Scribd
Upload
255 views10 pages

Runner Balancing InjectionMolding2 PDF

Injection molding requires balancing the size of runner systems to ensure even distribution of material flow. Uneven flows can lead to short shots or overpacking in some areas of the mold. The Hagen-Poiseuille law describes pressure drops in fluid flow and can be used to calculate the ideal sizes of runners to balance pressures. Hot-runner systems, while more expensive, eliminate the need to discard scrap material and produce more consistent parts.

Uploaded by

LEV JAMARE
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
255 views10 pages

Runner Balancing InjectionMolding2 PDF

Injection molding requires balancing the size of runner systems to ensure even distribution of material flow. Uneven flows can lead to short shots or overpacking in some areas of the mold. The Hagen-Poiseuille law describes pressure drops in fluid flow and can be used to calculate the ideal sizes of runners to balance pressures. Hot-runner systems, while more expensive, eliminate the need to discard scrap material and produce more consistent parts.

Uploaded by

LEV JAMARE
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
You are on page 1/ 10

Injection Molding

BALANCING RUNNER SYSTEMS

Figure 1: Two naturally balanced (symmetric) runner systems and one


counter-example.

Figure 2: An artificially balanced runner system.

1
Injection Molding
CONSEQUENCE OF IMBALANCED
RUNNER SYSTEMS

Figure 3: Need to overpack 1 and 6 to fill 3 and 4.

Figure 4: Short shots in a telephone-handle molding die.

2
Injection Molding
INCOMPRESSIBLE CONTINUITY
EQUATION FOR LIQUIDS
Cartesian coordinates: x, y, z
dVx dVy dVz
+ + =0
dx dy dz
Cylindrical coordinates: r, θ, z
1 d 1 dvθ dvz
(rvr ) + + =0
r dr r dθ dz
Spherical coordinates: r, θ, φ
1 d 2 1 d 1 dvφ
2
(r vr ) + (vθ sin θ) + =0
r dr r sin θ dθ r sin θ dφ
~ · ~v = 0
All are simply ∇

3
Injection Molding
Example: use Hagen-Poiseuille Law to balance the runners

8µLQ
Hagen-Poiseuille Law: ∆P =
πR4
Suppose: RAB = RBC = RCD = RDG ≡ R

What size do we make RBE and RCF to balance the pressures at E, F


and G?

Flow is split 6 ways: QAB ≡ Q

2
QBC = Q
3
1
QCD = Q
3
1
QBE = QCF = QDG = Q
6
All lengths are equal, define K ≡ 8µL/π

4
Injection Molding
Pressure drops are additive:

KQBC KQCD KQDG


∆PBG = 4
+ 4
+ 4
RBC RCD RDG
2KQ KQ KQ
= + +
3R4 3R4 6R4
7KQ
=
6R4

KQBC KQCF
∆PBF = 4
+ 4
RBC RCF
2 KQ KQ
= 4
+ 4
3 R 6RCF

1 1
First Result: ∆PBG = ∆PBF ⇒ 4
=
6RCF 2R4
R
RCF = = 0.76R
31/4
KQ
∆PBE = 4
6RBE
1 7
Second Result: ∆PBE = ∆PBG ⇒ 4
=
6RBE 6R4
R
RBE = = 0.61R
71/4

5
Injection Molding
EXTREME EXAMPLE OF RUNNER
BALANCING

Figure 5: Family mold (pair of dishwasher detergent holding set).

6
Injection Molding
CONVENTIONAL INJECTION MOLDING

Figure 6: Discard or regrind.

7
Injection Molding
INJECTION MOLDING DEFECTS
Weld lines

Figure 7: Cold flow fronts recombine to make a visible line that can be
mechanically weak.

Voids, Sink Marks, Shrinkage

Figure 8: Use of ribs instead of a solid section. Solid section (left) and thin
section (right). 10% shrink can be expected.

Thick sections cool after gate freezes.

Sticking - Injection pressure too high (overpack).

Warping - Insufficient cooling before ejection.

Burning - Extrusion temperature too high. Shear heating.

8
Injection Molding
MATERIAL AND INJECTION PRESSURE

FROZEN LAYER IN FOUNTAIN FLOW

9
Injection Molding
HOT-RUNNER SYSTEMS

More expensive mold


Potential degradation problems
Eliminates regrind
Automatic detachment

10

You might also like