Developing air core to produce complicated geometries in injection molding

Owing to developing of plastic industry, the researches about plastics rose. In this study, an alternative solution for the production of reverse geometric and complex forms development was studied. The method used for these solutions on the world are very scarce. In this study, existing technologies have been investigated and obtained information was used to develop the new method, the air core. Conducted detailed research in Materials Science, Electronic Science, Mould Technology Science, patents and standards for target products and techniques available were examined. Obtain this information acquired in the design phase was used in air core and mold design process. The solid modeling in the design process, mechanical analysis and analysis of cooling was studied in detail in the thesis. It is provided that reducing the number of parts within the mold by air core method. Altough , a more healthy and rapid cooling of the mold has been found to allow. The compressed air ,sent from the air core to the gasket, reduced of molten plastic's temperature from 180 °C to 146 °C for 5 seconds. In addition to this, the particular water passage formed in the Air Core was observed to influence the product cooling time(Conformal Cooling). Thus, mold cooling cycle time is about 1/3 reduction was observed. CFD - Plastic injection molding process simulation program, Moldex 3D was used for detection of inside of mold. In this way, optimization possibilities are occurred of the process and product As a result of analysis of in-mold, plastic filling has been seen that in 1.27 sec. In the filling stage seems to be the maximum pressure of 64.5 MPa. At 35.2% of the filling process, the pressure level shown by the 5.34 MPa level. In the injection molding operation, these values are taken into account. After the trials with design and manufacturing process is completed mold, which is the target of an academic thesis, new method has been developed to create a reverse angle on the plates gasget channel form for injection molds. Next in the process of this study, different materials and different geometrical forms of the trials are recommended.