AN INDUSTRY ORIENTED MAJOR PROJECT REPORT ON

DESIGN AND ANALYSIS OF TWO WHEELER MUDGURD BY USING

INJECTION MOULDING

A Thesis Submitted To JNTUH in Partial Fulfillment of the Requirements for the Degree
Of
BACHELOR OF TECHNOLOGY
in
Mechanical Engineering
Submittedby

P.NITHIN GOUD (16E11A0317)

T.NAGA KARTHIK (16E11A03112)

D.SIDDA BASH (16E11A0331)

D.CHANTI (17E15A0305)

Under the guidance of

Dr. J.S. Soni, Asst.Professor

Department of Mechanical Engineering

BHARAT INSTITUTE OF ENGINEERING AND TECHNOLOGY
Approved by AICTE, Affiliated to JNTUH
Mangalpally (V), Ibrahimpatnam (M), R. R. Dist., Telangana – 501510.
NOVEMBER- 2019

BHARAT INSTITUTE OF ENGINEERING & TECHNOLOGY

(Accredited by NBA OF AICTE, New Delhi and Affiliated to JNTUH)

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 Sponsored by: CHINTA REDDY MADHUSUDAN REDDY EDUCATIONAL SOCIETY
Mangalpally (Village), Ibrahimpatnam (Mandal), Ranga Reddy District - 501 510
Ph :(08414) 252313,399 Fax : 08414 – 252648 E – mail : admissions@biet.ac.in

CERTIFICATE

This is to certify that the project report entitled

DESIGN AND ANALYSIS OF TWO WHEELER MUDGURD BY USING INJECTION

MOULDING

Being Submitted by
P.NITHIN GOUD (16E11A0317)

T.NAGA KARTHIK (16E11A03112)

D.SIDDA BASH (16E11A0331)

D.CHANTI (17E15A0305)

In the Partial fulfillment of requirements for the award of BACHELOROF TECHNOLOGY

to JNTU, Hyderabad. This record is a bonafide work carried out by them under Dr. J.S. Soni,guidance
and supervision. The result embodied in this project report has not been submitted to any other
university or institute for the award of any degree or diploma.

Internal Guide Head of the Department

External Examiner Principal

ACKNOWLEDGEMENT
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The satisfaction that accompanies the successful completion of the task would be put
incomplete without the mention of the people who made it possible, whose constant
guidance and encouragement crown all the efforts with success.

We avail this opportunity to express our deep sense of gratitude and hearty thanks to Sri
CH. Venugopal Reddy,secretary and correspondent of BIET, for providing congenial
atmosphere and encouragement.

We would like to thank Prof. G. KumaraswamyRao, Director, Former Director &

O.S. of DLRL Ministry of Defence, Dr. B. PrasadaRao, I.P.S.(Retd.), Director of
Training & Placements, Industry Interface, Former Principal Secretary to Govt. of
AP, DGP of ACB, Commissioner of Police, Hyderabad, and Dr. V.Rambabu ,
Principal for having provided all the facilities and support.

We would like to thank Dr. J.S. Soni, Professor & HOD(ME) M.Tech, Ph.D and
Dr.C.Jagadeeshan, Professor, Admin I/C , Mechanical Engineering for their expert
guidance and encouragement at various levels of our project.

We are thankful to our guide Dr. J.S. Soni, Professor & HOD(ME) M.Tech, Ph.D and
Project Coordinator Mr.C.Anil Kumar Reddy, Asst. Professor, MR.V.Manish
Sharam Associate professor, Academic incharge,Mr.Naveen krishna

,Associate professor,Admin Incharge, for his sustained inspiring guidance and

cooperation throughout the process of this project. His wise counsel and suggestions were
invaluable.

We express our deep sense of gratitude and thanks to all the Teaching and nonteaching
staff of our college who stood with us during the project and helped us to make it a
successful venture.

We place highest regards our parent, our friends and Well wishers who helped in
making the report of this project.

DECLARATION

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 We declare that this project is titled “STUDY OF GAS TURBINE” is genuine
project work carried out by us in BTECH MECHANICAL course of JNTUH , HYDERBAD and
this project is written submission represents our own ideas and where others' ideas or
words have been included, we have adequately cited and referenced the original sources.
We also declare that we have adhered to all principles of academic honesty and integrity
and have not misrepresented any ideas or fabricated any data in our submission. We
understand that any violation of the above will be cause for disciplinary action by the
Institute and can also evoke penal action from the sources which have thus not been
properly cited or from whom proper permission has not been taken whenneeded.

Signature of the students

Name ROLL NO
P.NITHINGOUD. (16E11A0316)
T.NAGAKARTHIK. (16E11A0312)
D.SIDDA BASHA. (16E11A0332)
D.CHANTI. (17E15A0305)

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 Abstract

molding is one of the most Important processes in the plastic Manufacturing Industry.
More than one-third of all plastic materials are injection molded, and the mold is one of
the main components in the Injection Molding process. The aim of this engineering
thesis is to show detailed steps on how to design a complete mould. The product design
for this project is “Two Wheeler front wheel mud guard.” the material of the component
is polyurethane is replaced with existing Materials available in the markets due to
improve properties to withstand defects with existing materials. Design of the product
and the mold were made by the designing software PRO-El

The design parameters are evaluate for  each element in the Mould, location of the Gate,
Runner, requirement of inserts, draft angle, shrinkage factor, and location of cooling
channels were calculated. 
The result gives confident to design Quality components, and to encounter the problems
occurring in the production of plastic components included flash, over shrinkage, air
bubbles, shot fills, war page, lines in poor positions and flow marks.

