Desain Sistem Saluran

High-performance Mold

A high-performance mold harus memilliki karakteristik

yang baik dalam hal
High-performance dalam sistem pengisian

High-performance sistem packing

High-performance sistem pendinginan

Contoh Mold Casting System

Konsep Desain Sistem Saluran

Gating systemflow channel to the cavity
Effectsmooth and orderly filling of plastic fluid, fully pass
injection pressure to the various part during filling and
solidification process, get density
Classification
Common gating systemCold runner
runnerless gating systemHot runner, insulated runner

Gating System and their effects

Sprue

Runner

gate

Main
runner

Branch
runner

runner

Branch
runner
Cavity

runner system has a direct impact on the appearance, physical properties and of
dimensional accuracy and cycle time of molded product

Prinsip Desain Sistem Saluran

1. guarantee the quality of parts
(to avoid the common problem of filling)

Minimize hesitation
hesitation is easy to make overpacking on
some part of the workpiece, and underpacking

for other part

Prinsip Desain Sistem Saluran

1. guarantee the quality of parts
Gate Placed on the Thickest part of Product

From the thickest pouring provide better filling and packing effects
If there are underpacking, the thinner areas will solidify faster than thick
regions
Avoid gate on the region with sudden change of wall thickness, prevent
hysteresis or short shot
Sink
mark

Un-cure
Under
packing

gate

Sink
mark

Prinsip Desain Sistem Saluran

1. guarantee the quality of parts

Meltline

Try to avoid meltline

Meltline exists primarily affect the

appearance, making the poor surface of

product; poor Weld strength

Melt Lines

Melt from different directions, the front part of the molten resin is cooled in the
junction can not fully integrated. Under normal circumstances, affect the
appearance, impact on the coating, electroplating. Severe impact on the
product strength (especially fiber reinforced resin)

Prinsip Desain Sistem Saluran

1. guarantee the quality of parts
sink
avoid overpacking
and underpacking
overpacking
poor gating system design or improper operating conditions,
make the melt pressure in the cavity takes too long or too
high
overpacking will make the product density, to increase the
internal stress, or even flash

rib
underpacking

Prinsip Desain Sistem Saluran

1. guarantee the quality of parts
Minimize the flow disorderly

flow disorderly make poor workpiece strength and surface flow

Simple

Complex

Consider Molecules orientation

If the product is long and

narrow shape, provides a
single direction from a
unilateral into the pouring
uniform plastic flow
Although the volume
shrinkage of products at the
different ends is different,
there is no warpage
Molecular distribution in a
different direction often leads
to warping

gate

Uniform

Uneven

Uniform

Non-uniform
molecular orientation
()
and warpage
deformation and large

Uniform

Runner

()
Uniform
uniform molecular orientation and
warpage deformation
and large

Prinsip Desain Sistem Saluran

2. Minimize the cross-section and length of gating system
Minimize heat loss and pressure loss of the plastic melt
Reduce the amount of plastic and mold size

3. synchronize filling
For multi-cavity mold, make different cavity melt arrive at the same time, and
equal to the pressure at the entrance of each cavity

Filling in the Central

Gate placed in the central of the product are available for same flow
length

Long flow length will affect the required injection pressure

Central pouring makes all directions holding pressure evenly to avoid

uneven volume shrinkage

Symmetry of Gates

Symmetry gates can avoid product warpage

Asymmetric flow will lead to filling first in certain areas, even before solidification
may cause uneven product of the volume shrinkage, which will cause warpage

Sprue Design and Manufacture

EffectIs a bridge connecting the injection machine nozzle and mold, the first
part for plastic melt filling in
Design points
Sectional shape, taper, length, spherical R, fillet r

Nozzle
diameter

spheric radius

shape and size of sprue

Sprue Design and Manufacture

Sprue bushing through two plate should be a
ladder-like, or using gate sets

Runner Design and Manufacture

EffectSmooth conversion of flow and filling cavities as soon as possible

Runner section shape

Runner design points

Runner size design

Runner Road layout

Runner manufacturing points

Runner Design and Manufacture

cross-sectional shape of the flow channel will affect the volume of plastic
flow in the flow channel, and flow within the molten plastic

Runner Design and Manufacture

1. Runner section shape

Circular cross-section

AdvantageThe shape of flow channel with high efficiency, up to 0.25D

ShortcomingIncrease production costs, flow channel interleaving will
affect flow efficiency

