DZynSource Mold Engineering SOftware

1. Mold Engineering Software
Desktop Engineering Tools for Mold
Designers, Engineers, Moldmakers,
Processors, etc.

2.  Build better molds the first time
 Optimize mold cooling
 Plan for thermal expansion and contraction
 Specify chillers, cylinders, valves, and pumps
 Size mold plates appropriately
 Specify correct components and fasteners
 Troubleshoot molds and molding processes
 Over-design is expensive
 Under-design can be disastrous

4. These calculations
are commonly
used when
working with
heaters and hot
runner systems.
Calculate the
wattage of a spare
heater by entering
the measured
resistance in ohms,
and using the
known voltage in
the bottom
calculation.

5. Molds are heat exchangers, and
the medium is usually water. You
can calculate your pressure losses,
Reynolds Number and flow rates
to ensure turbulent flow for water,
laminar flow for hydraulics.
Hydraulic and pneumatic cylinder
calculations, for force flow rate
S.C.F.M. are done in seconds. This
makes it easier to size cylinders,
valves and pumps.

6. Don’t spend your time
doing repetitive
calculations. We do
these all of the time, so
why not automate
routine tasks?
The feeder line size
calculator works for
water manifolds too.
Enter the size line that
you need to feed, and
enter the number of
waterlines, and
instantly get the
required size for the
main feeding waterline.

7. The equivalent diameter of an The equivalent diameter of an annular
irregular shaped passage is not channel is much smaller than most
the same as a diameter of people think it is. Drilled holes in cores
equal area. It is much smaller are traditionally undersized in the
due to the increased periphery. moldmaking community.

8. You can calculate
the forward force,
the return force,
and number of
gallons per
minute of
hydraulic fluid
needed, all while
talking to your
customer on the
phone.

9. Calculate the correct piston bore
size for your application.
Calculate the forward force
Calculate the return force
Calculate the SCFM of air
required for operation.
Get the answers as fast as you
can type.

10. You can
calculate the
pressure losses
in your mold, or
hoses.
You can also
calculate the fact
that there is very
little pressure
lost through
small fittings, in
many cases.

11. Make sure that your cooling is maximized by achieving a flow rate that indicates a Reynolds
Number over 4000.
Make sure that your hydraulic lines don’t exceed a Reynolds Number of 2000.
See how anti-freeze hampers your mold cooling by increasing the coolant viscosity!
You can sometimes
increase cooling, in
marginal situations,
by warming the
water temperature.
When the Reynolds
Number is near
4000, and you can’t
increase the flow
rate, increasing the
water temperature
can sometimes
change the flow
from transitional to
turbulent due to
the decreased
viscosity.

12. Here’s a list of
questions that
you can use as a
checklist when
checking hot
runner
drawings. The
list is based on
experience .
The checklist is
in a limited
word processor,
so you can add
your own items
to the list.

13. DZynSource Mold Engineering
Software is not just for
designers. There is a section for
people involved in machining as
well.

14. When cutting with a ball
end mill, there will always
be ridges and valleys left
from the radius on the
bottom of the cutter. The
height of these ridges
increases with the amount
that you “step over” your
cutter.
Calculate the expected
roughness before you cut.

15. Calculate the amount
of chip load per tooth,
or the feed rate for
machining. Enter
your known data to
get your required
information.

16. When cutting with a
ball end mild, or a flat
bottom end mill with a
corner radius, the
effective cutter
diameter is
determined by the
diameter of the cutter
at the point on the
cutter radius where
the full depth of cut
intersects that radius.

19. You can open
up to 4
material
properties
windows to
compare the
properties of
36 different
mold making
metals.

20. Quickly estimate
the weight of
either steel or
aluminum
rectangular plates
and blocks.

21. DZynSource Mold
Engineering Software is
not just for designers and
toolmakers. The cooling
and molding calculations
make this software a
valuable tool for molders,
molding managers, and
production planners too.

22. Quickly calculates:
the pounds of material
to be processed per hour
The BTU’s per hour to
be removed
The gallons per minute
of water required to
remove the heat
And the chiller capacity,
in tons.

25. Calculates the
required
colorant in
terms of let-
down ratio, or
percentage.
Choose
pounds or
kilograms.

26. This allows you to calculate the pause time for the molding machine to wait for
the molded part to fall from the highest cavity to the bottom of the mold.

27. When you don’t
need the heat
content, water
requirements, or
chiller capacity,
you can just
calculate the
amount of
material to be
processed per
hour.

28. Calculate steel
sizes, knowing
plastic size and
shrink rate, or
calculate plastic
size, knowing
steel size and
shrink rate.
Includes a table
of typical shrink
rates for some
common plastic
materials.

30. Calculate the Amount of Material to be Processed Per
Hour is found here, as well as in the molding calculations
section.

31. Calculate
your
production
capacity
quickly and
easily!

32. Sometimes you know
your production run
in hours, and want to
convert it to a larger
unit of time. Done
and done.

36. Calculate runner
sizes based on part
wall thickness.
Calculate the size of
a feeder runner
based on the size
and number of
branch runners it
will be feeding.

37. The strength of materials section is
sort of the heart of the DZynSource
Mold Engineering Software, and the
reason that I originally started
writing this code.
There are many options from this
selection set, and many more choices
within each section.

38. You can calculate
the bending, or
deflection, of
plates, cores, or
many other mold
components.
For slightly
tapered parts, use
the average
diameter of the
part.

45. The Moment of
Inertia and Section
Modulus are
automatically sent
to the proper text
boxes.

46. 2 different
loading
scenarios,
2 different
support
scenarios.
Good for
calculating the
distortion from
gating on a
core, or the
collapse of a
cap or closure,
among other
things.