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 CHAPTER 1

INTRODUCTION OF POLYMER

1.1Polymer

A polymer (poly-, "many" + -mer, "parts") is a large molecule, or macromolecule, composed of

many repeated subunits. Because of their broad range of properties, both synthetic and natural
polymers play an essential and ubiquitous role in everyday life. Polymers range from familiar
synthetic plastics such as polystyrene to natural biopolymers such as DNA and proteins that are
fundamental to biological structure and function. Polymers, both natural and synthetic, are created
via polymerization of many small molecules, known as monomers. Their consequently large
molecular mass relative to small molecule compounds produces unique physical properties,
including toughness, visco elasticity, and a tendency to form glasses and semi crystalline
structures rather than crystal.

The term "polymer" derives from the ancient Greek word (polus, meaning "many, much") and
(meros, meaning "parts"), and refers to a molecule whose structure is composed of multiple
repeating units, from which originates a characteristic of high relative molecular mass and
attendant properties. The units composing polymers derive, actually or conceptually, from
molecules of low relative molecular mass. The term was coined in 1833 by Jöns Jacob Berzelius,
though with a definition distinct from the modern IUPAC definition. The modern concept of
polymers as covalently bonded macromolecular structures was proposed in 1920 by Hermann
Staudinger, who spent the next decade finding experimental evidence for this hypothesis.

1.1.1 Classification of polymer

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 Fig. 1.1 Classification of Polymer

1.1.2 Natural Polymer

Natural polymers are found in many forms such as horns of animals, tortoise shell, shellac
(from the lac beetle), rosin (from pine trees), asphalt, and tar from distillation of organic materials.
One of the most useful of the natural polymers was rubber, obtained from the sap of the hevea tree.
(Rubber was named by the chemist Joseph Priestley who found that a piece of solidified latex gum
was good for rubbing out pencil marks on paper. In Great Britain, erasers are still called
―rubbers.) Natural rubber had only limited use as it became brittle in the cold and melted when
warmed. In 1839, Charles Goodyear discovered, through a lucky accident, that by heating the latex
with sulfur, the properties were changed making the rubber more flexible and temperature stable.

1.1.3 Semi Synthetic Polymers

These polymers are mostly derived from naturally occurring polymers by chemical modification.
Example: Rayon and other cellulose derivatives like cellulose nitrate, cellulose acetate etc. are
semi crystalline polymers. Vulcanized rubber is also an example of semi synthetic polymers used
in making tires etc.

1.1.4 Synthetic Polymers

The polymers which are prepared in the laboratories are called synthetic polymers. These are also
called Man Made polymers.

Polyethylene, PVC, Nylon, Teflon, Bakelite, Terylene, Synthetic Rubber etc.

 Based on Structures

1.1.5 Liner Polymers

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 Fig. 1.2 Structure of Linear Polymer

Polyethylene is called a linear or straight-chain polymer because it consists of a long string of

carbon-carbon bonds. These terms are misleading because the geometry around each carbon atom
is tetrahedral and the chain is neither linear nor straight, as shown in the Fig.ure as the polymer
chain grows, it folds back on itself in a random fashion to form structures such as the one shown in
the figure. Straight chains can sometimes fold tightly enough to make crystal structures even
though the molecules are very long.

1.1.6 Branched Polymers

Fig. 1.3 Structure of Branched Polymer

Polymers with branches at irregular intervals along the polymer chain are called branched
polymers. These branches make it difficult for the polymer molecules to pack in a regular array,
and therefore make the polymer less crystalline and less dense. The amount and type of branching
also affects physical properties such as viscosity and elasticity. Branches often prevent chains from
getting close enough together for intermolecular forces to work effectively.

1.1.7 Cross Linked Polymers

Cross-linked polymers contain short side chains (Cross links) that connect different polymer
chains into polymer chains makes the polymer more elastic (they can stretch and return to their
original form.) The links can pull the chains back together when they are stretched. The
vulcanization of rubber, for example, results from the introduction of short chains of sulfur atoms

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 that link the polymer chains in natural rubber. Cross-linking also decreases the viscosity (the
resistance to flow) of polymers. In order for polymers to flow, the chains must move past each
other and cross-linking prevents this. Elastomers are elastic polymers created by limited cross-
linking. As the number of cross-links increases, however, the polymer becomes more rigid and
cannot stretch as much; the polymer will become less viscous and less elastic and might even
become brittle.

 Based on Molecular Force

1.1.8 Elastomers

An elastomer is a polymer with viscoelasticity (having both viscosity and elasticity) and very
weak inter-molecular forces, generally having low Young's modulus and high failure strain
compared with other materials. The term, which is derived from elastic polymer, is often used
interchangeably with the term rubber, although the latter is preferred when referring to
vulcanisates. Each of the monomers which link to form the polymer is usually made of carbon,
hydrogen, oxygen and/or silicon. Elastomers are amorphous polymers existing above their glass
transition temperature, so that considerable segmental motion is possible. At ambient temperatures,
rubbers are thus relatively soft (E~3MPa) and deformable. Their primary uses are for seals,
adhesives and moulded flexible parts. Application areas for different types of rubber are manifold
and cover segments as diverse as tires, shoe soles as well as dampening and insulating elements.

