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The modern "retro" style requires decorating pieces of furniture, fittings, the interior of the apartment with a multitude of repetitive, intricate configuration details; often enthusiasts undertake to make them carved - from soft woods, bent from metal strips, minted on copper. But modern chemistry gives us such a great material for such work as plastic. It is enough to make a shape - and any detail can be repeated as many times as you like. A simple casting plant, which greatly simplified and accelerated the production of such "small things", was designed at SYUT-2 in the city of Taganrog.

Press. The first thing that was required for the injection molding plant we conceived was a press: after all, the parts were supposed to be received under pressure. The training press available to us, produced by the industry, was not suitable, since it did not create sufficient pressure during stamping. We decided to make our own.

The hydraulic jack produced by the Baranovichi plant was taken as a basis. This is a powerful and reliable mechanism: it develops a force of up to 12 tons, has a piston stroke of 150 mm and an auxiliary screw outlet of 80 mm.

The jack was installed on a steel base plate 20 mm thick and secured with two M12 bolts. At the corners of the plate, four holes were drilled for the racks and M16 threads were cut. Spacer tubes were put on the racks: the top plate lay on them, which was fixed with nuts and locknuts. The general view and layout of the press are clear from the figure and the diagram given here.

injection molding plant
Jack press

injection molding plant
Press layout: 1 - bottom plate (240x240x20 mm), 2 - jack, 3 - stand (pipe Ø 25 mm), 4 - coupler, Ø 16 mm, 5 - top plate (240x240x40 mi), 6 - jack lever

Melting "furnace". Its role is played by a home-made electric stove - in a thick plate with a lid, in a milled nest, a spiral from an electric iron with a power of 1000 W in porcelain insulation is laid. The plug for connecting the power cord was also taken from the iron. "Melting" on a box-shaped pallet with heat insulation from sheet asbestos is installed on the heel of the jack. On top of it is placed a block of parts that make up the actual casting part.

Foundry. It consists of a hollow cylinder with a bottom and a tightly fitted, ground-in piston with a syringe hole. Plastic is placed in the cylinder, from which, after preliminary heating on the tile, the piston can be easily removed. The contents of the cylinder after being introduced into the piston should warm up slowly, reaching the required temperature in 40-45 minutes. The control sign of readiness and the end of heating is the self-punching of the molten mass through the syringe hole in the piston head. Now you can install a mold for casting a part on it, making sure that the casting hole of the mold and the injection hole of the piston match.

Having finished the preparatory operations, proceed to the actual casting. To do this, with the jack lever, the entire block is gradually moved up, all the way to the plate. In this case, the piston begins to be pressed into the cylinder, the plastic passes under pressure into the syringe hole, then through the injection hole into the mold and fills it.

injection molding plant
injection molding plant

injection molding plant
Scheme of the injection molding unit assembly (click to enlarge): 1 - jack screw. 2 - heel of the jack, 3 - upper plate of the press, 4 - mold, 5 - piston, 6 - cylinder 7 - tile, 8 - pallet with asbestos gasket

injection molding plant
Scheme of a casting pair cylinder - piston

injection molding plant
Electric stove diagram: 1 - base plate, 2 - plug, 3, 4 - covers, 5 - spiral

So that the plastic does not stick to the mold, you need to grease the inner surface with a thick soapy solution and dry it.

Of course, this method of manufacturing parts requires additional costs for tooling and fixtures. However, they are more than paid off by the quality of the parts received and the ability to "release" them in series, which is sometimes important.

Those interested in the installation may have a question: why does it consist of separate parts, and not combined into a "monolith", one whole?

This is dictated by technological convenience and the advantages of a collapsible option. When stamping parts from various plastics, it is possible to have several interchangeable cylinders. The furnace can be used and repaired separately; jack - as a general-purpose press, and not just for casting.

Author: V.Dvoeglazov

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