1. SELECT SERIES SIZE. Determine injection force on the core, pull force requirements, and any other design limiting issues. (Contact PFA for an initial “quick” review).

2. SELECT STROKE and EXTENDED (SET) POSITION. Determine stroke requirements and final "E*" Dimension - Place CAD layout into design and check clearance.

3. SELECT MOUNTING AND INTERFACE COMPONENTS. Determine mounting method and core attachment.

4. SELECT ENVIRONMENTAL OPTIONS Determine operating temperature and environment.

5. PROOF DESIGN LAYOUT. Perform a final check of layout and options.

6. FINAL REVIEW AND QUOTE. Request PFA review of final design.

7. ORDER SYSTEM.

8. ** HOW TO BUILD A PART NUMBER. Additional reference information.

9. ** SAMPLE APPLICATION. Additional reference information.

SELECT SERIES SIZE

While there are many inputs to the design of a core/slide system, the primary factor to be considered when sizing a KOR-LOK™ Side-Action System is the force on the core in line with the main unit shaft. This force is a function of the projected core area and maximum injection pressure (nozzle pack pressure) - contact PFA for details. Injection pressure generally ranges from 10,000 to 25,000 psi (hydraulic line pressure x 10).

FORCE (Ibs) = AREA (sq. in.) X PRESSURE (psi). The KOR-LOK™ Side-Action System is chosen with a force rating above this calculated force. (See Specifications page).

Many additional factors may affect performance, as it is also dependent on core lengths, stop location, stroke, and other mold geometry. For demanding pull applications, such as thermoset shrink around zero draft cores or penetrating die casting cores, the large pull force “LB” models should be considered (Example KL-H-112LB). How to build a part number and an example of a quote request is discussed below.

The final selection should not be made without a FREE review of sizing with a PFA Applications Specialist. While we are not responsible for the design decisions made by the customer, our experience with a wide range of complex and demanding applications has proven to be very helpful in preventing misapplications and/or sizing errors.

Please email the preliminary data and Layout CAD file(s) to us at pfaeng@wi.rr.com. Please provide the following information for optimal results from the review process:

1. Core Projected Area
2. Core Diameter
3. Core Length
4. Minimum Stroke need/Maximum stroke allowable
5. Maximum Injection Pressure
6. Hydraulic Pressure available7. Material Type
8. Sectional Views of the Core Arrangement (CAD files)

We can easily begin the process with a quick phone conversation to determine some basic boundaries of the application and provide our immediate recommendations.

For a self directed approach including core area/force calculations, angled wedge concepts, and other hints and ideas of how to use the system, see the Design Center.

SELECT STROKE and EXTENDED (SET) POSITION

Stroke is primarily determined by the need to clear the core from the part, but practical efforts should be made to simplify overall product selection, mounting, and adjustment (The cylinder must be allow to freely stroke fully set to pull without restriction to allow set preload and sensors to operate). Once the core face detail and KOR-LOK™ Series is determined, select the CAD file image that best fits the application -- Note that longer rods are available (which act like rod extensions) to make up the difference between the extended condition and desired mounting position – call PFA for details.

ATTENTION!

For non-integer strokes or fractional strokes, we employ a 'Variable E*" dimension (rod projection when retracted - see discussion below). For fractional strokes, a standard rod of the next longer integer stroke is used with the tubes cut to match the fractional stroke chosen.

Select and Download CAD Files. CAD files are available standard units shown in the set and pull position with all accessories installed and as separate components. With the stroke determined, it is easiest to drop in the appropriate unit and then determine any extension or mounting changes related to the interface. Information on the fractional stroke information and mounting accessories is discussed below.

Variable E dimensions – extended method. The easiest was to understand this is to view a KL-H-112 in use as either a 1, 2, 3, 4….inch stroke unit only. Then the cylinder section is sized to allow the rod to pull the desired stroke amount to clear the part. For example, if you think the stroke will need to be between 1 and 2 inches, say 1.75”, then just drop in the CAD file of the appropriate “set” position of a KL-H-112-2” stroke unit and simply “stroke” the slide/cylinder arrangement the desired1.75” back. The length of the cylinder end will be shorter by the amount of the missing stroke (2-1.75= 0.25”), which can be adjusted by shortening the cylinder tube section of the CAD drawing (overall length). This is easiest, as it works the same way that you tend to draw the tool – first you draw the arrangement in the set condition and then pull it all apart as needed and fill in the rest. Since the rod has a standard extension of 0.5”, the extended condition is 2” + .5” = 2.5” with a retracted position of 2.5” – stroke (1.75) = 0.75” The key is that we only use whole inch increment rods so the rod is always standard.