Example: Natural polyisoprene, Polybutadiene, Chloropene rubber, Styrene-butadiene Rubber, etc.

1.1.9 Thermoplastics

 Thermoplastic is a material, usually a plastic polymer, which becomes more soft when heated and
hard when cooled. Thermoplastic materials can be cooled and heated several times without any change
in their chemistry or mechanical properties. When Thermoplastics are heated to their melting point,
they melt to a liquid. They freeze to a glassy state when cooled below their glass
transition temperature. Thermoplastic materials are those materials that are made of polymers linked
by intermolecular interactions or Vander Waals forces, forming linear or branched structures.

Properties of thermoplastic materials are:

• It may melt before passing to a gaseous state.

• Allow plastic deformation when it is heated.

• They are soluble in certain solvents.

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 • Swell in the presence of certain solvents.

• Good resistance to creep.

Examples and applications of thermoplastic plastic materials:

• High pressure polyethylene as applied to rigid material covered with electrical machines, tubes,
etc

• Low pressure polyethylene elastic material used for insulation of electrical cables, etc.

• Polystyrene applied for electrical insulation, handles of tools...

• Polyamide used for making ropes, belts, etc...

• PVC or polyvinyl chloride for the manufacture of insulation materials, pipes, containers, etc

1.2.0 Thermosetting plastics

Thermosetting plastics are made up from long chains of molecules that are cross-linked. They have a
very rigid structure. Once heated, thermosetting plastics can be molded, shaped and pressed into
shapes. Once set they cannot be reheated since they are permanently set.
Examples of thermosetting polymers include:

 Vulcanized rubber
 Bakelite
 Polyurethane
 Epoxy resin..etc

1.1.10 Commodity Plastics

The more commonly used thermoplastic materials are known as commodity plastics as they are
traded and used in great quantities. Examples are polystyrene (PS), polyvinyl chloride (PVC),
polypropylene (PP) and polyethylene (PE). Commodity plastics are plastics that are used in high
volume and wide range of applications, such as film for packaging, photographic and magnetic
tape, clothing, beverage and trash containers and a variety of household products where
mechanical properties and service environments are not critical.

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 Table 1.1 Material Properties of Commodity Plastics:

1.2 Classification of Processing Methods

1. Primary Processing Methods:

 More importance by virtue of
 Extent of utilization for Varied applications
 Growth Potential

Ex: Injection Moulding, Extrusion, Blow Moulding, Compression / Transfer Moulding,

2. Secondary Processing Methods

 Lesser extent of utilization
 Acts as supplementary to primary operation

Ex: Roto Moulding, Thermoforming, Coating, Casting, FRP Fabrication Methods,

Calendaring, etc.

The process selection depends on several interrelated factors:

(1) Designing a part to meet performance and manufacturing requirements at the lowest cost

(2) Specifying the plastic

(3) Specifying the manufacturing process, this requires

 Designing a tool around the part

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 Putting the proper performance fabricating process around the tool
 Setting up necessary auxiliary equipment to interface with the main processing machine
 Setting up Completely integrated controls to meet the goal of zero defects

(4) Purchasing equipment and materials, and warehousing the materials.

 Parameters that help one to select the right options are:

 Setting up specific performance requirements.
 Evaluating material requirements and their processing capabilities.
 Designing parts on the basis of material and processing characteristics, considering part
complexity and size as well as a product and process cost comparison
 Designing and manufacturing tools (Moulds, Dies, etc) to permit ease of processing;
 Setting up the complete line, including auxiliary equipment.
 Testing and providing quality control, from delivery of the plastics, through production, to
the product.
 Interfacing all these parameters by using logic and experience and / or obtaining a
required update on technology.
 Processability: Processability means generally the ease or difficulty with which a plastic
can be handled during its fabrication into film, moulded products, pipe, etc. A plastic with good
Processability possesses the properties necessary to make it easy to process the plastics into desired
shapes. The main characteristics or properties which determine a plastic‘s Processability are
molecular weight, uniformity, additive type and content, and plastic feed rates.

1.2.1 Processing Methods

The type of process to be used depends on a variety of factors, including product shape and
size, type, quantity to be produced, quality and accuracy (Tolerances) required, design load
performance, cost limitation, and time schedule. Each of the processes provides different
methods to produce different products. As an example, extrusion with its many methods
produces films, pipe, sheet, profile, wire coating, etc. Almost all processing machines can
provide useful products with relative ease, and certain machines have the capability of
manufacturing products to very tight dimensions and performances. The coordination of plastic
and machine facilities these processes Depending upon the configuration of the part, economic
viability and the part tolerance, etc the process can be selected.

1.2.2 Injection moulding

In injection moulding, a plastic is heated to a molten state and then forcefully pushed through a
nozzle into a heated mould, typically made of stainless steel (though the ones used in this lab
are aluminum).2 The plastic enters the mould through the sprue, then through runners which

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distribute the molten plastic evenly to all cavities in the mould. The mould cavity is connected
to the runners via a gate. These extra pieces may be later removed, chopped up and recycled
back into the machine (called regrind). The mould is used to create the desired resulting part
shape and may consist of two or even three pieces.

