grain foil 175grain growth 467graining 567grain pattern 173grain sizes 526grain stamping 519grain structure 175, 506graphite 494, 657gravity casting 457grinding 272, 454, 531grinding pins 523, 525GRP supporting shell 177guide blocks 72guide bolts 72guide columns 263guide elements 56, 256, 336, 341, 460guide pins 72guide plates 72guide rails 192guides 269, 351guiding 264gypsum 142, 291

686 Subject Index

Hhairline crack 511hand crank 67handling fixture 132hand piece 531haptics 171hard anodized aluminum 224hard anodizing 299, 449hard chrome 653hard-chromed 238hard chrome-plated mold 59hard chrome plating 55, 256, 556hard chromium plating 438hard coating 649hard core technology 201hardened felt 148hardened inserts 71hardened mold steels 646hardened mold surface 55hardened plastic mold steel 571hardened steel 255hardening 205, 425, 461hard metal 529hardness 422hardness differences 524hard nickel deposits 504hard oxides 524hard turning 257hard wood 530HCl 650HDPE 125heart-shaped curve 116heat capacity 507heat conduction 39, 359heat conduction tip 29heat conductive cartridge 391heat conductive inserts 392heat conductivity 128heated sprue 28heater cartridge 37heating bands 265heating cartridge 265heating coils 265heating plates 53heat loss 31, 383heat penetration 462heat penetration ability 402heat pipe 40, 390heat points 347heat transfer 39, 40

heat transfer fluids 83heat-treated mold steels 55heat treatment 425, 437, 460, 544heavy-duty shelving 670helical spindle 20helical toothing 497high-alloyed steel 33high-alloy steel 193, 424high chromium steel polished surface 256high-density PE 126high energy light 589high filler content 329high-frequency oscillating magnetic field 221high-frequency spindles 522high-gloss 569high-gloss polish 414high-gloss polishing 427high molecular polyethylene 117high-quality mold surface 96high-speed machine 483high-speed machining 295high speed milling 451high-speed stack mold 351high-strength titanium 369high-temperature corrosion 645high-temperature mold steel 55high temperature oils 211high-temperature processing 599hinged split-cavity mold 66hinge system 162hobbing 439holding magnet 507holding pressure 6, 248holding pressure switchover 632holding pressure time 628hole screens 191hollow components 235hollow needle 46hollow probe 508hollow profiles 213, 236holographic security features 268honing stone 525hood side 190hot bath simulation 539hot-cold separation 372hot cracking tendency 457hot cracks 463hot cure foams 83hot curing PUR elastomers 111hot embossing 267

687 Subject Index

hot forming mold 154hot halves 33, 351hot runner 11, 29, 33, 48, 262, 647hot runner control 370hotrunner externally heated 31hotrunner insulation 29hotrunner internally heated 31hot runner manifold 247, 251hotrunner mold 31hot runner shut-off needle 36hot runner system 333, 349, 351, 667hot runner technology 349hot runner-valve gate 10hot sides 333hot spots 9, 40, 669hot stamping 267hot work steel 211, 292, 338, 357HPGL 584HSC machining 453HSC milling 257, 427HSC milling technology 534HSSE tools 464hybrid component 418hybrid mold 295hydraulic actuators 116hydraulic needle drive 362

Iice formation 396IMC 69IML 132immersing device 129impregnating 227imprinting of the surfac 381impurities 424inclined bolt 13inclined drillings 501index plate 46, 315indirect cooling 39indirect heater 53indirect tooling 586induction heating 265induction welding 220inductive heating 41, 411inductive mold temperature control 399infiltration 210, 596inflatable seal 88ingot mold 457inhibitors 449injecting blow pin 117

injection 248injection blow molding 112, 133injection bore holes 245injection-compression mold 43, 49injection compression molding 2, 250injection mold 332, 511injection molding 1, 290injection molding compression 638injection molding machines 2injection molding process 3, 246injection point 350injection rates 628injection speed 4injection transfer molding process 251In-Mold-Assembly 46, 48in-mold coating 69in-mold graining 513, 519inner centering 10insert frames 197inserts 9, 56, 67, 172, 226, 250, 266, 286,

