Ganeshkar et al.

, International Journal of Advanced Engineering Research and Studies E-ISSN22498974

Review Article
DESIGN OF PLASTIC INJECTION MOLD FOR AN
AUTOMOTIVE COMPONENT THROUGH FLOW ANALYSIS
(CAE) FOR DESIGN ENHANCEMENT
1
Jitendra Dilip Ganeshkar, 2Prof. R.B Patil, 3Swapnil S. Kulkarni
Address for Correspondence
1
ME CAD/ CAM pursuing, 2Associate Professor, Department of Mech.Engg. MGMs Jawaharlal Nehru
Engg.College, Aurangabad-431003 Maharashtra 3Director-Able Technologies India Pvt. Ltd., Pune
ABSTRACT:
While molding is a `process that would need study from this point of view, the physical Mold would need orientation from
the Designers perspective. The type of Mold to be designed, the dimensions/ specs for each of the element in the Mold, the
location of the gate, etc are considerations that a Design Engineer could offer more convincingly. The effort of this thesis
work is to identify the nuances in the Design of the Plastic Injection Mold while borrowing the inputs from the `Flow
Analysis conducted for the component to study the behavior of the Melt during processing. The Mold Design would
incorporate suitable checks for ensuring the best quality product in terms of `defect-free output.
INTRODUCTION position of spiral cooling channel in a plastic
The molding may cause defects and its processing injection mold that yields the maximum effect on the
offers a challenge during its development phase. The ratio of product cooling rates and coolant pumping
cost of the mold is high and any process that is not energy (CR/PE). Step by step optimization using
optimized renders heavy overheads during its CR/PE parameter on the simulation results by
development cycle and production. So designing the considering uniformity of product temperature during
mold which ensures best suitability for the features cooling.
on the component with smooth flow of molten plastic 3. R. Dubay, B. Pramujati and J. Hernandez
is very important part of development process. A new approach for controlling part cooling in plastic
The successful launch of any plastic product depends injection molding is developed using a Plastic
on knowing the true costs and profitability before the Injection controller and coolant flowrate as the
job is started. Injection molding typically involves manipulated variable. The method uses an average
large volumes of parts. Small cost overheads per part part surface temperature within the mold as the
can be compounded to large cost differences over the setpoint parameter. A mechatronic system was
life span of the part. Major cost components developed for providing variable coolant flowrates.
considered here are material, re-grind and machine 4. E. ONeill, C. Wilson and D. Brown
costs. Scrap, rejections and regrind costs are also This paper seeks to outline the benefits of the solid
accounted in the cost. model within the injection molding industry in
Simplified design greater detail. Solid modeling used as a fundamental
The problems which may occur in the development tool for communicating geometric information. Solid
phase of the product are solved in the design phase modeling has become a core communication of
itself. So the rework and modification of mold is concurrent engineering. The major benefit of CAE
avoided by minimizing the wastages and scrap. tools is reduced time to market. The reduced design
Design can also be simplified by using standardized time is an outcome which is a more important benefit
parts of the mold such as ejector pins. By eliminating of CAE is higher product quality.
the obstruction to smooth flow of plastic a good of 5. M. Dastagiri, and M. M. Annamacahrya
quality component can be achieved. Present work attempts applying the axiomatic design
To insure final quality of a product, it is necessary to & its software Accelero DFSSV5 to process design
start out with quality components. Injection molded of the component in injection molding process. By
parts can be molded to a high quality standard by this the number of process design iterations are
focusing on these areas of plastic technology: reduced in design aspect as well as manufacturing
1) Correct part design aspects. The accurate warpage in the model predicted
2) Proper selection of material using Moldflow Plastic Insight (MPI) 5.0 software.
3) Plastic processing 6. C. H. Lu and C. C. Tsai
Product designer may create quality molded parts, This paper develops a multivariable self-tuning
which will maximize performance and cost control method to improve performance of a
effectiveness, only by using capabilities from above temperature control system for an extruder barrel in
three areas of plastic technology. the plastic injection molding process. Computer
LITERATURE REVIEW simulation and experimental results are illustrated to
1. C. T. Wong, S. Sulaiman, N. Ismail and A.M.S. show the feasibility and effectiveness of the proposed
Hamouda method.
This paper presents the design of plastic injection 7. C.G. Li and Y. Wu
mold for producing a plastic product. Before This research paper well facilitate the automation of
proceeding to injection machine and mould design, plastic injection mould cooling system design. The
this part was analyzed and simulated by using mold cooling system is one of the most important systems
flow. The analysis and simulation can define the most in a plastic injection mould. It affects the quality and
suitable injection location, material temperature and productivity of the molded part. Adhoc evolutionary
pressure for injection. The predicted weld lines and operators and parameters adapting to the
air trap were also found and analyzed. characteristics of cooling system design are devised.
2. Fauzun, M. Hamdi, A.E. Tontowi and T. Ariga An experimental system is implemented to verify the
This paper presents a formula based on simulation feasibility of the approach, and the results of case
results using fluent software to determine the size and study confirm the validity.