47. The answers for this section appear in a separate dialog box.

50. I have seen ejector
pins buckle due to
injection pressure
when gating was
positioned directly
over the pin. This
long column test
will tell you if the
proportions of your
pin put it at risk of
buckling. Of course,
it is not restricted to
just ejector pins.

52. This feature will tell
you what the critical
load is to avoid long
column buckling for
your pin or post.
Here again, the modulus of elasticity can be chosen from a list, or entered
manually. The moment of inertia is transferred from the worksheet shown
earlier.

54. This calculation
becomes more
critical for face
mounted cavities.
Since there is no
plate to contain
cavity expansion,
you must ensure
that the wall
thickness of the
cavity is thick
enough so that the
expansion will be
less than the
expected shrinkage
of the wall stock of
your molded part.

56. When you press the
“Enter Modulus of
Elasticity”
command button,
you are presented
with a table of
materials to choose
from. The
appropriate
number will be
transferred to the
text box, when you
click on your
material. You can
always enter your
own data, if your
material isn’t listed.
The modulus of elasticity for steels is within 10% of
30,000,000 p.s.i. regardless of the steel or its hardness.

63. Moment of inertia,
section modulus, radius
of gyration, and area are
all used in the
calculations of strength of
materials.
Just enter your known
dimension for one of the
ten standard shapes to
get the values you need.
Most values are sent to
the appropriate text
boxes automatically.

64. Have you ever
seen a mold with
“A” side action
fail to keep the
slides fully closed
during injection?
You don’t have to
experience this
again if you size
the plate correctly
the first time.
Both through
pocket and blind
pocket options.

70. You can choose
to calculate the
expansion and
the final size.
You can also
calculate what to
make the initial
size in order for
a part to grow to
the correct size
after a change in
temperature.

72. You can calculate the
size for measuring
threads with the
“three wire
measurement”
technique.
You can calculate the
largest, smallest, and
best wire size to use
based on the threads
per inch, or the thread
pitch.

73. You can select N.P.T. threads,
or B.S.P.T threads. Once you
click on the thread size, you are
presented with the tap drill size
for that thread. You will get 2
answers, one for the drill size if
using a pipe reamer too, or a
larger size if no pipe reamer
will be used.

76. Using the image at the right to decide, choose the 3 options to
calculate the value that you need to know. You can calculate the
chord, the radius, or the height of the segment, if you know the
other two values.

77. Most calculators
include a decimal
degree to degree,
minute, second,
calculator.
We included one here
so that you have
another source for
when your calculator
batteries lose their
charge.

78. Choose any two
values that you
know, from the
list, and press
Calculate to get the
other 3 values.
The 90º corner is
constant.
You can enter your
angle in decimals
degrees or
degrees, minutes,
seconds.

79. Using a roll, dowel pin, or gage pin to measure angles is very common in mold
and tool making. There are two choices available to represent the orientation of
the angle. Just enter the angle, the height to the theoretical sharp corner, and the
pin or roll diameter, press calculate, and the height over the roll is calculated for
you. No more using charts and cheat sheets.

82. The tooling ball is often
used for measuring the
size of cone shaped holes.
You can calculate how
much the ball sits above
or below datum surface
S.
An answer with a minus
value indicates that the
ball is below the surface.
The tangent diameter is
given so you can tell if
the angle surface is large
enough for the ball to rest
tangent to the angle.

86. Of course, it’s still up to
you to put the vents in
the right spot. But this
calculator tells you the
minimum vent width
you need to prevent
burning” of the plastic
material.
It’s usually better to have
more vents, as long as
the structural integrity of
the core and cavity are
not compromised.

87. At $149, this software is extremely inexpensive.
At a $75 per hour shop rate, this software will pay for itself in 4
weeks, assuming 30 minutes per week of savings.
There will be times where each use will save you hours of time.
Some calculations are complicated, and can take an hour or more, if not done
regularly.
Instead of looking through notes and books for the appropriate formula or
equation, all of your engineering calculations are automated in one
convenient location.
Have you ever seen an “A” side action mold flash due to an under-designed
plate?
Imagine the money saved if you avoid just one engineering mistake!

88. “
"Finally, a one-source location for the plastics mold design engineer to find just about
everything from material properties to conversion tables to cooling requirement
calculations, the list just goes on. If you're involved in the design of plastic injection
molds, you need DZynSource on your Desktop. I highly recommend it."
--Dieter Meyer, Custom Micro-Cadd Systems
“Every mold making company should own a copy. Great idea, great
implementation.” Jim Philippe / Tooling Engineer CORNING LIFE SCIENCES
Very impressive and a must for anyone in the business from bench to processing”
Robert Pozzo, Sr. Design Engineer at Applied Medical; CSWP
I just purchased DZynSource tonight for use during estimation, design and analysis. I
have my own Excel workbook with many of the formulas I use for calculating similar
functions but I appreciate the way you have compiled them into an accessible package
with a friendly menu system. I am sure this will be a handy resource for years to come.
Derek Beattie, PolySurf Design Services

89. A while ago we switched from 32 bit to 64 bit computers.
When we did this our beam analysis software would no longer run.
So the main reason for buying your package was for the beam deflection
calculations.
We are finding more uses for it as we go along.
This leader pin calculation has me intrigued because we never could get a good
number for this.
So thanks!
Marty Ricciotti, Chief Engineer
Redoe Mold LTD
“ I am impressed with your software; talk about practical and useful! Anyone in the
business can sure appreciate what you have done.”
Brett Niggel, Designer, Studio One Eleven