3/2/2017 TutorialsonInjectionMouldDesigningGrabCAD

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TutorialsonInjectionMouldDesigning
Design&CADOther
engineeringmechanicalmouldmoldeducationalbasicsourbh
BySourbhonAugust31st,2013Nocomments
ThistutorialwasoriginallycreatedasananswertothisQuestion:
https://grabcad.com/questions/tutorialsoninjectionmoulddesigning

Todaythetopicis"FLOWSYSTEM"

NoslidejustTheoryonly,Iwilluploadtheslidesoon.

ThanksandEnjoy..!!

1.Step1

Flowsystem:Thedesignofaflowsystemtoinjectmoltenalloyintoadiecavitygreatlyinfluences
thesuccessofadie.Thefailureofmanydiescanbetracedtofaultydesignoftheflowsystem.By
applyingthebasicprinciplesofhydraulicsapropermoltenmetalflowsystemcanbedeveloped.
Thesystemaimsatanefficientcontrolleddeliveryofthroughtheflowsystemtothediecastingwith
mixingofmoltenalloyandair.
Machinesuitability:
Choiceofsuitablemachineisimportantaspectofdiedesigning.Twomainconsiderationdetermine
suitability:
Clampingforce.
Injectioncapability.

2.Step2

https://grabcad.com/tutorials/tutorialsoninjectionmoulddesigning3 1/4
3/2/2017 TutorialsonInjectionMouldDesigningGrabCAD

Clampingforcecanbecalculatedbymultiplyingtheprojectedareaoftheimpressionincluding
runners,gateoverflowbytheinjectionpressure.Theresultshouldbelessthantheclampingforceofthe
machine.Theinjectioncapabilityormetalpumpingcapacityofthemachinemustbedeterminedfrom
thepQ2diagram.
Theflowsystemcomprisesofaseriesofpassageofvaryinglengthsanddiameterswhichcarrymolten
alloyatvaryinghighvelocitiesfromtheundersideoftheinjectionplungertothegate.
Theflowsystemshouldbeproperlydesignedandmanufacturedtominimizetheenergylosses.
Theflowsystemshouldconvergefromgoosenecktogate,sharpcornersshouldbeavoidedandthe
surfaceoftheflowpathshouldsmoothandwellfinished.

3.Step3

Thesprue:
Thespruehastwobasicfunctions:
1.Toprovideasmoothflowpathbetweennozzleandrunner.
.
2.Toprovideameansofrapidlysolidifyingmoltenmetalalloyattheentranceofthedieafterthe
cavityhasfilledandtheflowhasstopped.

3.Runnertypesprueshavebeendevelopedtoachieveasmoothflowpathwithuniformcrosssection,
minimumchangeofdirectionandsmoothtransmissionfromnozzletosprueandspruetorunner.

4.Step4

Therunnersystemfromspruetogate:
Mainrunner:

Themainrunnerjointhespruetothefinaltaperedtangentialrunnersfeedingthegate.Theyshouldbe
asshotaspossibleandmusthaveaconstantcrosssectionalarea.

Taperedtangentialrunners:
Taperedtangentialrunnersprovidethefinalflowpathfrommainrunnerstogate.Theyprovidean
efficientflowpathbasedonsimplegeometryandpermittheuseoftheverythingates(from0.15
0.3mm).

5.Step5

Runnercrosssection:

Circularsectionsgivebestflowefficiencyandminimizethermallosses,butaretheleastpractical
crosssectionfromthetoolmakersview.

Fortaperedtangentialrunnersmodifiedsquareortrapezoidalshapesareused.Areacalculationsare
basedonsquaresectionsandareconvertedintotrapezoidalshapes.

Pairsoftaperedtangentialrunnerscanbeusedtofeedalonggateintoasinglecavity.Athindelta
shapedregionbetweenthepairedrunnersisfound.

6.Step6

ShockAbsorbers:
Thesmallendsoftaperedtangentialrunnersterminatesinsimplediskshapedshockabsorbers.The
controltheveryhightransientvelocitieswhichmayoccuratthesmallendsoftherunner.Shock
absorbersalsoprotectthediewhenthedoesnotflowcompletelyasinthecaseofacolddieduring
setup,whenveryhighvelocitiescanbereached.
FanGate:
Correctdesignanddimensionsofgatesisessentialtoachievehighcastingqualityandefficiency.The
https://grabcad.com/tutorials/tutorialsoninjectionmoulddesigning3 2/4
3/2/2017 TutorialsonInjectionMouldDesigningGrabCAD

fangatehasbeenlargelysupercededbybythetaperedtangentialrunner.Toincreaseitsefficiencythe
inletshouldbelargerthanthegate.

7.Step7

GatePositioning
Generalguidelinesforgatepositioning:
Centergating:Centergatingoffersthebestfeedingconfiguration.Itpermitstheuseofshortdirect
feedsystem.Itachievesanidealflowpathacrossthediecavity.
Edgegatingsusingtaperedtangentialrunners:
Thefollowingaretherecommendations:
Thelongestuninterruptedlengthofcastingavailableforcastingshouldbechoosebutitmustsatisfy
theshortestandsmoothestflowpathacrossthecavity.
Thedirectionofmetalflowinthecavitysho9uldbechosensuchthatatleastonesideorcornerbe
openduringfilltimetoallowforventing.

8.Step8

Gatearea:
Thetotalgateareamustalwaysbesmallerthannozzleexitarea.Butitsshouldnotbelessthan40%of
nozzleexitarea.
Gatevelocity:
Thevelocityofmoltenalloythroughthegatedependson:
Theenergyofmachine
Thepressurelossesinthetotalflowsysteminthegate.
Thetypeofrunner.
Truevelocitythroughgatesfedbytaperedtangentialrunnersishigherthanthefigurearrivedatusing
theformula:
Velocity(v)=volumeflowrate(Q)
gatearea(A)

9.Step9

Airvents:
Theuseofconvergingflowsystemwithcorrectlydesignedrunnersensuresthatairinthefeedsystem
ispushedoutaheadofthemoltenalloyflowandexpelledthroughthecavitytroughtheairvents.
Depthgreaterthan0.075mmwillleadtoflashingproblem.
Overflows:Nooverflowsneedbecutpriortothefirstcastingtrialunlesstheiruseisspecifiedfor
ejectionpurpose.Ontrialifthecastingsexhibitpoorfinishorblisterthefollowingconditionsmustbe
checkedfirst:
Machineoperationsandperformance
Feedsystemdesignandperformance.
Thiswillestablishbothmachineanddieareoperatingatthedesignparameters.

10.Step10

Thanks..!!!

Nocomments
Pleaselogintoaddcomments.

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