Int. J. Adv. Engg. Res. Studies/III/II/Jan.-March,2014/157-159
 Ganeshkar et al., International Journal of Advanced Engineering Research and Studies E-ISSN22498974
8. Z. Chun-ying and W. Li-tao
Plastic Advisor analysis method is used to optimize
the injection position and configure the process
parameters rationally so that the weld mark of bigger
wall thickness of PPR plumbing can be minimized.
The evaluation and optimization method with Plastic
Advisor analysis method in design scheme of
injection mold runner provides a reliable technical
method for improving the quality of injection mold.
9. B. Bona, L. Giacomello, C. Greco and A.
Malandra
This paper presents the application of the nonlinear
feedback linearization method to the position control
of the movable platen in a plastic injection molding
machine. The dynamic model of the platen
movement during the injection cycle presents much
different nonlinearity. Some are due to the hydraulic
subsystem while other depends on the movable platen
kinematic chain. Both were linearized according to
the theory, and the satisfactory results of many
simulated test show the applicability of these
concepts in this important industrial process.
10. R. G. W. Pye
The primary object of this text is to provide a
handbook on design for mold draftsmen and
industrial designers. In addition, the book has been
used as an introductory guide, as it progresses in
simple stages from the consideration of basic
principles and components to detailed explanations of
the more complex types of special purpose molds.
This book includes additional information on
standard parts and an enlarged section of worked
examples. The book is divided into three parts. Part 1
covers mould-making methods and other primary
considerations such as feed systems, parting surfaces
and mould cooling. Part 2 progresses to specific
designs such as splits, underfeed and hot-runner
types. The third part of the book includes chapters on
various procedures for designing an injection mold
and checking mould drawings and worked examples.
By referring to the above research papers and books
we get the information about design procedure of
injection mold for producing the plastic component
and also the related parameters like prediction of the
weight of the component, design of cooling lines,
injection location, temperature and pressure for
injection, prediction of air trap and related defects.
PRESENT THEORIES AND PRACTICES
This project requires knowledge of both plastic
injection molding and plastic injection mold design.
This can be discussed as follows.
Plastic Injection Molding:
In the plastic injection molding, granular plastic is
fed by gravity from hopper to heated barrel. As the
granules are slowly pushed forward by a screw-type
plunger, the plastic is forced into a heated chamber
called the barrel where it is melted. As the plunger
advances, the melted plastic is forced through a
nozzle that seats against the mold sprue bushing,
allowing it to enter the mold cavity through a gate
and runner system. The mold temperature is
maintained by use of cooling mechanism which is to
be designed as a part of mold design so as to solidify
the plastic as soon as the mold is filled.
The sequence of events during the injection molding
of a plastic part is called the injection molding cycle.
The cycle begins when the mold closes, followed by
the injection of the polymer into the mold cavity.
Int. J. Adv. Engg. Res. Studies/III/II/Jan.-March,2014/157-159
Once the cavity is filled, the holding pressure is
maintained to compensate for material shrinkage. In
the next step, the screw turns, feeding the next shot to
the front screw. This causes the screw to retract as the
next shot is prepared. Once the part is sufficiently
cooled, the mold opens up and the part gets ejected.
Plastic Injection Mold Design
Mold design is an integral part of producing a plastic
component by injection molding. With proper mold
design a customer can achieve adequate cycle times,
part strength, required level of surface finish and
maximum tooling life. The amount of time required
to build and rework a proper tool which may take a
year or more. Proper mold design reduces the
chances of setbacks occurring in process.
Tooling design review encompasses things such as-
Heater design
Cavity & Core layout
Venting
Balancing of runners & Gates
Parting line locking system
Proper sizing and balancing of the Manifold
Gating system locations
Materials for Cavity/Core
Slide design
Mold sized for proper machine pressure.
Material for mold and cavity
Water lines
For this thesis work, the Design would be limited to
choosing the type of Mold, its constructional features
and the generic layout of the Design
SCOPE OF WORK
To study the component design with the
prospective of a mold designer.
Generate a layout using 3D modeling tools.
Design and detailing for manufacturing the
mold.
Objective of the Project
Referring to the scope of the work the following are
the objective of the work
Understanding the component design.
Identifying the critical locations in the
component.
Suggest the modifications in the component
without affecting its functionality to simplify
the mold with smooth flow of molten plastic.
Modification in the mold design accordingly.
Manufacturing the mold as per new design.
Validation of mold by producing the plastic
component.
METHODOLOGY
The following steps are involved for achieving the
objectives of the project that can be enumerated as
Generation of 3D model of component from
2D drawing.
Study the component design with the
perspective of a Mold Designer.
(Query/ Analysis report)
Identification of the critical features that would
call for special elements while designing the
mold, such as critical dimensions, tolerances,
surface finish, abrupt changes in thickness,
undercuts.
Generation of a rough layout for the mold
design. Generate a layout using 3D modeling
 Ganeshkar et al., International Journal of Advanced Engineering Research and Studies E-ISSN22498974

