Injection Mould: Tricky Gate Trimming, Seeking Ideas

[CHRSCLLNGS]

I suggest a two fluted end mill. When you have the part nested securely and consistently just simply plunge cut to remove the gate. If you have a machinist or toolmaker in your company they will know what I mean.

I would personally go along with Terry's solution. We used to manufacture a similar product, with a similar 'internal' sprue position. We used to 'spot face' with a pillar drill. As long as the part can be jigged so that there is no movement and good consistency and the pillar drill set with a stop, it can be brought down onto the remaining sprue to flush the inside face. A standard flat cutter, or as Terry stated, a double fluted end mill would be the way to go.

 

[DanteCaspian]

Hot runner: Customer owns the tool and is not interested in paying for the hot runner, despite the savings we could pass on in the long term.

We currently cut the gate and then mill it with a fluted mill on a fixture, that is the step #3 I outlined in the OP, I should have explained that in more detail.
That is the process I would like to eliminate, so that there is one action that cuts the gate flush quicker and with better ergonomics.

 

[JohnCTB]

Perhaps you could create your own tool. Start with an existing gate cutter or maybe get a long nose pliers that will fit in the socket. Then have someone modify it to do the job in one step. A long nose pliers could have 90 degree cutting edges welded on the tips. A gate cutter that has 90 degree cutting edges may have to be lengthened. Of course this would involve some trial and error to get it just right, but it may be worth it if this is a high volume production part.

John

 

[D Scott G]

Greetings;

The only possible solution that has not been posted is the use of an ultrasonic unit to remove or melt the gate vestage down to your specs.

What type of material is this molded out of?

If your volume is high enough you might be able to modify the mold with a heated sprue to get rid of the runner and show a return of investment with the reducion of manpower. I would have your company do it and keep the savings.

Can anyone say design review,

Scott

 

[Stijloor]

Greetings;

The only possible solution that has not been posted is the use of an ultrasonic unit to remove or melt the gate vestage down to your specs.

What type of material is this molded out of?

If your volume is high enough you might be able to modify the mold with a heated sprue to get rid of the runner and show a return of investment with the reducion of manpower. I would have your company do it and keep the savings.

Can anyone say design review,

Scott

Scott,

Process FMEA comes to mind as well.

Interesting thread!

Stijloor.