- 1 What is Pipe Fitting Mold?
- 2 Materials Used for Pipe Fitting Mold
- 3 Pipe Fitting Mold Process Cycle
- 4 Equipment Used for Pipe Fitting Mold
- 5 Usage of Pipe Fitting Mold
- 6 Advantages of Pipe Fitting Mold
- 7 Disadvantages of Pipe Fitting Mold
What is Pipe Fitting Mold?
Pipe fitting mold refers to as the production of numerous pipes by a process known as injection mold. These pipes are used in housings such drainage of water etc.
The injection mold is the top-most process for the manufacture of high-quality pipe fitting molds. Innumerable designs of pipe fitting molds can be made from the injection molding process.
The materials used for the manufacture of pipe fitting mold consist primarily of plastics. Pipe fitting molds can be turned into a variety of shapes and sizes depending upon the needs.
Materials Used for Pipe Fitting Mold
The materials used for the pipe fitting mold consist primarily of plastics. There is a wide range of plastics used for the manufacture of finely finished pipe fittings through injection molding.
The following is the summary of the benefits of a few plastics that are being used in the pipe fitting mold.
Polyvinyl chloride is the type of plastic which is considered to be the most lightweight plastic and won’t be difficult to handle manually.
Moreover, it has several other exotic features because of which it is preferred over other materials. The primary feature of polyvinyl chloride is that it is highly abrasion resilient.
Polyvinyl chloride can be drawn into various shapes and sizes by cutting, welding, and joining. Therefore, it is a primary plastic used in the pipe fitting mold.
Because of its affordable and reasonable prices, polypropylene is being used in the injection mold for the manufacture of pipe fittings. Moreover, polypropylene is considered to have great bend power due to its semi-crystalline property.
Polyethylene has a number of striking features because of which it is in such a high demand for pipe fitting molds.
The primary and the most essential feature of polyethylene is that it is a high-density thermoplastic with crack resilient properties.
Moreover, this plastic can be heated and transformed into several other shapes without degrading the quality of the product. This thermoplastic is highly flexible and long-lasting.
This copolymer is primarily used for giving an opulent appearance to the pipe fittings.
POM is a high thermal and corrosion resistive polymer with a number of additional features such as high impact strength and heat stability.
POM is also a highly solvent resilient polymer, therefore, finds its application in the pipe fitting mold.
From being lightweight to being affordable, polybutylene has a number of essential features because of which it is one of the main plastics used in the pipe fitting mold.
Moreover, polybutylene can be drawn into various shapes and is much more convenient to install in the homes as compared to others.
ABS is a collective version of three exotic polymers namely; acrylonitrile, polybutadiene, and styrene. All of these polymers are combined to give strength, arduousness, and toughness. Moreover, ABS is a highly thermal resilient plastic.
All of the above-mentioned plastic and some other colored compounds are used in the injection molding for the manufacture of pipe fitting mold. All of these plastics give the required quality and rigidity to the pipe fittings.
Pipe Fitting Mold Process Cycle
There are five major steps of pipe fitting mold through which top-quality pipe fittings are manufactured. A summary of all the five major stages is given below.
The first step of the pipe fitting mold consists of the clamping of the two units together. A considerable amount of force must be supplied to the two units to keep them attached together.
The force is driven by the hydraulic unit. Afterward, the material is injected into the clamping unit. Enough force must be supplied in order to hold both the clamping units, as well as the material together.
Once the two units are perfectly clamped together, the injection of the material takes place. However, before entering the injection unit, the material is melted under specific temperature and pressure.
After melting the material, it is shot into the injection unit to give it its specific shape and size. In case of pipe fitting mold, the plastics are first melted up to a certain limit and then enter the injection unit.
Once the molten material enters into the mold cavity of the injection unit, it is subjected to the cooling process. It is highly recommended to keep the mold cavity shut until the end of the cooling time.
This will ensure a highly rigid surface of the pipe fittings which are undoubtedly essential. However, when the molten material gets cooled down, it slightly shrinks.
Therefore, a continual addition of extra molten material should be done in order to make up for the loss of the volume due to shrinkage.
When the molten material is perfectly cooled, then the time of ejection of the material comes. The material can be ejected out of the container by the use of force or some spray can also be used.
This is because when the material is getting cold down, some of the material not only sticks to the wall of the containers but also some of it also flows down to various channels and streams of the mold cavity.
Thus, a sufficient amount of force must be supplied in order to eject the material without damaging it.
As mentioned earlier, the molten material gets into the cavity of the mold and cools down, making several unnecessary edges.
These unwanted edges and boundaries are trimmed off by using a trimming press into a desired shape of the pipe fitting. This trimming doesn’t damage the quality of the product anyhow.
Equipment Used for Pipe Fitting Mold
The equipment for the pipe fitting mold includes two major parts.
- Clamping Unit
- Injection Unit
Both of these hold immense importance and are essential for the pipe fitting mold process.
Before starting the melting and injection process, the two mold halves are clamped together for the beginning of the pipe fitting mold.