570, 576, 639inspection 662insulating layer 408insulating plate 376insulation cap 30insulation runner 31integral skin product 100integral value 634intelligent electronics 635interchangeability 335interchangeable inserts 320, 418interchangeable standard molds 338intercrystalline attack 644intermediate material 643intermittent compression molding 210intermittent parison generation 114internal cavities 584, 597internal coating 39internal cooling channels 599internal gas pressure processes 638internal gating 354internal helical cooling channel 602internal hollow spaces 592internal pressure 85internal sliders 17internal stress 540, 630internal thread 19, 117internal undercut 10, 17Internet 636intersection change 417

688 Subject Index

investment casting 583ion flow 490ion implantation 449iron carbon equilibrium 425isobaric double belt press technology 211

Jjaws 654jet pump effect 101jetting 119jetting system 589joining technique 209Joule heating 399

KKeltool Course 4 Technology process 589knife edge 172K-plate 336

Llamellar mold 594laminated object manufacturing 592laminate mold 211laminate structure 201laminating 513laminating mold 516land 63lapping 523lapping grain 528lapping liquid 525lapping pressure 527large-sized galvanized molds 517laser-based generation 591laser beam 588laser beam build-up welding 273laser-beam welding 456laser cusing 600LaserCUSING® 290lasered leather surface 580laser hardening 549laser machining 257laser melting process 294laser processing 273laser sintering 269, 587, 599laser technology 580laser welding 178, 468, 513, 576latch conveyor 344lateral hotrunner injection 34lateral pinch area 119lateral venting 151

late switch over 630lattice stains 651lattice transformation 648layer adhesion 556, 563layer effect 586layer generation 583layer-laminate process 592layer milling process 594layer thickness 586layup 206LDPE 114leaching 647leakage 159, 666leak test 417leather 175, 291, 511, 531leather grains 505length-adjustable arrestor 220LFT 52, 69, 75lifetimes 511LIGA technology 275light sanding 590lightweight 518lightweight material 200linear expansion coefficient 144linear pressure gradient 629line gates 232liquid monomer 588liquid silicone injection molding 640liquid silicone rubber 49, 372lithography with synchronic radiation 275loading chamber 63loading device 53, 64locating element 169locating units 342locking device 91locking pin 419locking system 508locking wedge 16loss of functionality 642lost core 234, 236lost-core process 19lost foam areas 196lost models 583low-alloyed copper alloy 460low-contamination surface 658low density polyethylene 114low-density PUR foam 82lower mold half 54, 63, 89low pressure gravity casting 457low temperature horizontal (LTH) process 188

689 Subject Index

LTH 188lubricant-free operation 653lubricants 450lubrication 74, 654lubrication reservoir 342lug guidance 65

Mmachinability 444machine host computer interface 636machining 427, 483magnetron sputtering 656maintenance 662maintenance interval 642male core 206male mold 54male side 190mandrel 238mandrel head 116manifold 26manifold block 33, 364manifold block, single cavity 368manifold system 369manual labeling 669manufacture of a mold 471manufacturing costs 610maraging mold steels 543maraging plastic mold steels 440marking 55, 599martensite 440martensitic microstructure 539martensitic surface layer 547mass-related strength 446master model 166, 202, 207, 283mat-down treatment 407material costs 618material hardness 244material outbreak 653material removal 530material thickening 216mat-like thermosets 52matt surfaces 406mechanical design 9mechanical ejector 187mechanical energy 249mechanical marking 575mechanical processing technology 274melt channels 367melt core casting 236melt cushion 245