Injection moulding is a manufacturing process for producing parts by injecting material into a
mould. Injection moulding can be performed with a host of materials, including metals, glasses,
elastomers, confections, and most commonly thermoplastic and thermosetting polymers. Material
for the part is fed into a heated barrel, mixed, and forced into a mould cavity, where it cools and
hardens to the configuration of the cavity. After a product is designed, usually by an industrial
designer or an engineer, moulds are made by a mould maker (or toolmaker) from metal, usually
either steel or aluminum, and precision-machined to form the features of the desired part. Injection
moulding is widely used for manufacturing a variety of parts, from the smallest components to
entire body panels of cars. Advances in 3D printing technology, using photopolymers which do not
melt during the injection moulding of some lower temperature thermoplastics, can be used for
some simple injection moulds.

Fig.
1.4 Injection Moulding Machine

With Injection Moulding, granular plastic is fed by gravity from a hopper into a heated barrel. As
the granules are slowly moved forward by a screw-type plunger, the plastic is forced into a heated
chamber, where it is melted. As the plunger advances, the melted plastic is forced through a nozzle
that rests against the mould, allowing it to enter the mould cavity through a gate and runner system.
The mould remains cold so the plastic solidifies almost as soon as the mould is filled.

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 Fig. 1.5 Working of Injection Moulding Machine

Fig. 1.6: Clamping of a Mould

The Injection Molding Process:

Injection molding is used to manufacture higher volume quantities of plastic products ranging in
size from large components to small components requiring micro-precision accuracy.
There are many types of manufacturing  methods categorized under injection molding, such as
thermoplastic injection molding, over molding, insert molding, cold runner molding and hot
runner molding.
Thermoplastic Injection Molding:

Thermoplastic injection molding uses thermoplastic polymer, meaning it changes to a liquid state
when heated. Unlike thermoset plastics that cool into permanent solid, thermoplastics can be
remitted into a liquid after cooling into a solid.

Over molding:

Over molding, or two shot molding, is a process that covers an injection mold over another
substance, such as metal, to improve the performance or durability of a product. A rubber-like
compound, called thermoplastic elastomer (TPE), is a commonly used overmold material. An
example of a TPE overmold application is the handle grips on a toothbrush.   Overmolds can also
be used to seal products with parts made from several injection molds.
Insert Molding:

Like overmolding, insert molding is an injection moldingprocess that combines two or more
components into a single finished product. Insert injection molding inserts a component into the
injection mold cavity and plastic material is filled around the insert. Inserts can add strength to a
product and eliminate the need for additional parts to reduce the product weight.

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Cold Runner Injection Molding:

Cold runner molds use a sprue to fill the runners that inject plastic resin into the mold cavity.   In 2
plate molds, the runner system and parts are attached, and an ejection system may be used to
separate the pair from the mold.The cold runner can reduce waste by recycling and regrinding the
material, but this can also increase the total cycle time. Cold runner systems can be used for a
wide variety of polymers and can allow for easy color changes.
Hot Runner Molds

Hot runner molds use a manifold to heat melted plastic resin and then send the material through a
gate to fill the mold cavity. The two main types of hot runner molds are externally heated and
internally heated.  The externally heated molds can be used with polymer that is less sensitive to
thermal variations while internally heated hot runner molds allow for better control of material
flow.
Because  hot runner molding  does not require the use of runners, potential waste material is
reduced and  the recycling and regrind and process of virgin plastic does not impact the total run
cycle time.

1.3 Types of Injection Moulding Machine

There are various type of Injection Moulding Machine available based on their function and
utilization. According to the cost of machine, their functions and size are increased. Basically three
kinds of machineries are available:

 Hand Injection Moulding M/C

 Plunger type Injection Moulding M/C
 Reciprocating Screw Type Injection Moulding M/C
1.3.1 Reciprocating Screw Type Injection Moulding Machine

The reciprocating-screw machine is the most common. This design uses the same barrel for
melting and injection of plastic. An injection moulding machine consists of two principal
components: (1) the plastic injection unit and (2) the mould clamping unit.

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 Fig. 1.7 Reciprocating Screw Type Injection Moulding Machine

The injection unit is much like an extruder. It consists of a barrel that is fed from one end by a
hopper containing a supply of plastic pellets. Inside the barrel is a screw whose operation surpasses
that of an extruder screw in the following respect: in addition to turning for mixing and heating the
polymer, it also acts as a ram which rapidly moves forward to inject molten plastic into the mould.
A nonreturnable valve mounted near the tip of the screw prevents the melt from flowing backward
along the screw threads. Later in the moulding cycle the ram retracts to its former position.
Because of its dual action, it is called a reciprocating screw, which name also identifies the
machine type. Older injection moulding machines used a simple ram (without screw flights), but
the superiority of the reciprocating screw design has led to its widespread adoption in today's
moulding plants. To summarize, the functions of the injection unit are to melt and homogenize the
polymer, and then inject it into the mould cavity.

Fig.1.8 Parts of Injection Moulding Machine

Machines are classified primarily by the type of driving systems they use: hydraulic, mechanical,
electric, or hybrid.