One mold half is attached to a stationary, immovable surface while the other is attached to a movable platen.
Under specific temperature and pressure, the molten material enters the first half of the chamber which flows down to the second by the help of clamping bars.
The material then enters the injection unit where it is cooled to form the perfect pipe fittings.
In this unit, the melting and the injection of the material takes place for the pipe fitting mold.
The material is first entered into a giant container through a hopper. Afterward, the material enters a barrel where it is melted under specific temperature and pressure.
Once the material is heated to a fine degree it immediately injects into the mold cavity. Hydraulic pressure is supplied to do this melting and injection effectively.
Usage of Pipe Fitting Mold
A variety of pipe fitting molds are being manufactured such as the caps, reducers, elbows 90 degrees – 45 degrees, adapters, sockets, plugs, couplers, TEE, crosses, and much more.
All of these fittings are manufactured by injection mold as this process is capable of making high-degree pipe fitting molds. There are a number of daily uses of these fittings. Some of them are mentioned below.
- Storm sewer systems
- Sanitary sewer systems
- Roof Drains
- Drinking water supply
- Communication systems
- Exhaust systems
- Electrical systems
- And much more
These are the most important uses of the pipe fittings which are manufactured through injection molding for the high-degree performance of the pipe fittings.
Advantages of Pipe Fitting Mold
There are several benefits exhibited by the pipe fitting mold due to which a number of pipe fittings are being manufactured through this process.
Following are some of the significant benefits which clearly explain the demand for pipe fitting mold.
Great manufacturing speed
Injection molding for the pipe fittings is the finest method to produce pipe fittings at a faster rate as compared to other manufacturing methods.
Production at a larger rate does not mean that the quality of the pipe fittings is compromised or challenged instead the quality of the pipe fittings remains top-class and inimitable.
Therefore, the pipe fitting mold can be referred to as the fastest method for manufacturing a number of pipe fittings.
Able to form intricate profiles
You may have noticed that each pipe fitting is different in shape as compared to other fittings whether it’s a socket or an end cap, every shape holds its own specific importance.
Pipe fitting mold is the ultimate method for manufacturing intricate shapes and sizes of the pipe fittings.
Furthermore, the time taken for the manufacture of these complex and intricate fittings is not more than that taken for the simple profiles and silhouettes.
Therefore, the pipe fitting mold which is also known as the injection mold is in such a high demand for the manufacture of several pipe fittings.
Fewer labor expenditures
All the process of pipe fitting mold is handled by automatically operated machinery. Therefore, fewer workers are required for the correct handling of the machines and get the job done in right as all the work is efficiently done by the machines.
Hence, pipe fitting molding removes the hassle of large expenditures on the labor force for the manufacture of several pipe fittings.
Lesser labor expenditures ultimately lead to more expenditure on the materials being used in the pipe fitting molding which, in turn, enhances the quality of the fittings.
Exceptional configurational stability
Every plastic used in this pipe fitting molding process consists of a high impact strength and arduousness.
Moreover, every material has a great dimensional stability which is certainly transferred to the manufactured fitting. Pipe fittings are all about being rigid and dimensionally stable.
Therefore, this particular factor is instilled into the pipe fittings through the pipe fitting mold process.
Disadvantages of Pipe Fitting Mold
No doubt that the pipe fitting mold has a lot of advantages and beneficial features but there are certain limitations as well which should not be ignored. With every pro, comes a con. Similarly, the pipe fitting mold has some led backs too.
Great Initial Cost
Unarguably pipe fitting molding has a high production rate but this injection molding can prove much costly than one can imagine.
If someone wants to get a hold on a second-hand pipe fitting molding machine, the prices range from $5000 to $50,000.
However, the price of a newly built up injection molding machine is much higher as compared to a second-hand injection molding machine.
The price of the first-hand pipe fitting molding machine is as far as $400,000. Moreover, other machinery used in this machine can add up to this cost and the overall start-up cost of the molding process can be very expensive.
Furthermore, the design of the pipe fitting should be selected prior to the formation which can increase the time, as well as the production cost.
Constraint to thin-walled fittings
Pipe fitting mold restricts to the formation of thin-walled fittings because if thick-walled fittings are made with the injection molding machine, it may increase the time for cooling down of the molten material.
This will ultimately increase the cost of machinery being used for the pipe fitting mold process. Moreover, the quality of the thick-walled fittings may not be the same as that of the thin-walled.
There will not be a smooth and glossy finishing for the thick-walled fittings. Therefore, the pipe fitting molding process is limited to the thin-walled pipe fittings.
Moreover, this process also applies limitations to the designs of the pipe fittings.
Hiring fewer workers can be good for a lot of industrialists but this also invigorates unemployment. As mentioned earlier, all the process of pipe fitting mold is handled by the automatically controlled machinery and therefore, fewer workers are required to do the job.
Therefore, this not only unravels employment problems but also the skills of most are also being lost. In the past, the process was handled by manual power and they had the skills to do the work. Therefore, pipe fitting mold process loses the qualified and skillful workers.