melt filtration 457melt flow 640melt-front-dependent controls 638melt front-dependent opening 640melting 599mesh widening 651metal-coated model 120metal injection molding 260metallic hub 67metal mold insert 290metal slider 189metal spraying 161, 589metal stamp forming 215micro component 399micro-cracks 556micro-EDM 272micro-finishing 482, 494micro-geometric shape deviation 654micro-geometry 530micro-injection mold 261micro injection molded part 358micro injection molding 258micro machining 644micro mat 407micro-plastic parts 500micro-porous galvanized mold 519microporous PUR product 107microporous surface 506micro-precision part 502micro-radiation 407micro-reflectors 505micro roughness 407micro sanded 126micro-stamping 500microstructure 41, 411, 425, 522, 550, 571microstructure transformation 547micro-thermoforming 268micro-wire cutting 272middle plane mesh 325MIG/MAG 467milled cold runner 253milled cooling channel 127milled prototype mold 121milling 465milling command 480milling of the resin block 289milling strategy 482milling track 578miniature parts 500mini-hot runner system 359

690 Subject Index

minimum draft angle 479mirror gloss surface 526mirror-like surface 469mock-up 202model technology 175modular constructed core mold 235modular core mold 230modules 477modulus of elasticity 123mold 336mold alignment 123mold breathing 43mold calculation 614mold carrier 81mold cavity 319mold concept 351mold contamination 649, 658mold core 319mold costs 1, 609mold crater 665mold deposit 410, 546mold design 303mold failure 662mold filling analysis 109mold flanges 171Moldflow 8mold flow analysis 294mold frame 61mold halves 56mold handling 673molding accuracy 398molding shrinkage 144mold inquiry form 311mold insert 319, 460mold-in-systems 172mold labeling 673mold lid 94mold life time 609mold maintenance 278mold maintenance costs 674mold making 335mold management 671mold package 140mold-peripheral connection 479mold plate 341mold protection 7mold release 104molds for sampling 141mold shell 514mold-skinning 188

mold specification 611mold steels 341, 591mold surface 406mold temperature 376mold type 307mold venting gap 4mold wear 49, 218molybdenum 655molybdenum alloy 355, 356, 648molybdenum trioxide 656monitoring signals 628monitoring the process 633mono-block mold 189, 196mono-crystalline diamond 271, 528monolithic products 205MoS2 656MoS2-Me-layers 656mother-galvanized mold 507mother model 177mounting brackets 507mounting position 390movable slide function 479moving cores 638moving mold component 416multi-cavity, gateless injection 358multi-cavity hot runner mold 639multi-cavity mold 21, 64, 103, 140, 160,

353, 632multi-channel connector 626multi-component injection molding 266,

351multi-component metal powder 591multi-component process 303multi-component technology 45multi-etching 579multi-gating nozzle 360multi-hole nozzle 30multi-layer coating 656multi-layer composite 113multi-machine operation 484multi-nozzle pressure head 596multi-nozzles 360multiple-cavity mold 610multiple cutting speed 443multiple-density-process 189multiple etching 568multiple shifts 484multi-step process 190multi-zone controller 370mushroom ejector 376

691 Subject Index

Nnano range 275nanostructures in micro-optics 268narrow slits 531natural balancing 21neck rings 127needle blow method 118needle drives 361needle gripper 75needle shut-off nozzles 35needle valve 350, 361needle valve system 361negative deep-drawing 513negative forming 141negative mold 145, 164negative-stamping deep drawing process

519negotiation support 621net-sales price 618net-shaped preform 223, 225networking 635nickel 167, 571nickel coating 33, 276, 505nickel electroplated deposition 502nickel-galvanos 144nickel hardness 504nickel layer 503nickel plate 444nickel plating 434, 558nickel silver 571nickel sulfamate 504nickel sulfate 504nitrating 216nitriding 434, 552, 571nitriding steels 429, 441, 543non-conductive liquid medium 490non-isothermal diaphragm forming 217non-magnetic behavior 442non-metallic components 562nonmetallic inclusions 524nonporous sputtering 657nonwoven fabric 202normalizing 425nozzle cold runners 252nozzle control 372nozzles 355nozzle sided clamping platen 336number of cavities 610nylon vacuum casting 284