1.4 Process Cycle of Injection Moulding Machine:

The process cycle for injection moulding is very short, typically between 2 seconds and 2 minutes,
and consists of the following four stages:

1. Clamping- Prior to the injection of the material into the mould, the two halves of the mould must
first be securely closed by the clamping unit. Each half of the mould is attached to the injection
moulding machine and one half is allowed to slide. The hydraulically powered clamping unit
pushes the mould halves together and exerts sufficient force to keep the mould securely closed
while the material is injected. The time required to close and clamp the mould is dependent upon
the machine - larger machines (those with greater clamping forces) will require more time. This
time can be estimated from the dry cycle time of the machine

2. Injection - The raw plastic material, usually in the form of pellets, is fed into the injection
moulding machine, and advanced towards the mould by the injection unit. During this process, the

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material is melted by heat and pressure. The molten plastic is then injected into the mould very
quickly and the buildup of pressure packs and holds the material. The amount of material that is
injected is referred to as the shot. The injection time is difficult to calculate accurately due to the
complex and changing flow of the molten plastic into the mould. However, the injection time can
be estimated by the shot volume, injection pressure, and injection power.
3. Cooling - The molten plastic that is inside the mould begins to cool as soon as it makes
contact with the interior mould surfaces. As the plastic cools, it will solidify into the shape of the
desired part. However, during cooling some shrinkage of the part may occur. The packing of
material in the injection stage allows additional material to flow into the mould and reduce the
amount of visible shrinkage. The mould cannot be opened until the required cooling time has
elapsed. The cooling time can be estimated from several thermodynamic properties of the plastic
and the maximum wall thickness of the part.

Fig.1.9 Process Cycle of Injection Moulding Machine

4. Ejection - After sufficient time has passed, the cooled part may be ejected from the mould by the
ejection system, which is attached to the rear half of the mould. When the mould is opened, a
mechanism is used to push the part out of the mould. Force must be applied to eject the part
because during cooling the part shrinks and adheres to the mould. In order to facilitate the ejection
of the part, a mould release agent can be sprayed onto the surfaces of the mould cavity prior to
injection of the material. The time that is required to open the mould and eject the part can be
estimated from the dry cycle time of the machine and should include time for the part to fall free of
the mould. Once the part is ejected, the mould can be clamped shut for the next shot to be injected.
After the injection moulding cycle, some post processing is typically required. During cooling, the
material in the channels of the mould will solidify attached to the part. This excess material, along
with any flash that has occurred, must be trimmed from the part, typically by using cutters. For
some types of material, such as thermoplastics, the scrap material that results from this trimming
can be recycled by being placed into a plastic grinder, also called regrind machines or granulators,
which regrinds the scrap material into pellets. Du

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 Fig.1.10 Injection moulded part

1.5 Introduction to Mould Technology

Fig. 1.11 (a) Basic parts of a Mould

The mould or die refers to the tooling used to produce plastic parts in moulding. Traditionally
injection moulds have been expensive to manufacture and were only used in high-volume
production applications where thousands of parts were produced. Moulds are typically constructed
from hardened steel, pre-hardened steel, aluminum, and/or beryllium-copper alloy. The choice of
material to build a mould from is primarily one of economics. Steel moulds generally cost more to
construct but offer a longer lifespan that will offset the higher initial cost over a higher number of
parts made before wearing out. Pre-hardened steel moulds are less wear resistant and are primarily
used for lower volume requirements or larger components. The hardness of the pre-hardened steel
measures typically 38-45 on the Rockwell-C scale. Hardened steel moulds are heat treated after
machining, making them superior in terms of wear resistance and lifespan. Typical hardness ranges
between 50 and 60 Rockwell-C (HRC).

Mould is a hollow form or cavity into which molten plastic is forced to give the shape of the
required component. The term generally refers to the whole assembly of parts that make up the
section of the moulding equipment in which the parts are formed also called a tool or die. Moulds
separate into at least two halves (called the core and the cavity) to permit the part to be extracted;
in general the shape of a part must be such that it will not be locked into the mould. For example,
sides of objects typically cannot be parallel with the direction of draw (the direction in which the

18
core and cavity separate from each other). They are angled slightly; examination of most
household objects made from plastic will show this aspect of design, known as draft. Parts that are
"bucket-like" tend to shrink onto the core while cooling and, after the cavity is pulled away, are
typically ejected using pins. Parts can be easily welded together after moulding to allow for a
hollow part (like a water jug or doll's head) that couldn't physically be designed as one mould.
More complex parts are formed using more complex moulds, which may require moveable
sections, called slides, which are inserted into the mould to form particular features that cannot be
formed using only a core and a cavity, but are then withdrawn to allow the part to be released.
Some moulds even allow previously moulded parts to be re-inserted to allow a new plastic layer to
form around the first part. This system can allow for production of fully tyred wheels.
Traditionally, moulds have been very expensive to manufacture; therefore, they were usually only
used in mass production where thousands of parts are being produced. Moulds require:
Engineering and design, special materials, machinery and highly skilled personnel to manufacture,
assemble and test them.

Fig. 1.11 (b) Parts of a Mould

1.6 Types of Moulds

There are two major types of cold runner moulds: two plate and three plate.

1.6.1 Two plate mould

A two plate cold runner mould is the simplest type of mould. It is called a two plate mould because
there is one parting plane, and the mould splits into two halves. The runner system must be located
on this parting plane thus the part can only be gated on its perimeter.

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 Fig. 1.12 Two Plate Mould

1.6.2 Three plate mould

A three plate mould differs from a two plate in that it has two parting planes, and the mould splits
into three sections every time the part is ejected. Since the mould has two parting planes, the
runner system can be located on one, and the part on the other. Three plate moulds are used
because of their flexibility in gating location. A part can be gated virtually anywhere along its
surface.

Fig. 1.13 Three Plate Mould

1.6.3 Split Cavity Mould:

Suitable for Moulding components with all around External Undercuts.

