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    Injection Molding Balancing Runner Systems

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    Abir Roy
    This document discusses balancing runner systems in injection molding. Balanced runner systems help ensure even filling of the mold. The incompressible continuity equation for liquids is presented for Cartesian, cylindrical, and spherical coordinate systems. An example uses the Hagen-Poiseuille law to calculate sizes for runners to balance pressures at different points in a mold. Extreme examples of complex molds requiring careful runner balancing are shown. Common defects from unbalanced filling like weld lines and sinks marks are described.

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    Injection Molding Balancing Runner Systems

    Uploaded by

    Abir Roy
    85 views10 pages
    This document discusses balancing runner systems in injection molding. Balanced runner systems help ensure even filling of the mold. The incompressible continuity equation for liquids is presented for Cartesian, cylindrical, and spherical coordinate systems. An example uses the Hagen-Poiseuille law to calculate sizes for runners to balance pressures at different points in a mold. Extreme examples of complex molds requiring careful runner balancing are shown. Common defects from unbalanced filling like weld lines and sinks marks are described.

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    Production engineering

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    InjectionMolding

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    This document discusses balancing runner systems in injection molding. Balanced runner systems help ensure even filling of the mold. The incompressible continuity equation for liquids is presented for Cartesian, cylindrical, and spherical coordinate systems. An example uses the Hagen-Poiseuille law to calculate sizes for runners to balance pressures at different points in a mold. Extreme examples of complex molds requiring careful runner balancing are shown. Common defects from unbalanced filling like weld lines and sinks marks are described.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    85 views10 pages

    Injection Molding Balancing Runner Systems

    Uploaded by

    Abir Roy
    This document discusses balancing runner systems in injection molding. Balanced runner systems help ensure even filling of the mold. The incompressible continuity equation for liquids is presented for Cartesian, cylindrical, and spherical coordinate systems. An example uses the Hagen-Poiseuille law to calculate sizes for runners to balance pressures at different points in a mold. Extreme examples of complex molds requiring careful runner balancing are shown. Common defects from unbalanced filling like weld lines and sinks marks are described.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 10

    Injection Molding BALANCING RUNNER SYSTEMS

    Figure 1: Two naturally balanced (symmetric) runner systems and one counter-example.

    Figure 2: An articially balanced runner system.

    Injection Molding CONSEQUENCE OF IMBALANCED RUNNER SYSTEMS

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

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

    Injection Molding INCOMPRESSIBLE CONTINUITY EQUATION FOR LIQUIDS


    Cartesian coordinates: x, y, z dVx dVy dVz + + =0 dx dy dz Cylindrical coordinates: r, , z

    1 dv dvz 1 d (rvr ) + + =0 r dr r d dz Spherical coordinates: r, , 1 d 2 1 d 1 dv (r vr ) + (v sin ) + =0 2 r dr r sin d r sin d All are simply v = 0

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

    Hagen-Poiseuille Law: P = Suppose: RAB = RBC = RCD = RDG R

    8LQ R4

    What size do we make RBE and RCF to balance the pressures at E , F and G? Flow is split 6 ways: 2 QBC = Q 3 1 QCD = Q 3 1 QBE = QCF = QDG = Q 6 All lengths are equal, dene K 8L/ QAB Q

    Injection Molding
    Pressure drops are additive: KQBC KQCD KQDG + + 4 4 4 RBC RCD RDG 2KQ KQ KQ = + + 3R4 3R4 6R4 7KQ = 6R4 KQBC KQCF + 4 4 RBC RCF 2 KQ KQ = + 4 4 3 R 6RCF 1 1 = 4 6RCF 2R4

    PBG =

    PBF =

    First Result: PBG = PBF RCF =

    R = 0.76R 31/4 KQ 4 6RBE 1 7 = 4 6RBE 6R4

    PBE =

    Second Result: PBE = PBG RBE =

    R = 0.61R 71/4

    Injection Molding EXTREME EXAMPLE OF RUNNER BALANCING

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

    Injection Molding CONVENTIONAL INJECTION MOLDING

    Figure 6: Discard or regrind.

    Injection Molding INJECTION MOLDING DEFECTS


    Weld lines

    Figure 7: Cold ow 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 - Insucient cooling before ejection. Burning - Extrusion temperature too high. Shear heating.

    Injection Molding MATERIAL AND INJECTION PRESSURE

    FROZEN LAYER IN FOUNTAIN FLOW

    Injection Molding HOT-RUNNER SYSTEMS

    More expensive mold Potential degradation problems Eliminates regrind Automatic detachment

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