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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.
*Corresponding Author:
products.
Literature survey
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 diameter 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 viscosity, 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 5.
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International Journal of Research and Innovation on Science, Engineering and Technology (IJRISET)
Secondary Runners
Secondary runner channel are used for multi cavity
molds
The flow into the secondary channel should be streamlined (angle in flow direction)
The streamlined minimizes shear on the resin
New
Gate type
As important as selecting the optimal gate size and location is the choice of the type of gate.
Gate types can be divided between manually and automatically trimmed gates.
Manually trimmed gates Manually trimmed gates are
those that require an operator to separate parts from runners 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.
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International Journal of Research and Innovation on Science, Engineering and Technology (IJRISET)
MATERIALS
Polypropylene (pp)
Acrylonitrile Butadiene Styrene (ABS)
High Density Polyethylene (HDPE)
Polyvinyl Chloride (PVC)
PLASTIC FLOW ANALYSIS OF SPECIMEN USING SEMI
CIRCULAR RUNNER
MATERIAL: PP
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International Journal of Research and Innovation on Science, Engineering and Technology (IJRISET)
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International Journal of Research and Innovation on Science, Engineering and Technology (IJRISET)
Runner system
The above image shows fill time
SemiCircular
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
240.02
240.02
240.01
Surface
Temp
Variance
89.18
101.80
39.99
SemiCircular
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
240.03
240.02
240
Surface
Temp
Variance
1.67
1.69
1.61
91.58
Gate geometry
The above image shows injection pressure
1.46
Gate systems
Over
Lap
Bottom
Top
Tap
Fan
Ring
Fill
Time
4.93
5.58
5.21
6.02
5.34
3.37
Injection
Pressure
4.05
8.11
5.97
10.12
7.34
8.75
Pressure
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
Surface
Temp
Variance
1.99
1.87
1.60
3.84
1.45
4.68
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International Journal of Research and Innovation on Science, Engineering and Technology (IJRISET)
Multi cavity
REFERENCE
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
230.16
210.46
170.45
Surface
Temp
Variance
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 modified 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 modified trapezoid runner is having optimum quality.
In third case:-Different methods of gate systems are implemented 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 cases this research work concludes that modified trapezoid
runner and gate system with overlap method will perform
better injection moulding process, it uses very low pressure, it losses pressure drop with nominal surface temperature variance.
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International Journal of Research and Innovation on Science, Engineering and Technology (IJRISET)
AUTHORS
N.Rajesh,
Assistant professor,
Department of Mechanical Engineering,
Sri Venkateswara College of Engineering Technology,
Andhra Pradesh, India.
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