Husky HRDC-DESIGN-GUIDELINES-060814 User Manual

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Design Guidelines

CAVITY DESIGN

To maximize the integrity and life of the gate area, various factors must be considered:
Recessed Gate Areas
When designing gates into recessed areas such as dimples, a generous radius should be incorporated to avoid extended thin sections of plate steel (see figure at right).
Nozzle Seal Off Diameter
To provide a durable nozzle seal diameter surface in the gate bubble, a surface hardness range between 49 - 53 Rc is recommended (see figure at right). If softer materials are used (e.g. BeCu), these should be hard chrome plated to increase hardness.
Gate Steel
Hardened tool steels such as 49 - 51 Rc AISI H13/DIN 1.2344 provide a good combination of strength and ductility.
Nozzle Seal Off Diameter
Thin Section
It is not recommended to EDM (electro-discharge machine) the gate area. A hardened surface layer resulting from the EDM procedure makes the steel increasingly brittle, potentially leading to premature gate failure . It is also g ood pr actice to machine the gate hole after hardening to avoid brittleness, caused by rapid quenching.
Gate Cooling
Gate area cooling is required to remove excess heat generate d by the system. Sufficient cooling provides many benefits including:
Consistent gate quality
Consistent gate vestige
Greater control over material stringing
Greater control over resin drool
Greater control of gate blushing
Faster cycles
Gate Cooling
2006.08
Please confirm all dimensions and nozzle/gating suitability with Husky prior to machining.
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Optimized Gate Cooling (Key Elements)
1) Minimize the distance from the cooling channel to the gate detail The maximum recommended distance between the cooling channel and the gate detail is 3 times the cooling channel diameter.
2) Cooling should surround the insert. The cooling water should reach flow speeds that cause effective mixing of the fluid. For most inserts, a flow rate of about 6.8 - 8.3 liters (1.8 - 2.2 gallons) per minute is sufficient.
Design Guidelines
3) The gate insert material affects heat dissip ation and longevity. Insert materials such as H13 (material of choice) and 420 SS are 7x less heat conductive than BeCu Alloys. The trade-off with conductivity is hardness and gate life. Material choice will depend upon the number of projected cycles and the cycle time goals,
Independent Circuits
The cavity plate cooling circuit should be independent of the manifold plate cooling circuit. This prevents coolant from leaking onto the hot runner components whenever the plates are separated.
2-3X
X
min 1-1.5X
Please confirm all dimensions and nozzle/gating suitability with Husky prior to machining.
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Design Guidelines
Gate Inserts
Gate inserts provide an effective method of cooling the gate area, since the entire circumference is cooled. Cooling circuits for the gate insert should be independent from the plate cooling circuit to provide better control. The gate insert is a replaceable wear item.
Gate Insert
Gate Cooling
2006.08
Please confirm all dimensions and nozzle/gating suitability with Husky prior to machining.
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Cavity Plate Interface Bolts
Cavity plate interface bolts are used to fasten the cavity plate to the hot runner.
The interface bolts should be installed from the clamp (moving) side of the cavity plate, to enable separation of the cavity plate while the mold is still secured within the machine press.
Latching
Nozzle tips, nozzle thermocouples, nozzle heaters, and nozzles are replaceable while the hot runner remains in the press, minimizing downtime when performing main te na nc e.
Cavity Plate
Interface Bolts
Design Guidelines
Hot Half
Cavity Plate
Latch
Please confirm all dimensions and nozzle/gating suitability with Husky prior to machining.
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Page 5
Design Guidelines

MACHINE INTERFACE

Machine Nozzle Requirements
To prevent pressure loss, dead spots, and to provide a leak-free seal, the mating surfaces and orifice diameters of the machine nozzle and sprue bushing must match. To optimize hot runner performance, the sprue bushing orifice should be the same diameter as the primary sprue bushing flow channel.
Shut Off Nozzle
Resin decompression within the hot runner melt channels is re qu ire d for each molding cycle. Resin decompression is essential for controlling gate vestige and minimizing material stringing. Husky recommends that a shut-off nozzle be incorporated onto the machine injection unit. The shut off nozzle:
Allows screw recovery after decompression without re-pressurizing the melt within the hot runner system.
Enables screw recovery during mold open, which may lead to reduced cycle times.
Melt Filters
Melt filters are used to screen out any contaminants that may be present within the melt. However, melt filters increase pressure loss, and can prevent material decompression. Melt filters ar e not recommend ed when mold ing small p art s, since decompression is essential for producing consistent small gate vestige.
Restricted Size
Optimal Size (preferred)
Sprue Bushing
2006.08
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Design Guidelines