Ooffer phase 607offset 668oil-sealed bonded 175one-stage process 112online flow path control 232open control loop 633open controls 627open molds 208optimal switch over point 633optimization 629, 669optimization process 489orange peel 651orange peel effect 531orange skin effect 521organic sheet 209, 213organo-metallic reaction 650orientation lines 365orientations 70, 323, 381orifice angle 117O-rings 387oscillating motion 528outgassing 571outlet channels 192outserts 37outsert technology 48overall costs 611over-etched structure 579over-etching 573overflow bean 417overflow grooves 242over-injection 417overmeasure 544overmolded parts 633, 639overmolding 44over-polishing 531oxide 645oxide ceramic grinding files 526oxide film 443oxide protective layer 448oxygen-poor water 449

PPA 6 158, 284PA 11 591PA 12 158, 591PACVD coating 561painting 489paint-like surface 406paper-layering process 592

692 Subject Index

parallel connections 40parallel-controlled quick stroke press 76parallel guide system 212parallel temperature control 386parison 113parison forming 134parison tooling 129part design 7partial pressure drop 126particle cleavage 646particle foams 179particle size range 529parting plane 100, 186, 245, 256, 372, 416,

477parts list 332passive layer 652pass through channel 29pattern protocol 315Pb 444PBT 659PC 126, 158, 659PE 150, 158, 659PE-E 184PEEK 48PE foam 159perforated foil 227perforation 191permanent release coatings 171peroxide 241PET 125, 659phase before 307phenolic plywood 141photochemical etching 178, 567photo-resist 574physical blowing agent 179piezoelectric cavity pressure sensors 623pilot series molds 458pinch areas 119pinch-off edge 121, 124pinch relief 125pinpoint gate 25, 232, 375pins 239PIR 111piston 244pitch circle 360pitting 644place holder 228planetary-EDM 454planning of molds 608plasma channel 492

plasma nitriding 554plastic body 523plastic coatings 276plasticizing screw 247plastic mold steels 422, 534plastisols 158plate guidance 363plates, drilled/undrilled 335pleat formation 153pluggable wiring 369plywood 224PMI foam 237PMMA 181, 505pneumatic cylinders 168pneumatic needl 362pneumatic piston actuator 361poli-rotor 523polishability 428, 437polished 55, 126, 238polishing 276, 454, 469, 487, 521polishing defects 521polish lapping 523polyacetal 359polyamide 114polyamide casting 285polyamide-imides 463polycarbonate 114, 448polycarbonate-acrylonitrile butadiene styrene

(PC-ABS) blend 126polycrystalline diamond 271polycrystalline synthetic diamond 528polyester 69polyether ether ketone 463polymerization 588polyolefin 116, 126, 353, 354polyoxymethylene 448polypropylene 75, 126polystyrene 114polyurethane 78, 280, 290, 506, 589polyurethane casting 287polyvinyl chloride 116POM 149, 659porous galvanic molds 144porous material 191, 264porous sintered material 396porous stamping mass 142position of the melt 625position of the parting plane 311positive forming 141positive form mold 140

693 Subject Index

positively etched mold 567positive model 503positive mold 62, 145postblow machining 131post-calculations 618postcooling 130post-crystallization 382post-curing 202post-curing cabinet 589post-electroplating 512post-engraving 178post-graining 572post-shrinkage 381powder bed 591powder box 178powder cake 590, 596powder nozzle 591, 599powder slush 173PP 125, 150, 158, 595, 650, 659PP-E 179P-plates 336PPSU 595pre-calculations 613pre-centered 364precipitated carbides 437precipitation hardening 424, 429, 440, 460,

543, 559precision machining 523pre-defined molds 337pre-dimensioned blank 244pre-expanded particles 179pre-expanders 182prefabricated blank 601prefinishing 482pre-foaming 182preform 45, 64, 112preform assembly step 225preform carriers 47pre-forming 141preform technology 223pre-hardened mold steel 338, 548pre-hardened plastic mold steel 421, 434, 535pre-impregnated fiber fabrics 205pre-machining 482pre-polishing 469prepreg 69prepreg-low pressure-autoclave technology

