DESIGN AND ANALYSIS OF INJECTION

MOULD WITH HOT RUNNER

Under the guidance of,

E.SANDEEP REDDY
Asst. Prof

Presented by,
P.SAGAR
149A1D1616

PROJECT OVERVIEW :
ABSTRACT
INTRODUCTION
PROCESS OF INJECTION MOULDING
BLOCK DIAGRAM
CLASSIFICATION
COLD RUNNER SYSTEM
HOT RUNNER SYSTEM
RESULTS
CONCLUSION
REFERENCES

ABSTRACT
To design a Multi cavity Injection Moulding.
Design and comparisons of a two different moulds using injection moulding with
hot runner system.
These moulds have been process analyzed and documented with assembly
drawings.
Injection mold designing was done in CAD application CATIA
V5R19 and evaluated by injection molding analysis in Autodesk
Moldflow Synergy 2014 software.

INTRODUCTION :
Injection moulding is a manufacturing process for
producing parts by injecting material into a mould.
The polymers are processed by different technologies
which for example include injection molding, extrusion,
blow molding and compression molding.
It is very accurate and efficient manu-facturing
technology, which can produce products with complex
shapes without additional adjustments.

Process Of Injection Moulding

Stage 1( Fill stage): During this stage, the mold
cavities are filled with molten resin. As the material is
forced forward, it passes over a spreader within the
barrel, which causes mixing.
Stage 2(Pack stage): As the melt enters the mold, it
cools and introduces shrinkage. The pack stage is
necessary to force more melt into the mold to
compensate for shrinkage.
Stage 3(Hold stage): When no more material can be
forced into the mold, melt can still leak back through the
gate. The hold stage applies forces against the material
in the cavity until the gate freezes to prevent leaking of
the melt.

Classification of Injection moulding :

Injection mould can be classified in several ways and one of them is also by the
type of runner system. According to the type of runner system injection moulds
are divided as
1. Cold runner system,
2. Hot runner system,
3. Combination of cold and hot runner systems.

Cold Runner System:

This system is mostly used with thermo plastic materials.
A cold runner mould refers to a mould in which the runner is cooled,
solidified, and ejected with the moulded part(s) during each moulding cycle.
System consists of sprue, runner and at least one gate.

Advantages:
Cheaper to build due to its simplicity.
Low Maintenance cost as there will be no use of heaters, heater controllers,
thermocouples and other hot runner components.
Easy to operate

Hot Runner System:

A hot runner system is an assembly of heated components in plastic
injection moulds that inject plastic in to the cavities of the mould.
A hot runner system usually includes a heated manifold and a number of
heated nozzles.
Hot runners are fairly complicated systems as they have to maintain plastic
material within them in molten state, while the rest of the injection mould is
being cooled in order to solidify the products quickly.

Block Diagram (Hot Runner system) :

Main Benefits of Hot Runner System:

Reduces cycle time.
Eliminates the cold runner that would be scrap or require regrind.
Improves part consistency and quality.
Reduced gate mark.
Reduces injection pressure.
Sequential filling and family of parts are made possible by using valve
gates.
Increases process control for fine tuning mould and part.

Advantages of Hot Runner System:

Material cost savingno runners to regrind or reprocess.

Low cost least expensive for large volume production.
Smaller machines reduced shot volume into runners.
Automated processing- runners do not need to be separated
from the parts.

Dis-advantages of Hot Runner System:

Higher maintenance cost because susceptible to

Break downs
Leakages
Heating element failure
Wear caused by filling elements
Elaborate temperature control required.
Higher initial start-up costs than for cold runner systems.

Result:
Injection mold was designed with an effort to maximize the usage of
standard parts in or-der to reduce the cost of mold and simplify designing
in the 3D software.
From filling analysis can be observed that filling of the cavities is done
simultaneously proving that hot runner system is balanced.
These results can be justified by small wall thickness and insufficient
cooling in this area. Due to occurrence of stripper rings no cooling
circuits were designed in this area.

Conclusion:
Concept of cold runner mold is similar to the first variant with hot runner
system. However due to cold runner system a three plate mold concept
had to be chosen.
Opening in individual parting planes is done with help of latch locking
system selected from Hasco catalog
After considering pros and cons of individual variants, injection mold
with hot runner was chosen.

REFERENCES
[1] BEAUMONT, John P., R. NAGEL a R. SHERMAN. Successfulinjectionmolding: process,
design, and simulation; with CD-ROM.Munich [u.a.]: Hanser, 2002. ISBN 34-461-9433-9.
[2] REES, Herbert. Moldengineering. 2nd ed. Munich: HanserPublishers, 2002, 688 s. ISBN
34-462-1659-6.
[3] BEAUMONT, John P. Runner and gating design handbook: tools for successful in-jection
molding. 2nd ed. Cincinnati: Hanser, c2007, xvi, 308 p. ISBN 1569904219.
[4] BOBK, L. Formy pro zpracovn plast: vstikovn termoplast. Dl 1. 2. upr.
vyd. Brno: Uniplast, 1999. 133 s.
[5]MENGES, Georg. How to makeinjectionmolds. 3rd ed. Munich: HanserPublishers, 2001,
612 s. ISBN 34-462-1256-6.

THANK YOU