Ijri me-02-031 predictive analysis of gate and runner system for plastic injection mould

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International Journal of Research and Innovation on Science, Engineering and Technology (IJRISET)

International Journal of Research and Innovation in Mechanical Engineering (IJRIME)

PREDICTIVE ANALYSIS OF GATE AND RUNNER SYSTEM FOR PLASTIC INJECTION MOULD

Botla Sudheer Kumar1, N.Rajesh2.

1 Research Scholar, Department of Mechanical Engineering, Sri Venkateswara College of Engineering Technology, Andhra Pradesh, India.2 Assistant professor, Department of Mechanical Engineering, Sri Venkateswara College of Engineering Technology, Andhra Pradesh, India.

*Corresponding Author:

Botla Sudheer Kumar, Research Scholar, Department of Mechanical Engineering, Sri Venkateswara College of Engineering Technology, Andhra Pradesh, India.Email: [email protected]

Year of publication: 2016Review Type: peer reviewedVolume: III, Issue : I

Citation: Botla Sudheer Kumar, Research Scholar, "Predictive Analysis of Gate And Runner System For Plastic Injection Mould" International Journal of Research and Innovation on Science, Engineering and Technology (IJRISET) (2016) 199-206

Literature survey

[1 ]Mr. Tangqing Kuang Wenjuan Gu from School of Me-chanical and Electrical Engineering, East China Jiaotong University, Nanchang 330013, China has done the re-search work on “Optimum Design of Runner System for Router Cover Based on Mold Flow Analysis Technology” in that publication they have done comparison and worked on selection of different gate settings by using mold flow analysis. Finally they got the best gate location and gate panel number for the router, the length and cross section size can be determined by the following choice of mold plate and the mold specifically designs. The runner sec-tion size can be optimized by runner balance analysis. And the gate section size can be optimized to ensure the full compensation by packing analysis and cooling analy-sis. The resulting optimum runner system can be used to improve product quality.

From this example, we know that the successful applica-tion of mold flow analysis for injection mold design pro-vides the scientific basis and reference for mold design-ers and aids designers to optimize the design programs, reduce testing time, and improve qualities of mold and

products.

[2] Mr.Chandan Deep Singh fromUniversity College of Engineering, Punjabi University has done the reasearch work on “Feature Library of Gating System for a Die-Cast-ing Die” and he has given the conclusions as “The system has inbuilt feature library for gate, runnerand overflow designs. The system helps a die-castingengineer in re-ducing time and efforts as there is noneed to design the gating system for a part fromscratch. The system would go a long way in bridging the gap between designing and manufacturing of diecasting.The present work has over-come the shortcomings of the previous.”

INTRODUCTION

RUNNERS

Distribution system for the resin from the sprue to the cavities Flow characteristics (viscosity), temperature and other factors are important in determining the runner di-ameter and length If the diameter of the runner is too small or the length is too long, the resin can freeze in the runner before the mold is completely full If the runner system is too large, excess material would be ejected and too much regrind created If the resins have a high viscos-ity, larger runners are needed compared to low viscosity resin.

The optimum flow of the resin through the runner system depends on the shape and diameter of the channel Round channel give the best flow characteristics but difficult to machine Machining cost can be reduce by machining one side of the mold plates Better shape where the depth of the channel is at least two-thirds the size of the width and the sides are tapered between 2 to 5º.

Abstract

The aim of the project work is to specify optimum design of runner and gate systems to enhance the production rate for plastic part manufacturing.

Literature survey will be done on runner and gate system to understand simulation or analysis approach.

Data collection will be done to brief about runner and gate system importance, design method and variations.

Plastic flow analysis will be done on digital prototype of a specimen by various runner and gate profiles and also done by changing materials.

The optimum profiles for the runner and gate system will be suggested by comparing flow results with specific materials and profiles.

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Secondary Runners

• Secondary runner channel are used for multi cavity molds• The flow into the secondary channel should be stream-lined (angle in flow direction)• The streamlined minimizes shear on the resin

Runners are the major part of feed system of moulding process it has to design very carefully most commonly USED CROSS-SECTIONS AS BELOW.

New

Gate type

As important as selecting the optimal gate size and loca-tion is the choice of the type of gate.Gate types can be divided between manually and auto-matically trimmed gates.

Manually trimmed gates Manually trimmed gates are those that require an operator to separate parts from run-ners during a secondary operation. The reasons for using manually trimmed gates are:

• The gate is too bulky to be sheared from the part as the tool is opened.