Runner Design and Manufacture

1. Runner section shape

Rectangular cross section

The efficiency of flow channel is nearly

equal to Circular section, 27% area more
than that of Circular, increase injection
waste and demolding force

Runner Design and Manufacture

1. Runner section shape
Trapezoidal cross section

39% more area than that of circular, and more waste, while with simple
making method

Runner Design and Manufacture

1. Runner section shape

U shaped

Also known as the modified trapezoidal flow channel, combined with the round and
trapezoid advantages, 14% area more than that of circular

Runner Design and Manufacture

1. Runner section shape

Hexagonal cross-section

An area of only 82% of the

circular flow channel, but
manufacturing is not easy, and
seldom used

Runner Design and Manufacture

2. Runner design points
Volume and wall thickness of the products, the Runner section thickness is greater
than the wall thickness of the products
The fluidity of the molding resin, the resin with glass fiber and less flowability, larger
flow channel cross-section needed

Change the direction of the flow channel around the corner, should be properly set
cold slug
make the plastic parts and flow channel in the geometric center of the clamping
force, in the center of projected area

Runner Design and Manufacture

2. Runner design points
Ensure quickly and evenly filling
Runner size as short as possible, easily as small as possible
To facilitate the processing and tool selection
Each branch runner is larger than the next branch
10 ~ 20% (D = d+d 10 ~ 20%)

Runner Design and Manufacture

3. Runner size design

D>=Product most wall thickness+1.5mm

B=1.25D

Runner Design and Manufacture

3. Runner size design

Flow channel diameter is too large: not only a waste of materials, and the cooling
time increased, the molding cycle also grows, resulting in waste costs.
Flow channel diameter is too small: the flow resistance of the material, could
easily lead to the filling or injection pressure must be increased in order to fill.
Runner diameter should be suitable for the weight of the product or the projected
area

Diameter of the
flow channel(mm)

Product weight(g)

95

375

8
10

More than 375

12

Large-scale

Diameter of the
Projected area(cm2)
flow channel(mm)
4

Less than 10

200

500

10

1200

12

Large-scale

Runner Design and Manufacture

2. Runner size design
The length of the flow channel can be calculated by the following empirical
formula:
D=

DRunner diameter mm W - product weight g L - stream channel length

(mm)

Runner Design and Manufacture

4. Runner Road layout

principle of flow channel array

same distance for molten plastic from sprue to different gate

The cavity center of pressure coincide with the center of injection

molding machine
The layout of the flow channel

Natural balance

Unbalanced

Artificial balance

Natural balance

Artificial balance

Flow Balance

Naturally balanced runner system

The same distance from nozzle and to different cavity, filling all cavities in the
same time under the same pressure
Artificially balanced runner system
Resizing flow channel to complete filling of all cavities in the same time under
the same pressure

Artificially Balanced Runner System

filling order for different cavity is extremely complex, not only with the
section size and length of the Runner, and the plastic melt temperature,
pressure, viscosity, mold temperature and viscosity on pressure drop
and temperaturelowering the degree of sensitivity. Gate size of the
balance of each cavity can be fixed after the test mold or mold flow
analysis

Runner Design and Manufacture

4. Runner
Road
layout

balance of Runner arrangement

unbalance of Runner arrangement

Design and Manufacture of Gate

Design and Manufacture of Gate

1. role of gate
gateGate: a bridge connected Runner and cavity, is the weakest and

most critical part in the system

Adjust flow speed

Adjust feed time
Prevent back flow
Gate dimension often determined by experience,
take low value first, then revised by trying.
generally, the gate area size is about 3-9% of
that of runner, with short length about 1-1.5mm,
often using rectangle or round section

Design and Manufacture of Gate

Non restrict gate(sprue gate)

restrict gate(side gate, point gate, fan gate)

Melt through the narrow gate, raising speed and temperature growth, good for
filling

narrow gate first coagulation and closed cavity after Injection and packing,
which reducing the deformation and rupture of plastic parts
Narrow gate facilitate the separation flow condensate from plastic part
demolding convenient

Design and Manufacture of Gate

1.role of gate
the suitability of Gate location, number, shape, size has a direct impact on
product appearance, dimensional accuracy, physical properties and molding
efficiency
too small Gate : easily lead to the
filling (short shots), sink marks,
weld defects in appearance, and
shrinkage increases

too large Gate: excess residual

stress around gate, resulting in
deformation or rupture, and the
gate removal difficult