Alternative Variable E dimension – retracted method. Aternatively, the set and pull rod lengths can be determined from the dimensional chart and then drawn in using the following calculations. The difference between the next larger standard stroke rod (rounding up to the next full inch) and fractional stroke (the possibly overly particular one you want) is added to the E dimension in the chart. [For example: A KL-H-112 with a stroke of 1", 2", 3" etc. stroke will have a standard E dimension of 0.5". If a 1.75" stroke is required, a standard 2" stroke rod will be used, with the 'extra' stroke rod material (2.0"-1.75" = 0.25") extending beyond the standard chart E dimension. The new E dimension would be 0.50" (chart) + 0.25" (extra) = 0.75". To determine extend rod dimension, add the stroke of 1.75" to the new 0.75" E to get 2.5".]

MOUNTING AND INTERFACE COMPONENTS

Note: For a graphic of these components, see the How It Works page.

PFA Round [RFC] or Square [SFC] Flange. Mounting can be done using a standard flange (threaded center hole only) or by threading directly into the mold base. The flange mount is recommended as it allows easy mating of parts and a simple “bolt on” solution. Counter bore bolt locations are recommended (see flange drawing on the Specifications page), but actual locations are left up to the designer for flexibility.

Jam Nuts [JN], which mate the main unit and flange together after installation and preload adjustment, are standard on nearly every order. Unless you are making a custom flange or threading into the mold base directly, you need these two items.

Alignment Screws [AS] help mate the core to the cylinder rod and are critical to compensate for slight misalignments and to prevent side loading of the KL unit. The “T” in the “T Slot” arrangement, Alignment Screws provide critical decoupling of the core and cylinder, allow for cylinder rotation during adjustment, and are designed to drive any misaligned force to the center of the interface. These are standard on nearly every order and unless you make your own, you need to order them as well.

Alignment Couplers [AC] are the “Slot” in the “T Slot” arrangement and allow for easy adapting to the core via a threaded shaft. With the slot often machined into the core itself, these are always ordered. Replication of our slot dimensions with our screw is recommended. Custom interface is fine as long as it allows for misalignment and rotation of the rod for adjustment. We try to make it easy, but you’re the customer so feel free to make it as difficult as you want.

Sensors Included. Relay style pull and set sensors (switches w/ cables) are included in each unit. Reading of the sensors assists in verification of proper operation during setup and adjustment. Sensors are a simple two wire relay switch requiring no power or additional equipment.

SELECT ENVIRONMENTAL OPTIONS

High Temperature Seals [VI] are made available primarily for Thermoset and Die Casting applications where mold and die temperatures are maintained well above normal hydraulic fluid temperatures. High Temperature seals, while helpful in these environments, are not immune to the effects of high heat due to the dead heading of fluid at the cylinders themselves. Units must continue to be cycled while exposed to heat and may also require additional cooling or “recycling” circuit to exchange hot fluid with new cooler fluid, which most prevalent in systems with long hydraulic connections. Viton® seals are especially sensitive to steam effects in water glycol mixtures above 200 degrees F, which can lead to excessive swelling and seal damage.

Metal Rod Wiper [MW] are available for die casting and other environments where material contamination can adhere to the rod and would damage seals as the rod retracts. The metal wiper assists in removing this contamination to prevent damage.

PROOF DESIGN LAYOUT

Check layout for 1) proper core clearance when retracted, 2) Complete Flange engagement and allowance for KL unit to extend through the flange during adjustment 3) clearance for sensors/guards during rotational preload adjustment (360 degree rotation in flange) OR non-interference for alternate sensor locations in the event final adjustment interferes with primary sensor location, and 4) clearance to press or other items during mold/die installation in press.

FINAL REVIEW AND QUOTE

Very Experienced PFA Customers. After downloading files and doing the intended layout, experienced customers can obtain a real time online quote. Application information can then be forwarded for Final Review. While this process is intended to help you keep the project moving forward, the review may bring to light new information requiring changes.

New and Less/Experience Customers. For designers less experienced with our product selection process, we recommend a preliminary layout, forwarding of the review information/Layout CAD files, and discussion with an Applications Specialist prior to detailed work on the rest of the design. We will then contact you and provide our recommendations and quote a system, as you desire.