HOT RUNNER PLATE DESIGN GUIDELINES

Stainless steel is the preferred material for plate manufacture. Suitable steel types are listed below:
Type Hardness (Rc)
AISI 4140 30 - 35 Rc
AISI P20 30 - 35 Rc AISI 420 30 - 35 Rc
DIN 1.2316 30 - 35 Rc
Manifold Pocket / Pillar Support
Husky recommends that a pocket be machined into the manifold plate for the manifold. The manifold pocket:
Allows close positioning of the plate bolts to the nozzle components, minimizing plate deflection.
Provides superior structural support for the mold and cavities.
An air gap should be maintained between the manifold and manifold pocket to thermally insulate the manifold from the surrounding plates.
The structural rigidity of the design is increased with the incorporation of pillar supports. Pillar supports:
Resist manifold plate deflection, by absorbing machine clamping pressure.
Pillars allow additional fastening of the manifold plate to the backing plate within the manifold pocket.
Manifold
Manifold Pocket
Plate Bolt (see chart following page)
Manifold Plate
Please confirm all dimensions and nozzle/gating suitability with Husky prior to machining.
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Design Guidelines
Plate Bolting
To maintain constant sea l-o ff and minimize plate deflection, bolts should be position ed ar ound e ach n ozzle dr op and a l ong the outside plate perimeter.
Recommended Quantity Per Drop
Bolt Size
M8 (5/16 UNC) 1.0 (All Pitch) 1.0 (All Pitch) N/A N/A N/A M10 (3/8 UNC)
M12 (1/2 UNC) M16 (5/8 UNC) N/A N/A 3 (All Pitch) 3 (All Pitch) 3 (All Pitch)
M20 (3/4 UNC) N/A N/A 3 (All Pitch) 3 (All Pitch) 3 (All Pitch)
The quantity and size of bolts assigned to each drop location is depend ent upon the nozzle series an d the number of drop s (see table above). For systems greater than 12 drops, it is acceptable for drop locations to share drop bolts.
Ultra 250 Ultra 500 Ultra 750 Ultra 1000 1250 Series
0.75 (Small Pitch)
1.0 (Large Pitch)
0.5 (Small Pitch)
0.75 (Large Pitch)
0.75 (Small Pitch)
1.0 (Large Pitch)
0.5 (Small Pitch)
0.75 (Large Pitch)
N/A N/A N/A
3 (All Pitch) 3 (All Pitch) 3 (All Pitch)
2006.08
Please confirm all dimensions and nozzle/gating suitability with Husky prior to machining.
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Page 8
Design Guidelines

PLATE COOLING

Plate cooling circuits maintain a uniform mold plate temperature and match thermal expansion of the mold plates. To design a uniformly cooled mold, consideration must be given to the cooling circuit layout, number of channels, lengths,
and diameters. Typical cooling circuit layouts for 2, 4, 6, and 8 drop systems are provided below.
2 Drop 4 Drop 6 Drop 8 Drop
The cooling circuit should be routed around areas of high heat transfer, while maintaining a minimum material thickness of 5,0 mm (0.20") between the cooling line and other features.
Thermal Gate Valve Gate
5,0 (0.20")
5,0 (0.20")
Backing Plate Cooling
Manifold Plate Cooling
5,0 (0.20")
3,0 (0.12")
NOTE:
5,0 (0.20")
5,0 (0.20")
Avoid routing water lines in a manner that would result in uneven cooling of the nozzles and cavities.
Please confirm all dimensions and nozzle/gating suitability with Husky prior to machining.
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Design Guidelines

WIRE GROOVES

Power and thermocouple wires are typically routed to the electrical connectors within wire grooves. Wire grooves:
Protect the machine operator from live wires.
Provide orderly routing of hot runner wires.
Prevent potential wire damage.
Wire Grooves
2006.08
Please confirm all dimensions and nozzle/gating suitability with Husky prior to machining.
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SERVICE CONNECTIONS

