Cowl Grille Mould

What makes it so important for mould design? It is the soul of mould manufacture that it provides not only the mould construction but also data support based on which product can be well molded by CAE simulation analysis. Normally we use UG Works for plastic injection mold design and as soon as the design finished it births BOM according to which we can procure mold components. The 2D and 3D designed CAD data will be imported to components machining and reference for mould assembly. Here we are going to introduce some basic points for a cowl grille mold design:

Taking a case of plated grille for example, it is unavoidable weld lines coming about due to the ABS material which is not that good in fluidity and many grids. Thus previously mold flow analysis is necessary to make weld lines locate at corners or other relatively invisible areas. Sufficient sequential valve gate hotrunner is required.

Tip 1: Comparison for different gating

Construction like in image bellow shows that lifers are at narrow areas, there should be gates set for different trim features, thus weld line will locate at non-appearance-area.

Tip2: Part ejection

As there are many grids for cowl grille products, normally ejector block or blade are applied to eject deep rib areas. If using ejector pins quite possibly there will be eject marks on the part surface.

Tip3 Part configuration

For non-plated part, clip housing connects to part B-surface with no pass-through space. On the contrary, plated grille clip housing should be designed open to avoid plating liquid effusion.

There are always problems for boss like air trap, polish difficulty and depth over-machining which lead to part burned, adhered to mold, hard to assemble and so on. Consequently for easy to modify the grille tooling, it is very necessary to add insert block or insert pin to boss areas.

Tip4 Grille mould tooling structure

As the radiator grille mold has the big length width rate, we need to guarantee the ejector plate toughness and return pin proper layout that making spacer block as 6 extra ejector plate to add return pin area and use 4 nitrogen springs for ejection.

Sometimes if the front cowl mold required very high quality appearance we have to use top-class mold steel for the core as insert to save cost. When core length is over 300mm, wedge has to be applied; to prevent mold frame crack we have to make the frame bottom R corners bigger.

For other aspects about cowl grille mould design we may not discuss here or if interested you are welcome to discuss with our designers.

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