202prepreg processing 201press forming 520

pressure-assisted resin injection 232pressure-controlled holding pressure 632pressure-dependent switchover 625pressure distribution 43pressure filling 183pressure filling container 184pressure loading 182pressure losses 35pressure peaks 630pressure threshold 633pressure transmitters 219pretension 33pretreatment 503PRIASAFE™ principle 623PRIASED™ principle 623process capability 622process optimization 625process parameters 327, 622process simulation 5, 314process step integration 219process variations 633product costing 613product life cycle 608product transporting grabber 129profiled temperature 41profile milling 120profile mold 212Profit Pins 169programmable delay times 637programming 480project stage 613propellant-coated material 159propellant gas 80propellants 182, 649protective gas layer 456protective gas line 586protective passive top layer 646prototype blow mold 120prototype mold 161, 255, 458, 473, 506prototype molding 280prototype tooling 586, 599prototyping 582PS 591PS-E 179PSU 659PTFE 148, 193, 508PTFE tube 171pulsating method 491pulsed cooling 485, 669punching 214, 219

694 Subject Index

punching standards 269punch mold 143PU processing 505PUR 506PUR casting systems 110PUR foam 79, 159, 237PUR foam processing 514PUR integral skin foams 99PUR spray molds 515pushback pins 12PVC 95, 125, 158, 165, 505, 511, 650PVC foam 237PVC tape 568, 574PVD 409, 429, 434, 449, 450, 469, 648PVD coating 561PVD composite layers 653PVD slide coatings 656p-V-T-diagram 629

Qquality assurance 622quenched steel 571quenching 547quick change mold system 338quick connector 133, 626quick release 508quotation processing 607

Rradiation 178radiation heat loss 33radius 146RAL colors 158rapid-connect couplings 345rapid manufacturing 586rapid prototyping 275, 586rapid tooling 295, 582reaction heat 83reaction mixture 101reaction speed 626reactive matrix systems 234ready-to-install pre-series parts 287real time 627, 634reaming 466reception flanges 507re-coating 590reduced friction edges 212reference curve 635reference value methodology 614reflecting surface 188

reflection 573reflector plate 369Reinforced Reaction Injection Molding 108reinforcement elements 219reinforcement plies 230release agent 171, 206, 216, 224, 239releases 484release steps 478releasing agent 202removal rate 492repair 468, 512, 591, 601, 665replacement demand 609reproducibility 622reproduction accuracy 143residual porosities 423residual pressure 632residual stress 144, 186, 209, 382, 443residue 245resin bath 238resin compound 142resin injection 224resin injection technology 221resin molds 142, 287resin spray coating 142resin transfer molding 222resin trap 232resistance heating 265restoring force 146restraining undercuts 28returning cores 20reweldings 468rework 591rework-free 249rework-free parts 245reworking 560Reynolds number 384R-factor 463rheological analysis 8rheological design 323ribbing 446rigid 83rigid integral skin foam 106rigid PUR foam 96, 100RIM systems 108ring-finish 523ring gate 25, 375risk assessment 674Rohacell 202rotary molds 44rotatable carrier 48

695 Subject Index

rotating core 19rotating tool 525rotationally symmetrical component 238rotational mold 507rotational molding 158, 513rotomolded products 158rough coarse patterns 256roughing 494rough machining 482rough milling 427roughness depth 523, 572round-matte 579round tables 90routine inspection 665RRIM 108RTM 222RT methods 587RTM process 518rubber 241, 530rubber-bonded abrasive wheels 525runner 24runner demolding 28runner separation 26runner types 23run-off-surface 175