1.7. Gate types:

As important as selecting the optimal gate size and location is the choice of the type of gate. Gate
types can be divided between manually and automatically trimmed gates. Manually trimmed gates
manually trimmed gates are those that require an operator to separate parts from runners during a
secondary operation. The reasons for using manually trimmed gates are:

20
1. The gate is too bulky to be sheared from the part as the tool is opened.
2. Some shear-sensitive materials (e.g., PVC) should not be exposed to the high shear rates
inherent to the design of automatically trimmed gates.
3. Simultaneous flow distribution across a wide front to achieve specific orientation of fibers of
molecules often precludes automatic gate trimming.
Gate types trimmed from the cavity manually include:

1. Sprue gate
2. Edge gate
3. Tab gate
4. Overlap gate
5. Fan gate
6. Film gate
7. Diaphragm gate
8. External ring
9. Spoke or multipoint gate
1.7.1 Automatically Trimmed Gates

Automatically trimmed gates incorporate features in the tool to break or shear the gate as the
molding tool is opened to eject the part. Automatically trimmed gates should be used to:

1. Avoid gate removal as a secondary operation.

2. Maintain consistent cycle times for all shots.
3. Minimize gate scars.
Gate types trimmed from the cavity automatically include:

1. Pin gate
2. Submarine (tunnel) gates
3. Hot runner gates
4. Valve gate

1.7.2 Sprue gate

Recommended for single cavity moulds or for parts requiring symmetrical filling. This type of gate
is suitable for thick sections because holding pressure is more effective. A short sprue is favored,
enabling rapid mould filling and low-pressure losses. A cold slug well should be included opposite
the gate. The disadvantage of using this type of gate is the gate mark left on the part surface after
the runner (or sprue) is trimmed off. Freeze-off is controlled by the part thickness rather than
determined the gate thickness. Typically, the part shrinkage near the sprue gate will be low;
shrinkage in the sprue gate will be high. This results in high tensile stresses near the gate.

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Dimensions:

The starting sprue diameter is controlled by the machine nozzle. The sprue diameter here must be
about 0.5 mm larger than the nozzle exit diameter. Standard sprue bushings have a taper of 2.4
degrees, opening toward the part. Therefore, the sprue length will control the diameter of the gate
where it meets the part; the diameter should be at least 1.5 mm larger than or approximately twice
the thickness of the part at that point. The junction of sprue and part should be reduced to prevent
stress cracking.

Fig. 1.14 Sprue Gate

1.7.3 Tab Gate

A tab gate is typically employed for flat and thin parts, to reduce the shear stress in the cavity. The
high shear stress generated around the gate is confined to the auxiliary tab, which is trimmed off
after moulding. A tab gate is often used for moulding.

Dimensions: The minimum tab width is 6 mm.

Fig. 1.15 Tab Gate

1.7.4 Fan Gate

A fan gate is a wide edge gate with variable thickness. This type is often used for thick sectioned
mouldings and enables slow injection without freeze-off, which is favored for low stress
mouldings or where warpage and dimensional stability are main concerns. The gate should taper in
both width and thickness, to maintain a constant cross sectional area. This will ensure that:

22
1. The melt velocity will be constant.
2. The entire width is being used for the flow.
3. The pressure is the same across the entire width.
Dimensions:

As with other manually trimmed gates, the maximum thickness should be no more than 80% of the
part thickness. The gate width varies typically from 6 mm up to 25% of the cavity length.

1.7.5 Film or Flash Gate

A film or flash gate consists of a straight runner and a gate land across either the entire length or a
portion of the cavity. It is used for long flat thin walled parts and provides even filling. Shrinkage
will be more uniform which is important especially for fiber reinforced thermoplastics and where
warpage must be kept to a minimum.

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Dimensions:

The gate size is small, typically 0.25mm to 0.5mm thick. The land area (gate length) must also be
kept small, approximately 0.5 to 1.0 mm long.

Fig. 1.16 Film Gate

1.7.6 Diaphragm Gate

A diaphragm gate is often used for gating cylindrical or round parts that have an open inside
diameter. It is used for single cavity moulds that have a small to medium internal diameter. It is
used when concentricity is important and the presence of a weld line is not acceptable.

Dimensions:

Typical gate thickness is 0.25 to 1.5 mm.

1.7.7 External Ring Gate

This gate is used for cylindrical or round parts in a multi cavity mould or when a diaphragm gate is
not practical. Material enters the external ring from one side forming a weld line on the opposite
side of the runner this weld line is not typically transferred to the part.Typical gate thickness is
0.25 to 1.5 mm

Fig. 1.17 External Ring Gate

1.7.8 Spoke Gate or Multipoint Gate

This kind of gate is used for cylindrical parts and offers easy de-gating and material savings.
Disadvantages are the possibility of weld lines and the fact that perfect roundness is unlikely.

24
Dimensions: Typical gate size ranges from 0.8 to 5 mm diameter.

1.7.9 Pin Gates

Pin gates are only feasible with a 3-plate tool because it must be ejected separately from the part in
the opposite direction .The gate must be weak enough to break off without damaging the part. This
type of gate is most suitable for use with thin sections. The design is particularly useful when
multiple gates per part are needed to assure symmetric filling or where long flow paths must be
reduced to assure packing to all areas of the part.

Dimensions:

Gate diameters for unreinforced thermoplastics range from 0.8 up to 6 mm. smaller gates may
induce high shear and thus thermal degradation. Reinforced thermoplastics require slightly larger
gates > 1 mm the maximal land length should be 1 mm. Advised gate dimensions can be found in
the table below.