A hot runner requires a number of service connections such as electrical for heaters, water for plate cooling and air for valve gate operation. Locations for these connections are flexible, however based on experience the schematic indicates recommended pos itions.
AIR
WATER
Design Guidelines
ELECTRICAL
AIR
TOP
OPERATOR

CAVITY NUMBERING

Clear nozzle identification is necessary to ensure the hot runner properly interfaces with the mold, and that the nozzles are mapped correctly. The sequence illustrated to the right is recommended for simplicity.
AIR
WATER
Please confirm all dimensions and nozzle/gating suitability with Husky prior to machining.
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Design Guidelines

VALVE GATING DESIGN CONSIDERATIONS

To ensure optimum gate quality, valve stems must respond q uickly to the ope n/clo se signa ls. To avoid sluggish valve stem movement, the following should be considered prior to installation:
Air supply should be clean and dry at a pressure between 550-830 kPa (80-120 psi). For thin wa ll parts and engineering re sins the pressure should be between 100-120 psi.
A four way solenoid valve is required to activate valve stems.
Quick exhaust valves should be installed on both air lines to increase the speed at which the stems open and close.
Quick air disconnects are not recommended since these can cause flow restrictions.
Air plumbed direct from compressor.
Minimize length of air lines.
Use a Husky Air Kit for optimal performance.
Quick Exhaust Valve
Solenoid
Gate Close
Line A
Line B
Exhaust B
Exhaust A
Solenoid (Machine indicates when to actuate)
Gate Close
Gate Open
Quick Exhaust Valve
Solenoid
Gate Open
Line A
Line B
Exhaust B
Exhaust A
Solenoid (Machine indicates when to actuate)
Gate Close
Gate Open
2006.08
Please confirm all dimensions and nozzle/gating suitability with Husky prior to machining.
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Design Guidelines

CONTROLLER INTERFACE

Voltage Supply
To determine the correct manifold heater wattage, the available voltage supply must be specified. This practice is necessary since a significant wattage reduction can occur if the lower voltage is not compensated for. For a given heater
the power output at 208V is only 75% of that at 240V.
Voltage Supply Wattage
240 V 2,880 W 208 V 2,160 W
Amperage Limitations
The amperage limit for each zone of the temperature controller needs to be identified. This ensures that the manifold heaters will not exceed the amperage limit.
Electrical Connectors
Electrical connectors are supplied with complete hot runner systems (optional for manifold systems). Refer to Electrical Connectors in the Accessories Section for installation information.
Connectors are available with either side or end clamps, and top or side entry, depending upon customer preference.
Side Clamp
End Clamp
Please confirm all dimensions and nozzle/gating suitability with Husky prior to machining.
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Design Guidelines
Husky Standard Electrica l Connector Requirements
Establishing an electrical wiring and connector standard will allow future interchangeability of hot runners and temperature controllers. The following Husky standards have been developed around typical controller capabilities for systems ranging from 2 to 16 drops. The departure from the standards may be required if space is not available or if the current requirements exceed the connectors limitations. 2-8 Drops For applications up to 8 drops, two 24 pin connectors are sufficient: one for power, and the other for thermocouples.
24 Pin
(Power)
Standard connector pin mapping for both power and thermocouples is listed below. Pins for both connectors are rated to 16A.
Sprue Heater 1 13 Manifold Zone #1 2 14 Manifold Zone #2 3 15
Tip #1 4 16
Tip #7 10 22 Tip #8 11 23 Spare 12 24
24 Pin
(Thermocouple)
Pin
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Design Guidelines
2-8 Drop HR System Alternative (DME Standard)
An alternative approach, is to employ one 25 pin connector for power and one 24 pin connector for thermocouples.
25 Pin
(Power)
Standard connector pin mapping for 24 pin connectors shown on previous page. Standard connector pin mapping for 25 pin connectors.This connector is used for power. Pins are rated to 10A.
Sprue Heater A1 Manifold Zone #1 A3 Manifold Zone #2 A5
Tip #1 A7
Tip #7 C5 Tip #8 C7
Spare A9
24 Pin
(Thermocouple)
Pin
Please confirm all dimensions and nozzle/gating suitability with Husky prior to machining.
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Design Guidelines
12-16 Drop HR System
Applications between 12 to 16 drops use the following connector types. Figure 1-4: 12-16 Drop System Connector Configuration
6 Pin
(Power)
Standard connector pin mapping for 6 pin connectors. Pins for zone control are rated to 30A.
Standard connector pin mapping for 16 pin connectors. This connector is used for controlling manifold thermocouples. Pins are rated to 16A.
16 Pin
(Thermocouple)
Sprue Heater 1 2 Manifold Zone #1 3 4 Manifold Zone #2 5 6
Sprue Heater 1 9 Manifold Zone #1 2 10 Manifold Zone #2 3 11 Manifold Zone #3 4 12 Manifold Zone #4 5 13 Manifold Zone #5 6 14
Spare 7 15 Spare 8 16
32 Pin
(Power)
Pin
32 Pin
(Thermocouple)
Pin
Standard connector pin mapping for 32 pin connectors. This connector is used for nozzle power and thermocouples. Eachconnector can accommodate 16 nozzle zones. Pins are rated to 16A.
Pin Tip #1 1 9 Tip #2 2 10
Tip #7 7 15 Tip #8 8 16 Tip #9 17 25
Tip #10 18 26
Tip #15 23 31 Tip #16 24 32
2006.08
Please confirm all dimensions and nozzle/gating suitability with Husky prior to machining.
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Design Guidelines