Ssagging strength 113salt bath 539salt bath hardening 650sample parts 322sampling 309SAN 650sandblast finish 126sand blasting 575sand casting 457, 583sand casting mold 165sand cast parts 193sanding file 525sandpaper 531sandwich component 218sandwich forming 218sandwich molding 44sandwich structures 96scaling 645scanning 521scorch 244scoring 644screw/piston 246seal 153, 171, 263

sealing 416sealing cap 360sealing effect 33sealing element 87sealing elements 48sealing material 360sealing point 5sealing rings 354sealing surface 175sealing time 6, 381sealing with open pores 88seaming 214seamless hollow articles 158secondary operation 131segment carrier plate 140segregation 578seizing 654Selar® RB 124selective laser melting 273selective laser sintering 283, 395selective mask sintering 587selective opening 361self-hardening 456self-healing effect 443self-locking molds 81self-sealing 4self-skinning foam product 80self-skinning foams 99semi-crystalline thermoplastics 384semifinished fiber products 222semifinished product 138semi-matte 579semirigid 83semirigid integral skin foam 105sensor body 623sensor front 623sensor position 625separation plate 389sequential connection 40sequential control 631sequential gating 361sequential injection 351sequential machining 524sequential molding 637series molds 458series temperature control 385service 662service life 642, 648, 658servo motor 363servomotor drive 36

696 Subject Index

setup time 443shape change 555shape molding machine 182shear cutting 154, 156shearing edge 210, 231shear rate 323, 649shear stress 34, 647sheathing of insert 243sheet molding compound 69sheet processing machine 149shell model 324shell mold 502shielding gas 456SHN-hardening 648Shore A 244, 374short-stroke-polish lapping 523shot peening 170shrinkage 3, 5, 80, 142, 186, 193, 242, 255,

328, 382, 507shrinkage allowance 478shrinkage analysis 109shrinkage behavior 631shrinkage conditions 630shrinkage forecast 308shrinkage prognosis 5shrinking 577shut-off edge 62, 71, 76shut-off needles 11shut-off nozzles 372shut-off region 62shuttle machines 123shuttle-type blowing machine 113SiC stones 526side-mounted alignment bars 72signal slew rates 635silicone 177, 291, 505, 508silicone molds 280silicone molds PU 283silicone negative molds 167silicone oils 211silicone rubber 108, 142, 373silicone stamp 216silver 571silver coating 167silver layer 510simplified costing 614SIMS 650simulation 323simulation programs 136, 232simulation technology 22

simultaneous costing 613simultaneous engineering 306single component powders 591single data level 324single-stage processes 591sink marks 235, 293, 415, 569sintered diamond ring 524sintered mold inserts 669sintered nozzles 191sintered steel 396sintered tool 525sintering 585size of the sensor body 624skeleton molds 147skin depth 411skin effect 412skin layer 4, 96skin texture 505slag barrier 457SLC data 584sleeve 361slicing operation 583slide mechanism 478slide mold 459slider 13, 16, 74, 89, 128, 570, 654slider guidance 15slider modules 219slider parts 476slider positions 311slides 319sliding partners 654sliding properties 410, 460sliding sleeve 344slits 512slot nozzles 150, 191slotted sheets 191slush-molding 515slush molds 165slush skin 95, 173slush technology 173, 504, 513small edges 531small series 287small-series mold 60SMC 52, 69, 518, 555snorkel 41soaking times 540soft core technology 201, 202soft foams 150soft tool 524, 531soft touch 95

697 Subject Index

software 480software solutions 635solenoid armature 363solidified eutectic 444solidifying runner 23, 25solid lubricant 656solid reaction layers 645solid wood 141solution-annealed 460spacer sleeve 210, 355spare parts production 609spark erosion 299, 490spatial expansion 381special machining 337specifications requirements 609specific heat capacity 123, 193specific heat removal 347speed-controlled 629spider 46spider concept 161spindle sleeve 193spiral core 346, 390spiral grooves 116spiral screw 497split cold runners 253split mold 17, 66, 337, 338spot-grinding 488spotting color 575spotting press 488spray cone 192spray forming 424spray nozzles 192spreading film 594spring back behavior 518spring-loaded pressing device 195sprue 23sprue bushing 24sprue gate 24sprue gripper 674sprue system 24sprue taper angle 24squeeze-off sliders 119stack mold 41, 43stagnation 630stainless steel 292, 506, 591, 597stamp forming 214stamp forming system 224stamping flash 417stand-alone web server 636standard cavity pressure sensors 624

standard deflectors 367standard injection molds 307standardization 332standardized components 334standard modules 336standard mold 60standard mold unit 343standard parts 351, 488, 602standards 332standards in mold making 335standard web browser 636start hole EDM 491static pressing units 212stationary layers 4steam chamber 182, 185steel 70, 101, 108, 121, 143, 161, 207, 233,