Fig. 1.19 Pin Gate

1.7.10 Submarine (tunnel) Gates

A submarine gate is used in two-plate mould construction. An angled, tapered tunnel is machined
from the end of the runner to the cavity, just below the parting line. As the parts and runners are
ejected, the gate is sheared at the part. The tunnel can be located either in the moving mould half or
in the fixed half. A sub-gate is often located into the side of an ejector pin on the non-visible side
of the part when appearance is important.

Dimensions:

Typical gate sizes 0.8 mm to 1.5 mm, for glass reinforced materials sizes could be larger.

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 Fig. 1.20 Submarine Gate

A variation of the tunnel gate design is the curved tunnel gate where the tunnel is machined in the
movable mould half. This is not suitable for reinforced materials.

1.7.11 Hot Runner Gates

Hot runner gates are also known as sprue less gating. The nozzle of a runner less mould is
extended forward to the part and the material is injected through a pinpoint gate. The face of the
nozzle is part of the cavity surface; this can cause appearance problems. The nozzle diameter
should be kept as small as possible. Most suitable for thin walled parts with short cycle times, this
avoid freezing of the nozzle.

Fig. 1.21 Hot Runner Gate

1.8 Runner System

Runner systems can broadly be classified into artificially balanced runner systems, and unbalanced
runner systems. Fig.ure illustrates an example of an artificially balanced runner system. As can be
seen, the lengths of the flow paths to the various cavities is not the same, therefore the diameters of
the various runner segments need to be sized appropriately to have all the cavities fill at the same
time. An artificially balanced runner system generally has a smaller volume as compared to the
naturally balanced runner system and hence produces less scrap material. However, in practice, it
is usually very difficult to balance, especially for small parts, or when the differences in runner
lengths are large

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Fig. 1.22 Types of Runner systems

27
 Chapter: 2

Literature Review & Problem Definition

2.1 Literature Review

Literature search was carried out extensively. Large numbers of technical papers from various
journals are studied. Few of them are discussed below in brief.

Mehdi Moayyedian, Kazem Abhary, Romeo Marian in their research paper discussed
about New Design Feature of Mold in Injection Molding for Scrap Reduction. This paper presents
a new cross sectional shape of runner system in the injection molding. The aim of the new
geometry is to reduce the scrap and cycle time and also the easier ejection of runner system from
mold tools. Short shot defect in the plastic part during the injection molding process is analyzed by
Solid Works Plastic to validate the new proposed geometry. Runner system with elliptical cross
section is proposed with different ratio for two circular flat plates with thickness of 1mm. Finite
Element Method (FEM) are employed in Solid Works Plastic for simulation of injected part.
Filling time, melt temperature, mold temperature, pressure holding time, and pure cooling time are
chosen as input for the injection machine. The contribution of this study is the design of new
geometry of cold runner system for reduction in scrap and cycle time and also easier ejection of
runner system in injection molding. This study outcomes show no short shot defect with the new
geometry. Also, it was shown the significant reduction in scarp and cooling time. 25% and 2.5%
reduction in scrap and cooling time were achieved compared to round cross section, respectively.
Reduction in contact surface of runner system with mold walls improved the easier ejection of
runner system out of the cavity as well.
The main reason of scrap in cold runner system of injection molding is the feeding system
which consists of sprue, runner and gate system. Runner has different cross sections for different
applications. In this study, new geometry of runner system with elliptical cross section in
comparison with round cross section was successfully developed for injecting two circular plates
with thickness 1mm. filling time, melt temperature; mold temperature; pressure holding time and
pure cooling time are evaluated as process parameters. Elliptical cross section in comparison with
round cross section which has the highest efficiency among current geometries of cross section has
25% reduction in scrap and 2.5% in cooling time for injected parts. The result from simulation
demonstrates that the elliptical cross sectional shape of runner is an effective geometry to reduce
the scrap and total cycle time and also the easy ejection of molded part out of the cavity. It
demonstrates the robustness of new geometry of runner system. Further than our anticipation,
remarkable phenomena was detected which is related to process parameters and new geometry of
runner system that will be discussed in another paper. The experimental set up will be conducted to
justify the simulation result.[1]

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 Jitendra Dilip Ganeshkar, Prof. R.B Patil, Swapnil S. Kulkarni in their research paper
discussed about Design of ‘Plastic injection Mold’ for an automotive component through ‘Flow
analysis’ (CAE) for design Enhancement. While molding is a `process’ that would need study from
this point of view, the physical Mold would need orientation from the Designer’s 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.
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, Mold flow 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 over packing. 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 without affecting the
component’s 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.[2]

K. Giridhar Reddy, K. Rajagopal in their research paper discussed about Blow Mould
Tool Design and Manufacturing Process for 1litre Pet Bottle. The concepts of Blow molding is a
process used to produce hollow objects from thermoplastic. The basic blow molding process has
two fundamental phases. First, a parson (or a perform) of hot plastic resin in a somewhat tubular
shape is created. Second, compressed air is used to expand the hot perform and press it against
mould cavities. The pressure is held until the plastic cools. Blow molding process is used for which
has thin wall sections. In this thesis, blow mould design is to be done for a bottle having 0.5mm
thickness. This thickness cannot be filled in pressure injection molding. So blow molding is
considered for pet bottle design. The mould is prepared by first modeling the part, extracting core

