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Injection Molding Balancing Runner Systems

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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Abir Roy
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137 views

Injection Molding Balancing Runner Systems

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.

Uploaded by

Abir Roy
Copyright
© Attribution Non-Commercial (BY-NC)
Available Formats
Download as PDF, TXT or read online on Scribd
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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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