271, 294, 339, 571, 591steel/copper core pins 347steel deflectors 368steel frame 514steel plates 337steel quality 529steel rule die 157steel tube 168steel tubing 127steel weld construction 199stentering frame 674stepped parting plane 100stereolithography 280, 472, 588stiffeners 205stiffness 98stitching technique 225stitching template 225STL data 604STL dataset 584storage 669storage location 672storage space 249stress corrosion cracking 449, 644, 646stress crack failures 537stress cracks 178stress relieving 535stretchable films 579stretch-blowing 112stretching 152stretching processes 443stretch ratio 138striker plate 117stringer 204, 206stripper for neck flash 118

698 Subject Index

stripper plate 129stripper ring 18stroke length 362stroke movement 344, 528structure hardenings 577structure tips 263structuring 470styrene 354sub-distributor 27submarine gate 28substitute 204suction 596suction blow molding 119sulfamate nickel 504sulfur 241, 571sulfur content 339sulphamate nickel 167, 175super-elastic foils 217superfinishing 524supply bore holes 366supply range 612support 588support core 98supporting frame 177support pin 11support rib 507support structure 591, 597surface coating 449surface cooling 293surface crack testing 428surface defect 406, 578surface design 568surface extension 477surface fatigue 643surface finish 55, 292, 427surface finishing 487, 545surface mesh 325surface model 324surface preparatory leveling technology

524surface quality 381, 405, 503, 591surface replication 406surface reproduction 138surface roughness 147, 521, 654surface-sealed wood 229surface sealing 508surface spalling 644surface structure 169surface structuring 567surface treatment 169, 449, 571

surface treatment process 564surrounding medium 643switchover method 633synthetic foam 148synthetic resin mold 287system boundary method 400system characteristics 642

Ttableted 53tablets 64tailored blanks technology 219Tailored Reinforcement 225tandem mold 43tapered guide 244technical porous nickel 519Teflon 148Teflon-free preservative 671temperature control 154, 265, 345, 383,

384, 514temperature control finger 389temperature control tube 389temperature distribution 40temperature fluctuation 380temperature resistance 511temperature sensors 351temperature variance 39tempered sprue bushing 354tempered steel 571, 648tempering 537, 540, 551tempering of mold 377tempering temperature 437template 318, 569Tenifer treatment 553tensile strength 123tension crack 382tessellation 584test mold 60test run 479textured molded part surface 406texturing 601thermal conductivity 96, 123, 142, 161,

193, 428, 442, 460, 597thermal design 9, 329thermal expansion 10, 204, 364thermal expansion coefficient 201, 446thermal imaging cameras 669thermal insulation 49thermal process 547thermal shock resistance 462

699 Subject Index

thermal surface coating 537thermal wave analysis 409thermo-chemical process 550thermocouple 353, 402, 625thermoelastic range 112thermo forming 209thermoforming 138, 213, 520thermoplastic 200, 380thermoplastic foam 179thermoplastics for micro injection molding

260thermoplastic skin 188thermoplastic wax 589thermoset 52, 200, 372, 640thermoset mold 49thermoset surface 406thin layer chrome 653thin-walled molded part 53thin-walled technology 197thin-wall technology 188threaded insert 172threading 466three-body abrasion 646three-hole tips 360three-plate mold 28through-hardenability 435through-hardening 429through-hardening plastic mold steel 436through-hardening steel 536TiAlN 409TiCN 466tiered calculation method 621TIG welding 575Time-Temperature-Transformation 537tin alloy 106TiN-coated CuCoBe alloy 355TiN coating 449titanium 354, 424, 586, 591titanium alloy 33titanium aluminum nitride 409titanium-based surface 256titanium dioxide 646titanium insulation ring 355tolerance agreement 475tool changer 483tool electrode 491, 494tooling 483tooling material 506tool wear 492topography 406