STACK HOT RUNNER

HUSKY offers 2 level and 4 level stack hot runners in Ultra 250, Ultra 500, Ultra 750, Ultra 1000 and 1250 series nozzles. A 2 level stack mold will nearly double the output per machine of a single face mold; using a 4 level stack mold, productivity gains increase to nearly four times. Husky’s experience gained in building over 1500 stack hot runners assures that all aspects of integrating the hot runner into the mold will be taken into account during design.
Mold Shut Height
Moving - Side Cavity Plate
Mold Opening Stroke
Example of standard 2 level stack system
Machine Tie Bars
Center Section
Stationary-Side Cavity Plate
Sprue Bar Length
2 level stack hot runners come in four configura tions: sta ndard, of fset sprue b ar, stack platen and family mold. 4 level st ack hot runners come in standard configurations only.
Standard 2 level Stand ard 2 level st ack hot runners are used wh en molding the same p art on both the stationary and moving side of the mold and when the cavity layout allows the sprue bar to pass through the center of the stationary core and cavity plates.
Offset sprue bar 2 level Offset sprue bar 2 level stack hot runners are used when the cavities are laid out such that the sprue bar can not pass through the center of the stationary core and cavity plates.
Family mold 2 level Family mold 2 level stack hot runners are used to mold d i fferent parts on the moving and stationary sides of the mold. These hot runner s are available with either a center sprue bar or an offset sprue bar.
Stack platens Stack platens are used to run two new or existing single face molds in one machine without making any significant modifications to the molds. The molds are mounted back to back on a moving, center platen. St ack platens become a p art of the machine rather than the mold.
Please confirm all dimensions and nozzle/gating suitability with Husky prior to machining.
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Design Guidelines

MACHINE REQUIREMENTS FOR STACK MOLD OPERATION

In order to successfully run a stack mold; a molding machine must meet several criteria:
Injection unit
The injection unit must be able to provide double the shot weight, plasticizing ability, and injection rate than would be required for a comparable single face mold.
Sprue Break Capability
The machine must feature sprue break capability. The injection unit of the machine must retract from the sprue bar to provide clearance to prevent collision and possible damage between the injection nozzle and sprue bar when the mold closes.
Shut-off Nozzle
Upon sprue bar disengagement from the machine injection nozzle, a shut-off nozzle on the injection unit is necessary to prevent resin drooling.
Shut Height Requirements
Sta ck mold applications require approximately doubl e the mold shut height and clamp stroke requirements re lative to single face applications.
Center Section Support
The machine tie bars must provide accurate alignment of the hot runner during mold open and close. The machine specifications must be reviewed to ensure that the tie bars provide sufficient support and accurate repetitive alignment.
Clamp
The clamp will require approximately 10t greater tonnage. This increased tonnage is necessary to oppose the force exerted by the machine nozzle on the movable platen which is usually opposed by the stationary platen.
2006.08
Please confirm all dimensions and nozzle/gating suitability with Husky prior to machining.
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THERMAL GATE CONSIDERATION