• Some shear-sensitive materials (e.g., PVC) should not be exposed to the high shear rates inherent to the design of automatically trimmed gates.• Simultaneous flow distribution across a wide front to achieve specific orientation of fibers of molecules often precludes automatic gate trimming.

Gate types trimmed from the cavity manually include:• Sprue gate• Edge gate• Tab gate• Overlap gate• Fan gate• Film gate• Diaphragm gate• External ring• Spoke or multipoint gate

MODEL OF SPECIMAN WITH RUNNERS

The above image shows semicircular runner

The above image shows square runner

The above image shows trapezoid

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The above image shows modified trapezoid

MOULD FLOW ANALYSIS

Mould flow, 3D solids-based plastics flow simulation that allows plastics part designers to determine the manu-facturability of their parts during the preliminary design stages and avoid potential downstream problems, which can lead to delays and cost overruns. Following are the benefits:

• Optimize the part wall thickness to achieve uniform fill-ing patterns, minimum cycle time and lowest part cost Identify and eliminate cosmetic issues such as sink marks, weld lines and air traps.

• Determine the best injection locations for a given part design

Mould flow analysis gives you the ability to maintain the integrity of your product designs. It provides you the tools to quickly optimize part designs and check the impact of critical design decisions on the manufacturability and quality of the product early in the design process.

MATERIALS

Polypropylene (pp)Acrylonitrile Butadiene Styrene (ABS)High Density Polyethylene (HDPE)Polyvinyl Chloride (PVC)

PLASTIC FLOW ANALYSIS OF SPECIMEN USING SEMI CIRCULAR RUNNERMATERIAL: PP

The above image shows fill time

The above image shows injection pressure

The above image shows surface temp variance

PLASTIC FLOW ANALYSIS OF SPECIMEN USING SQUARE RUNNERMATERIAL: PP


The above image shows Injection Pressure

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PLASTIC FLOW ANALYSIS OF SPECIMEN USING TRAPEZOID RUNNERMATERIAL: PP



PLASTIC FLOW ANALYSIS OF SPECIMEN USING MOD-IFIED TRAPEZOID RUNNER MATERIAL: PP



Plastic Flow analysis of Specimen using Semi - Circu-lar Gate MATERIAL: PP



PLASTIC FLOW ANALYSIS OF SPECIMEN USING SQUARE GATE MATERIAL: PP



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PLASTIC FLOW ANALYSIS OF SPECIMEN USING TRAP-EZOID GATE



PLASTIC FLOW OF SPECIMEN USING MODIFIED TRAPEZOID GATE MATERIAL: PP



Plastic Flow analysis of Specimen using modified trapezoid runner with over Lap GateMATERIAL: PP



Plastic Flow analysis of Specimen using modified trapezoid runner with Bottom GateMATERIAL: PP



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Plastic Flow analysis of Specimen using modified trapezoid runner with Top GateMATERIAL: PP



Plastic Flow Analysis Using Multi Cavity System Poly-propylene (PP)


The above image shows confidence of fill


Runner system

Semi-Circular

Square Trapezoid Modified Trapezoid

Fill Time 6.82 5.12 5.34 5.27

Injection Pressure

14.45 5.92 7.24 5.90

Pressure Drop

14.45 5.92 7.24 5.90

Flow Front Temp

240.10 240.02 240.02 240.01

Surface Temp Variance

91.58 89.18 101.80 39.99

Gate geometry

Semi-Circular

Square Trapezoid Modified Trapezoid

Fill Time 5.34 5.56 5.77 5.11

Injection Pressure

6.55 7.82 7.44 6.12

Pressure Drop

6.55 7.81 7.44 6.04

Flow Front Temp

240 240.03 240.02 240


1.46 1.67 1.69 1.61

Gate systems

Over Lap

Bot-tom

Top Tap Fan Ring

Fill Time

4.93 5.58 5.21 6.02 5.34 3.37

Injec-tion Pres-sure

4.05 8.11 5.97 10.12 7.34 8.75

Pres-sure Drop

4.05 8.11 5.97 10.12 7.34 8.75

Flow Front Temp

240 240.01 240 240.02 240.01 240.02

Sur-face Temp Vari-ance

1.99 1.87 1.60 3.84 1.45 4.68

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Multi cavity

PP ABS HDPE PVC

Fill Time 6.03 7.84 6.40 13.82

Injection Pressure

18.77 28.38 34.87 43.87

Pressure Drop

18.77 28.38 34.87 43.87

Flow Front Temp

240.08 230.16 210.46 170.45


11.30 11.30 11.30 11.30

CONCLUSION

This research paper gives the complete orientation on runner and gate system of plastic product manufacturing Mould.