Please email the Final Design data and Layout CAD file(s) to us at pfaeng@wi.rr.com. Please provide the following information for optimal results from the review process (If some of this information was sent previously, please reference the prior communications):

1. Core Projected Area
2. Core Diameter
3. Core Length
4. Stroke
5. Maximum Injection Pressure
6. Hydraulic Pressure
7. Material Type
8. Sectional Views of the Core Arrangement or 3D CAD files*.

* File formats can be the native file (*.prt, *.dwg, etc.) preferably zipped (*.zip). For elaborate CAD systems, we recommend exporting as an IGES file (*.igs) or other format commonly used to share files between systems.

ORDER SYSTEM

With a quote in hand, you are now ready to order the system. At PFA, we pride ourselves on outstanding service, so if you would like product faster or have any questions on shipping time, training, on site training and/or setup assistance, please contact us to see if we can do more, better, faster for you.

For best service, please 1) Send credit references as soon as possible, if you do not yet have an account set up, 2) reference the quote number on your purchase order, and 3) Call to discuss any special desires you have with your Applications Specialist.

PFA Terms of Sale apply to all orders and attention to proper information on the order will assist in prompt order confirmation. (Note that PFA will confirm the order within a day or so after receipt, please watch for it to ensure that your order was received and processed).

HOW TO BUILD PART NUMBERS

Please note that large bore option units are specified as part of the series size – Example:

KLH-150LB-3.00. For Interface accessories the “LB” is not used, as the accessories are the same regardless of the LB option. For example, a “150LB” and “150” both use 150 series accessories. Accessories are ordered as individual items. See discussion of individual components above and the “Sample Application” at the bottom of this page.

MAIN UNIT

MOUNTING AND INTERFACE COMPONENTS

SAMPLE APPLICATION

1. First, the designer reviews the "How It Works" section to refresh the understanding of the basics of system operation, preload (force intensification), and the need for proper product adjustment and setup.

2. The application is a seal off core with a shallow taper. Movement is 30 degrees off the parting line. A call is made to PFA and an application specialist confirms your assumptions and calculations. You then download the CAD file and select the stroke with correct variable E dimension. The main unit is sized as a 150 series and a stroke of 2.25” The variable E calculation shows the rod extended is 3.75” (3” standard rod + .75” standard = 3.75”) and retracted is 1.5” (3.75”- 2.25” stroke = 1.5”). The part number is KLH-150-2.25 and the CAD drawing used in the layout is the KLH-150-3.0 Full assembly EXTENDED, with the rear end tubes redrawn to match the 2.25” stroke. The unit is shown with the flange cut into the base, and the rod directly coupled to the core with a threaded rod because there was no room for the Alignment Screw.

3. A PFA Application Specialist is contacted to review the design and provide a quote. The PFA application specialist recommends adding a stop to the core and better timing so the stop takes the load to prevent jamming the taper into the pocket. Stop size recommendation is generously large due to the large output force of the 150 series on the indicated area and close to the part to ensure best preload with little remaining material unloaded. The specialist also recommends that rear porting be used to avoid interference with the clamping plate. A standoff for the mounting flange is recommended as the best alternative to direct coupling the rod to the core – the standoff allows for use of the alignment screw (AS) and mating T-slot in the core, as well as allowing space forward of the flange for the preload adjustment (Without clearance for the unit to thread through the flange, adjustment cannot be done).

4. The PFA specialist supplies a quote on the main unit and mounting accessories:

5. The layout is redone based on the new recommendations and the file emailed to the Application Specialist for final review. After a quick review and email from PFA, the quote is sent to purchasing.

6. PFA receives the Purchase Order and sends back confirmation of the order and ship date. PFA then enters the order and verifies credit. The system ships within about 1 week of placing the order.

7. After receiving the order, some questions arise while doing the initial installation. Its Thursday night and you really need to get answers right away to have the mold in the press for tryout Friday morning. After being completely frustrated for not having done this before close of business, you remember that PFA has a 24/7/365 Emergency Technical Help Line and you call 1-888-296-6663. An on call Specialist calls you back in about 15 minutes and talks you through the setup procedure. On Firday morning, you are running beautiful flash free parts. Of course, you still have the 10 Engineering Changes, but wow, those cores are running GREAT!