Ultra 250, Ultra 500, Ultra 750, Ultra 1000 and 1250 Series For all thermal gating methods, the nozzles can be positioned back to back.
Design Guidelines
Clamp Side
Leak Proof UltraSeal Technology
Injection Side
Back-to­Back Nozzles
Sprue Bar
Anti-Drool Bushing
*Ultra 750 HT stack shown
Please confirm all dimensions and nozzle/gating suitability with Husky prior to machining.
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Sprue Bar Heat Shield
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Design Guidelines

VALVE GATE CONSIDERATION

Ultra 500, Ultra 750, Ultra 1000 and 1250 Series In order to accommodate customer requirements Ultra VG nozzles can be positioned offset or back to back. These designs provide ease of assembly and service access to the cylinders provided via air plates.
Leak Proof UltraSeal Technology
Nozzles Offset to Accommodate Customer Features
*Ultra 1000 Offset Valve Gate Stack System
Removable Air Plate for Ease of Maintenance
Sprue Bar
Anti-Drool Bushing
2006.08
Please confirm all dimensions and nozzle/gating suitability with Husky prior to machining.
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Design Guidelines

SPRUE BAR

The purpose of the sprue bar is to transfer the molten resin from the machine injection unit to the center section. When the mold is in the closed position, the machine nozzle seats against the sprue bar. When the mold opens the sprue bar moves with the center section and disengages from the machine nozzle.
Husky calculates the correct sprue bar length based on the mold shut height and the required mold opening stroke. This ensures that the end of the sprue bar remains guided in th e stationary platen when the mold is in the open position and that it will not contact the machine nozzle prematurely on mold close.
The sprue bar is aligned to the machine n ozzle by the sprue ba r guide, wh ich is inst alled behind the locating ring, or on the cavity plate. To prevent damage during operation, the sprue bar must not pull out of the sprue bar guide during the mold opening stroke.
Sprue Bar Guide

ANTI-DROOL BUSHING

The function of the anti-drool bushing is to minimize the amount of resin that drools out of the sprue bar when it is not in contact with the machine nozzle. As the sprue bar moves with the center section during mold open, the residual melt pressure in the manifold forces the anti-drool bushing backward
Residual Pressure
Please confirm all dimensions and nozzle/gating suitability with Husky prior to machining.
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Design Guidelines

OFFSET SPRUE BAR

When the sprue bar can not be positioned at the mold centerline, an offset sprue bar can be used. Using an offset sprue bar requires additional mold shut height to accommodate the transfer ma nifold att ached to the st ationar y platen. The sprue bar can be positioned at any side of the mold.
Transfer Manifold
2006.08
Offset Sprue Bar
Please confirm all dimensions and nozzle/gating suitability with Husky prior to machining.
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Sprue Nozzle
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Design Guidelines

CENTER SECTION SUPPORT TYPES

The center section of a stack mold is supported by the tie bars of the injection molding machine using one of three methods.
Horizontal Support
Vertical Support
Machine Mounted Carrier
For all three methods, it is essential that the machine be level to avoid unnecessary wear on the mold and machine components caused by misalignment.
Horizontal Support
The horizontal support a ppro ach uses an H-shap ed sle d that rid es on the lower machine tie bars to suppor t the hot run ner. The upper machine tie bars are used to guide the sled during normal operation. The wide stance of the horizontal support enables the weight of the hot runner to be evenly distributed along a wide section of the machine tie bars. A horizontal support is used when the mold is wider than the machine tie bar spacing. For safety reasons the mold must be at least as wide as the center to center tie bar spacing. The mold must also have a minimum of 70,0mm (2.76") and a maximum of 120,0mm (4.72") clearance over the lower tie bars and a min imum of 30,0mm (1.18") cleara nce beneath the upper tie bar s. Two options exist for controlling hot runner movement:
Rack and Pinion Gear Mechanism
Harmonic Linkage Mechanism (available only with Husky machines)
>210,0 (8.27")
>30,0 (1.18") Clearance
>70,0 (2.76") Clearance <120,0 (4.72") Clearance
Vertical Support
Mold Edges Must Be Wider Than Tie Bars Inside Spacing
Please confirm all dimensions and nozzle/gating suitability with Husky prior to machining.
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Design Guidelines
The vertical support uses an hourglass shaped outrider that is fastened to the operator and non-operator sides of the center section. The weight of the hot runner is evenly distributed over a wide area of the lower machine tie bars by half shoes. The mold must be between 10,0mm (0.39") and 85,0mm (3.35") narrower than the horizontal tie bar spacing. The upper tie bars provide guidance and stability to the center section during operation. A rack and pinion gear mechanism provides center section movement.
Drop Limiters
Mold Support
Tie Bar Spacing >420,0 (16.54") <920,0 (36.22")
Mold to Tie Bar S pacing <10,0 (0.39") >85,0 (3.35")
2006.08
Please confirm all dimensions and nozzle/gating suitability with Husky prior to machining.
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Design Guidelines