Initially literature survey and data collection was done on gate and runner system to understand the methodology and selection of geometry.

Mould flow analysis was done using plastic advisor on various runners and gate profiles, to specify the optimum model for gate and runner.

In first case:- Semi circular, square, trapezoid and modi-fied trapezoid models where analyzed using standard pressure with regular material polypropylene, In this case modified trapezoid runner system is giving optimum Flow with low pressure.

In second case:- Various geometric profiles of gate system are implemented to provide the optimum gate geometry.In this case modified trapezoid gate geometry with modi-fied trapezoid runner is having optimum quality.

In third case:-Different methods of gate systems are im-plemented to fine optimum feed system.

In this case overlap type is showing good charter sticks.

In fourth case:-The mould flow analysis was done using different materials on multi cavity model. In this case all the thermo plastics (PP, ABS, HDPE) is showing good charter sticks, along with trapezoid gate with runner with overlap system , but when coming to thermo setting plastic(PVC) is not suitable for multicavity system.

As per the obtaining results of above four different cas-es this research work concludes that modified trapezoid runner and gate system with overlap method will perform better injection moulding process, it uses very low pres-sure, it losses pressure drop with nominal surface tem-perature variance.

REFERENCE

1 Tangqing Kuang “Optimum Design of Runner System for Router Cover Based on Mold Flow Analysis Technol-ogy” School of Mechanical and Electrical Engineering, East China Jiaotong University, Nanchang 330013, Chi-na.2015 .pp1-13

2 Chandan Deep Singh Department of Mechanical Engi-neering, University College of Engineering, Punjabi Uni-versity, Patiala, (PB) (India

3 Mohd. RizwanHamsin, AzuddinMamat and AznijarAh-mad-Yazid Department of Engineering Design and Manu-facture Faculty of Engineering, University of Malaya,

4 E. Bociąga, T. Jaruga* Institute of Polymer Processing and Production Management, Al. ArmiiKrajowej 19c 42-200 Częstochowa, Poland * Corresponding author: E-mail address: [email protected]

5 E. Bociąga, T. Jaruga* Institute of Polymer Processing and Production Management, Czestochowa University of Technology, Al. ArmiiKrajowej 19c, 42-200 Częstochowa, Poland * Corresponding author: E-mail address: [email protected]

6 Yuan Hsu1, Mark R. Jolly2and John Campbell2 1 De-partment of Materials Science and Engineering, National United University, No.1 Lein-Da, Kung-Ching Li, MiaoLi, 36003 Taiwan, R.O.C. 2Engineering School, University of Birmingham, Edgbaston, Birmingham B15 2TT, UK

7 ThiTruc-Ngan Huynh* Department of Mechanical En-gineering, National Kaohsiung University of Applied Sci-ences Kaohsiung, Taiwan, R.O.C. *E-mail: [email protected]

8 Srisit Chianrabutra1, a, Anchana Wongsto2, b, Ta-weedej Sirithanapipat1, 2, c Research and Development Institute of Industrial Production Technology (RDiPT)1 Department of Mechanical Engineering2 Faculty of En-gineering, Kasetsart University, 50, Phaholyothin Rd., Bangkok, 10900, Thailand Tel: 0-29428567-70, Fax: 0-29428571, E-mail: [email protected], [email protected], [email protected]

9 SahajanandKamble1, Prof. Girish V A2, Mr. Shridhar Bagalkot3 1Department of mechanical engineering R.V. college of Engineering, Bangalore,560059 India E-mail id:[email protected] 2 Professor, Department of mechanical engineering R.V. college of Engineering, Ban-galore, India E-mail id:[email protected] 3Mr. ShridharBagalkot NTTF, Peenya 2nd stage Bangalore, Karnataka, 560058, India E-mail id:[email protected]

10 Vikas B J 1, Chandra Kumar R 2 1M. Tech. Student, 2Asst. Professor, Department of Mechanical Engineering, R V College of Engineering, Karnataka, India, [email protected]., [email protected]

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AUTHORS

Botla Sudheer Kumar,Research Scholar, Department of Mechanical Engineering, Sri Venkateswara College of Engineering Technology, Andhra Pradesh, India.

N.Rajesh,Assistant professor, Department of Mechanical Engineering, Sri Venkateswara College of Engineering Technology, Andhra Pradesh, India.

Ijri me-02-031 predictive analysis of gate and runner system for plastic injection mould

Education

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