29
& cavity and generating CNC program. Blow mould tool design is done in Pro/Engineer according
to HASCO standards. A prototype of the pet bottle using blow mould design is also included .
In this project a pet bottle is molded in CATIAV5. The manufacturing process for pet
bottle is stretch blow molding. In this work the total die is designed for the pet bottle under the
guidance of expert. A prototype is also prepared for the bottle and the free form. To validate the
strength of the bottle, structural analysis is done on two models of pet bottle by applying pressure
in the bottle when soft drink is taken. For the both models the analyzed stress values are less than
the permissible value. It is concluded that this design of pet bottle withstands the pressures when
soft drink is filled in the bottle. The pressure values are taken from standards of Coco – Cola
Company. I have completed blow molding die according to standards. The design is ready for
production.[3]

N. Sreenivasulu, Dr. D. Ravikanth in their research paper discussed about Injection Molding Tool
Design Manufacturing, Estimation and Comparison of L&T Power Box Side Panel Using Plastic
Materials HDPE, ABS, PP and PC. Power box is a component which is used in earth movers. It
controls the power circuit. It has top cover, front cover, back cover and side panel. The aim of the
paper is to create the L&T power box side panel by using parametric pro/E wild fire 5.0. The part
modeling, Core-cavity design, CNC manufacturing programming and Mould flow analysis i.e.
simulation to avoid potential mould-filling problems is done by pro/E wild fire 5.0. Mould base
design and Mould calculations are also done in this paper according to HASCO standards. The
material selection for mould design is taken as EN31B steel. Structural analysis is done for core
and cavity by using ANSYS software to know the pressure, displacement, stress results. Cost of
the total die assembly and cost comparison of different plastic components (HDPE, ABS, PP, and
PC) are estimated. Here the process is using in injection molding and manufacturing a variety of
parts from simple to complex components.
In this paper, power box side panel which is used in earth movers is designed. The
modeling of component, Core-Cavity design and mold flow analysis is done in Pro/Engineer wild
fire 5.0The component according to standards by providing shrinkage allowance 1.25%, draft
angle 1deg along core side and 1mm radius in all sharp corners are provided. For above designed
model, the complete mould base for side panel is design. The machine, runner design, over flow
design, cooling channel design is also selected. CNC programming is generated for core and
cavity. Cost of total die assembly and cost Comparison of power box side panel component with
different plastic materials such as (HDPE, ABS, PP, and PC) and cost per each piece are estimated.
Among these materials ABS is best material for manufacturing of injection molding die because of
the total cost of the material is less. Structural analysis on core and cavity by applying clamping
force is done. The material used is EN31B Steel. By observing the analysis results, the stress
values are obtained for both core and cavity are less than the yield stress value of EN31B. So by
using material EN31B for die can withstand the forces. This work is useful for making complete
injection mould tool design for the power box side panel.[4]

30
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 REFRENCES

[1] Mehdi Moayyedian, Kazem Abhary, Romeo Marian- New Design Feature of Mold in Injection
Molding For Scrap Reduction, 2nd International Materials, Industrial, and Manufacturing
Engineering Conference, MIMEC2015, 4-6 February 2015, Bali Indonesia.

[2] Jitendra Dilip Ganeshkar, Prof. R.B Patil, Swapnil S. Kulkarni Design of ‘Plastic Injection
Mold’ for an Automotive Component Through ‘Flow Analysis’ (CAE) for Design Enhancement,
International Journal of Advanced Engineering Research and Studies E-ISSN2249–8974.

[3] K. GiridharReddy, K. Rajagopal, Blow Mould Tool Design and Manufacturing Process for
1litre Pet Bottle, IOSR Journal of Mechanical and Civil Engineering (IOSR-JMCE)e-ISSN: 2278-
1684,p-ISSN: 2320-334X, Volume 8, Issue 1 (Jul. - Aug. 2013).

[4] N. Sreenivasulu, Dr. D. Ravikanth, Injection Moulding Tool Design Manufacturing, Estimation
and Comparison of L&T Power Box Side Panel Using Plastic Materials HDPE, ABS, PPand PC,
IOSR Journal of Mechanical and Civil Engineering (IOSR-JMCE)e-ISSN: 2278-1684,p-ISSN:
2320-334X, Volume 8, Issue 3 (Sep. - Oct. 2013).

[5] 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].
[6] R. G. W. Pye,“Injection Mold Design an introduction and design manual for the thermoplastic
industry“.
[7] 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 ]
[8] S.Rajalingam, Awang Bono and Jumat bin Sulaiman“A statistical experimental study on
shrinkage of injection-molded part” International Journal of Humanities and Management Sciences
(IJHMS) Volume 1, Issue 1, 2013 pp 2320–4044
[9] Dr.A. RiazAhamed, Dr.A.K. ShaikDawood, R.Karthikeyan“Designing and optimizing the
parameters which affect the molding process using Design of Experiment” International Journal of
Research in Mechanical Engineering Volume 1, Issue 2, October-December, 2013 pp.116-122

[10] Wen-Chin Chen a, Gong-LoungFub,c, Pei-HaoTaib, Wei-Jaw Deng d“Process parameter

optimization for MIMO plastic injection molding via soft computing”Expert Systems with
Applications vol 36, 2009 pp1114–1122
[11] Progelhof, R.C. and J.L. Throne, "Polymer Engineering Principles: Properties, Processes, and
Tests for Design", Hanser Publishers, New York, 1993.

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[12] Elias, Hans-Georg. (2003).An Introduction to Plastics. Weinheim: Wiley-VCH GmbH & Co.
KGaA.

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