CONTROLLED CENTER SECTION MOVEMENT

Controlled movement of the center section is critical to ensure that as the mold opens, the hot runner always remains centered between the clamp and injection sides of the mold. The recommended methods of controlling center section movement include:
Rack and Pinion Mechanism (Single and Multiple Gea r)
Harmonic Linkage Mechanism (available only with Husky machines)
The method employed for a given application is customer specified. Each method is examined in greater detail in the sections that follow.
Rack and Pinion Mechanism
With the rack and pinion single gear mechanism, two racks are employed per mold side. The top rack is fastened to the clamp side while the bottom rack is fastened to the injection side.
Design Considerations:
Machine stroke must be 25,0 mm (0.98") less than the mold shut height to ensure that rack e nga gement is main tained.
Rack Mounting to Mold
230,0mm (9.06") Keep the Surface of this Area Clear of all Mold Components to Avoid Interference with Racks
Please confirm all dimensions and nozzle/gating suitability with Husky prior to machining.
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Design Guidelines
Harmonic Linkage
The Harmonic Linkage mechanism is only available for use in a Husky machine. With the harmonic linkage mechanism, a propeller and harmonic arm mechanism is fastened to the center section. The harmonic linkage mechanism is used for molds that have a short ejection stroke and a machine stroke less than 305mm (12.01").
Keep Sides of Mold Clear of all Components to Avoid Interference with Harmonic Linkage Movement
Harmonic Arms
Propeller
2006.08
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Design Guidelines

CUSTOMER DRAWING REQUIREMENTS (HOT RUNNER SYSTEMS)

Before Husky can begin engineering, the hot runner interfacing features indicated in the figure below must be defined by the customer when submitting the Mold Layout drawings along with the Design Information Form.
Contact Husky if you have any questions when completing the Mold Layout Sheets or the Design Information Form.
Customer Specified L-
Dimension
Distance from Clamp
Face of Manifold Plate
to Mold Surface
Customer Mold
Interface Taps
(Specify Thread,
Guide Pin Protrusion
Measured from
Clamp Face of
Depth, Quantity)
Manifold Plate
Customer Features
Critical Dimensions Needed:
Latch Tap
ie. Depth, Width, Length,
Diameter
Maximum
Hot Runner
Thickness
OPERATOR
SIDE
Machine Type
Tiebar Diameter
Customer Features
Latch Tap
Guide Pin X & Y Location
Type & Diameter
TOP
Horizontal
Tiebar Spacing
Customer Specified Electrical
Connector Type
Customer Mold Interface
Clamp Slot X & Y Location
Tap X & Y Location
(Width, Length, Depth)
Customer Mold
Drop Number
X & Y Location
X & Y Location
Customer
Specified
Water Fittings
Type & Location
Plate
Width
Length Plate
Spacing Vertical Tie Bar
Please confirm all dimensions and nozzle/gating suitability with Husky prior to machining.
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Design Guidelines

CUSTOMER DRAWING REQUIREMENTS (MANIFOLD SYSTEMS)

Before Husky can begin engineering, the customer features indicated in the figure below must be defined by the customer when submitting the Mold Layout drawings along with the Design Information Form.
Contact Husky if you have any questions when completing the Mold Layout Sheets or the Design Information Form.
Customer Specified
L-Dimension
Distance from Clamp
Face of Manifold
Plate to Mold
Surface
OPERATOR
SIDE
Customer Mold
Drop Number
X & Y Location
Plate
TOP
Customer Specified Electrical
Connector Type
Length Plate
Width
2006.08
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