tools (3D model generation by using tools like
CATIA-V5/ UG)
Design and detailing for manufacturing the
mold. (Final 3D model and 2D drawings)
Design a simplified mold as per the functional
requirements of the component.
Review and get the approval from the product
designer for changes in design.
Design validation of Mold for cycle time
optimization and required level of dimensional
accuracy, surface finish and strength.
Proposed Flow of Work and Methodology
Input data in the form of Component
without affecting the components functionality.
Flow of plastic will be observed. Dimensional
accuracy will be measured and checked with the
specified dimensions. Visual and actual inspection
will be done while attempting to identify the defects.
Further, the component will be checked for fitment in
the sub-assembly.
REFERENCES
1. C. T. Wong, Shamsuddin-Sulaiman, Napsiah Ismail &
A.M.S. Hamouda, Design and Simulation of Plastic
Injection Molding Process Pertanika J. Sci. & Techno.
Supplement (2004) [ 85-99 ]
2. Fauzun, M. Hamdi , A.E. Tontowi, T. Ariga, Formulation
of the size and position of spiral cooling channel in plastic
injection mold based on fluent simulation results. IEEE
2008 [ 1728-1733 ]
3. R. Dubay, B. Pramujati and J. Hernandez, Cavity
temperature control in plastic injection molding, IEEE
July 2005 [ 911-916 ]
4. E ONeill, C. Wilson and D. Brown, The benefits of solid
modelling in the plastics injection molding industry,
IEEE April 1997 [ 99-107 ]
5. M. Dastagiri , M. Prasad and M Annamacahrya ,
Application of Axiomatic Design in injection molding
process, IEEE 2010 [ 222-228 ]
6. Chi-Huang Lu and Ching-Chih Tsai,Multivariable Self-
Tuning Temperature Control for Plastic Injection Molding
Process, [ 702-709 ]
7. C.G. Li, Yuguang Wu,Evolutionary optimization of
plastic injection mould cooling system layout design,
IEEE 2010 [ 693-696]
8. Zhou Chun-ying, Wang Li-tao, Injection Mold Design
based on Plastic Advisor Analysis Software in Pro/E,
IEEE 2011 [ 205-208 ]
9. B. Bona, L. Giacomello, C. Greco, A. Malandra,Position
Control of a Plastic Injection Moulding via Feedback
Linearization Machine, Arizona December 1992 [ 2591-
2593 ]
10. R. G. W. Pye,Injection Mold Design an introduction and
design manual for the thermoplastic industry.

EXPERIMENTATION
The draft analysis and/or the flow analysis of the
component would provide useful inputs for
anticipating the performance of the component
during its processing phase. It is generally not
feasible to generate a soft mold for experimentation
because of high cost involved.
Experimentation of mold design will be done by
varying the parameters like type of gate, gating
system location, venting location and location of
runners and risers for producing the defect free
component. These parameters will be changed at
least in three levels and appropriate experimentation
method will be followed.
From the simulation and analysis, Moldflow
software provides sufficient information regarding its
filling time, injection pressure and pressure drop.
With these results, users can avoid the defect of the
plastic in actual injection such as sink mark,
hesitation, air traps, and overpacking. The analysis
will also help the mould designer to design a perfect
mold with minimum modifications and which will
also reduce the mold setup time. With this analysis
and simulation, it will help to reduce time and cost.
Validation
The design will be validated by producing the
component with the help of the developed mold

Int. J. Adv. Engg. Res. Studies/III/II/Jan.-March,2014/157-159