Dimension
reduced
too small gate

swell
too big Gate

Design and Manufacture of Gate

2. type and characteristics of gate

Direct gate(sprue gate)

Direct gate is widely used in single-cavity mold

Disadvantages: difficult removal of gate, leave

marks on surface of molding

Design and Manufacture of Gate

2. type and characteristics of gate
side gate

Generally opened in the parting surface,

suitable for multi-cavity mold, convenient
gate removal; but the pressure loss, shellshaped venting inconvenience, easy to
produce the weld.

typical size : thickness of 0.4 to 6.4mm,

width from 1.6 to 12.7mm.

Design and Manufacture of Gate

2. type and characteristics of gate
overlap gate

Overlapping gate and side gate is similar,

there is overlap between gate and the
finished wall or finished surfaces

typical gate size: thickness 0.4 to 6.4mm,

width from 1.6 to 12.7mm.

Design and Manufacture of Gate

2. type and characteristics of gate
fan gate

Typical gate size: thickness 0.25-1.6mm, width of 6.4 to 25% of the length
of the cavity sidewall.

Design and Manufacture of Gate

2. type and characteristics of gate
disk gate or dish gate

Disc gate is often used for forming the inside of the

opening of the cylinder or round products
This type of gate for concentric, demanding strict
dimension, and not allow Weld line

Typical gate thickness : 0.25 to 1.27mm

Design and Manufacture of Gate

2. type and characteristics of gate
ring gate

melt flow freely along the center part of ring

gate, and then melt down to filling the mold
Typical gate thickness: 0.25 to 1.6mm.

Design and Manufacture of Gate

2. type and characteristics of gate

spoke gate
Spoke gate, also known as 4-point gate or cross gate.
Mostly for tubular plastic products, and gate removing

easy and material saving

Disadvantages: may produce weld line , not possible to
create perfect roundness
Typical gate thickness: 0.8 to 4.8mm, width from 1.6 to
6.4mm.

Design and Manufacture of Gate

2. type and characteristics of gate
film gate
Similar to ring gate, with straight edge of the plastic parts
Applies to flat and large area, warping reducing
Typical thickness: 0.25 to 0.63mm, with short length, approximately 0.63mm

Design and Manufacture of Gate

2. type and characteristics of gate
tab gate
Normally used in tablet-shaped and thin moldings,
in order to reduce the shear stress
Gate around high shear stress is limited to
the secondary tabs, tabs will be removed
Convex tablets gate is widely applied to
the PC, SAN, and ABS resin molding

Tabs on the minimum width of 6.4mm,

the minimum thickness for 75% of the
cavity depth.

Design and Manufacture of Gate

2. type and characteristics of gate
pin point gate

Suitable for multi-cavity, three boards

and two open mold, the mold point
gate off automatically.

Small Gate with high pressure loss,

which need higher injection pressure

Design and Manufacture of Gate

2. type and characteristics of gate

Banana gate
Gate in core side, cut off during
ejection, L>L1+L2, and L1
could not too short

Design and Manufacture of Gate

Gate design principles

A good gate can make fast, uniform and better single-directional flow, and
suitable gate solidification time

To prevent the gate at the jet

phenomenon in the filling process,
the traces of the corrugated.
To prevent the approach: increase

Nonimpact
gate

Core

the gate size or impact-type gate.

impact
gate

Design and Manufacture of Gate

Gate design principles

Symmetric gate can prevent warping

Set up multiple gates to reduce the deformation

gate location good for melt flow and feeding

Not recommended

Recommend

Design and Manufacture of Gate

Gate design principles

Gate location good for venting

Gate location good for venting, which

prevent short shot, burnt, or high
pressure in the gate

Gate Location Options

Gate Location Options

Gate Location Options

Location of
the gate

Reasonable
location of the
gate

Gate location example

TUGAS (Work in Pairs)

A.
B.

Part diatas akan dibuat sand casting dari aluminum casting alloy.
Buat desain sistem saluran dengan mempertimbangkan shrinkage
dan machining. Dapat menggunakan software yang anda miliki.
Desain dibuat dengan 2 jenis pola, yaitu :
Pola 1 bagian
Pola 2 bagian (atas dan bawah)