torpedo heads 116torpedo nozzle 357torpedos 31total balancing 21total shot volume 349touching-up 525toughness 382TPO 95, 165TPU 165traceability 672transfer mold 57transfer molding 45, 52, 244transfer molding cold runner 251transfer piston 57transfer pot 251transfer technology 189transformation behaviour 537transparency 147transverse steam flow 186trials 489trial welding 576triangulation 584tribochemical reaction 468tribological element 643tribologically stressed material 654tribological system 643tribooxidation 643trimming 138, 214trimming station 130T-slots 15TTT 537tube cold runner 254tube system 195tubing 346tubular heater 32tubular preform 114tungsten 498, 655tungsten carbide 356tungsten inert gas welding 456tunnel gate 26, 27, 351, 375turbulent flow 39, 129turning 464turning cube technology 47turntable mold 46twin cube mold 47two-body abrasion 646two-colored slush skins 516two-component casting 280two-component mold 47two-component technology 2

700 Subject Index

two-stage ejector 344two-stage process 112

Uultra-precision machining 271Ultrasonic Consolidation principle 594ultrasonic lapping 532ultrasonic machining 273ultrasonic welding 593unattended operations 484undercut 10, 74, 110, 145, 165, 192, 216,

255, 286, 475, 508, 514, 570under-etching 579under water post-cooling 129uneven heat balance 669unfilled parts 633unidirectional reinforced tapes 238unscrewing 20unscrewing mold 67uphill casting 458upper mold half 54, 63, 89ureol 202, 224UV lithography 275

Vvacuum 96, 138, 193, 217, 246, 509vacuum assisted process 227Vacuum Assisted Resin Injection 222vacuum bag 201vacuum bagging 227vacuum brazing technology 394vacuum casting 589vacuum casting PU process 280vacuum connection 263vacuum forming 150vacuum hot embossing 267vacuum sucker 674vacuum system 518vacuum technology 375, 416vacuum vented 50valve gate cold runner manifold 254valve gate nozzle 360valve gate technology 361vapor pressure 180variable costing 616variothermal mold 41variothermal process 411variothermal process control 397variotherm process 265vectorized executions 575

vent holes 94ventilation 4, 57, 73, 256, 415venting 87, 105, 126, 147, 170, 232, 245,

263, 308, 665venting bore hole 150venting channel system 151venting groove 38venting slot 150vent slot 104venturi nozzle 183vertically adapted melt deflectors 368vestige quality 354vibration welding 220vinyl ester 69viscosity 242, 375, 632, 647visualization 475Viton seals 362voids 85, 205volatile products 650volume mesh 325volume model 324volumetric filling 3, 5, 638vulcanization 241vulcanized fiber 530, 532

Wwall thickness 8, 169warp 53warpage 7, 40, 203, 293, 328, 382, 457, 586warpage behavior 323warp-free mold plates 443warping 83washing process 588waste-free shaping 138water-assisted injection 667water injection 361water-soluble core material 236water-soluble material 236wave propagation theory 326wax 291wax models 167wax plates 216WC/C layer systems 657WC/Co 656wear 58, 360, 545, 665wear low state/high state characteristic 654wear mechanisms 643wear on mold surfaces 642wear resistance 188, 277, 410, 449, 504, 658wear supply 663

701 Subject Index

webbing 150web browser 627wedge angle 13wedges 204wedge-shaped parting plane 111wedge wire screens 199weight-cost ratio 614weight savings 446weldability 429welding 219, 454, 467weld line 22, 119, 327, 361, 381, 398, 409,

569, 637, 649weld line notches 413wetting 210wet-winding process 238white light interferometer 572WIG 467

winding technology 238wire-cut EDM 491wire EDM 454wood 141, 148, 202, 291, 511, 532working stroke 526wrinkling 215wrought alloys 443wüstite 645

XX-ray lithography 275

Zzamac 571zero-defect production 633zinc 77, 571zinc alloy 70, 120, 121