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