L-9 Ultimate Guide to Runner Design for Molds | Improve Flow & Efficiency!

tell me what is this spr is spr is nothing but it is like a Tapper type thing you can say that right like this so this is nothing but this is the entry point this is the entry point for for melted plastic right for melted plastic right and here for example you have a single gravity component to your sprw will be H with the with the component right like this then this portion this portion is the waste material right which you have to cut after the after the complete process right okay so here we will deal with the multicavity which is the lecture N9 see here so uh if I'm talking about the multicavity mold design steps so basically we should understood these points okay first of all for example if we are dealing with the multi cavity what what the meaning of multi cavity tell me what is the meaning of the multi cavity more than one number more than one yes more than one or two you can say that so basically if we are dealing with the uh large component large comp number of components right so that that's that's why it is known as multicavity okay so first of all we have to decide that depending upon the component and depending upon the component and how uh what type of ejection customer need for the compon for the component right so depending upon that we have to select the mold types okay we have to select the mold type first of all though we should have a clear idea about that what type of mold we are going to design understood or not yes sir I'm I'm talking about the mold type what is the meaning of Mo type here in in first lecture or the second lecture I have introduced about the introduction of the mold right in which we I have covered the uh some types of mold like two cavity mold three three plate mold right sorry not two plate mold three plate mold a steeper plate mold like slider type of mold or lifter type of mold right we have seen that type of mold yes sir but in 2D so that's why first of all we have to understood that for example if the customer requirement customer is required uh uh manual ejection you can say that for what is the meaning of manual ejection manual e uh ejection means or you can say that uh manual ejection means you can say that for example this is the runner you have okay or just for example this is the component okay and it means component will be ejected component will be ejected from the mold with the runner or the feed system what is the meaning of that it is manual degating of the feed system with the component right or wrong so this type of component or feed system it can be prepared in two plate mode right in which in which we need we need only one parting line right or wrong in which we need only one parting line understood now for example customer need customer need autod deating so for the autod deating our component Position will be here okay so that's why this is the this is the runner again this is the runner and here this is the main Runner okay so that's why we have to attach the gate with the runner like this the basically this will this will be the one parting line this will be the second parting line right or wrong so that's why it will be open from Two Face it will be open from two surface right or wrong that's why it is known as three plate mold I hope understood if depending upon the customer right now see here for example if customer need ejection system okay so just for an example if we we we are designing very simple model to we will use the uh pin ejection right pin e we will choose the pin injection but instead of the pin injection customer says that but sir basically we need we need steeper plate injection what we what customer need they need steeper plate injection the customer don't don't want any ejector mark on the component customer don't want any ejection mark on the component for example if I'm talking about the pin ejection the pin ejection you you can say that because of the pin ejection there will be the mark in the component right inner surface of the component right yes but customer don't need that okay customer customer want that there should not be any mark on the component right so that's why we are using steeper plate depending upon the customer requirement we are using steeper plate so that's why it will become three plate three plate plus steeper plate mold right or wrong but because of this mechanism or because of this all the amendment the mold costing will be high right or wrong okay so if I'm talking about the point number one basically for for the selecting the mold or for understanding that what type of mold we are going to design for that we have to discuss with the customer is it is it clear understood so for that we should have knowledge about the component application and what the appearance needed right and what is the fitment required for the component right or no understood yes sir okay this is all about the first point okay which is very important and you should you should apply this first point for every type of component understood for every for example right now we are dealing with the multi cavity but if you have a split concept component or you have a slider concept component like external or the internal undercut or the threaded component though you have to apply this point number one for any type of component you are any type of mold you are designing for any specific component okay understood okay now first you have decided that what what is the mole type you are choosing okay second one is prepare the multi cavity layout prepare the multicavity layout now multicavity layout is depending upon the manufacturing possibility as I told you for example this is the component one here right this is the component two and three and four here right so there should be distance from one component to another component right or wrong there should be distance from one component to another distance why manufacturing possibility right now right now I'm talking about the runner for example if you are designing a runner the runner thickness is the maximum 10 diameter for any type of material you can select if you are dealing with the cold runner okay so you can select 10 mm maximum diameter for the runner is it clear so if if I assuming that 10 mm diameter Runner I'm considering here right like this okay if this is the sub runner for example this is the sub Runner so you can say that from this point to this point I can take around 20 mm right or wrong right or wrong from this point to this point I have to take 20 mm minimum right or wrong just tell me correct right and from this point to this point I have to take 20 mm only okay there is Yes again if I'm taking sub Runner here to from this point to this point again it will be 20 mm it will be 20 mm right understood so basically what what we are preparing here we are preparing multicavity layout as I told you right now what we are we are dealing with the we are dealing with the multi cavity but the cold runner and this is this is the layout for the cold runner okay cold runner for example if we are we are taking again uh three plate mod the for the three plate mod where will be the location for the getting gate Point tell me on the top right or wrong yes sir on the top right we have not covered uh gate selection and the runners runner system right now right that's why we are confusing there right we are not discussed yet about the runner design and the gate design right don't worry we will cover don't worry okay see here okay don't worry today I will not start the complete multi design right I I'm just uh I'm just explaining the steps okay see here this is the point for example for the for the three plate mode okay so this is the point for the gate so that's why your Runner will be like this this will be the runner and this will be the runner now you can say that this is this Runner is on the top plate so basically this Runner will be like it will be top play and where will be the component position component Position will be here right like here okay so you can say that from one component to another component there is a distance about 20 mm okay again from one component to another component there is a distance about 20 M right because because the runner and the component both are on different plates that's why both are on different plates that's why understood depending upon the mole type depending upon the ejection system we are H we are selecting the multi cavity layout okay right now you understood about this layout forget this okay right now you understood about this and this is the two plate two plate cold runner system right and once you select once you prepared the multi cavity layout on the software in the software okay design the core and cavity first of all and for example if you are using insert so you have to prepare the inserts core and cavity inserts right once you prepar the cor and cavity insert then you have to design the runner and the gate now again now again as I told you when we are selecting the mole type to dep when we are selecting the mole type during the selection of the mole type we have to consider consider that what type of gate we are choosing there right what type of gate we are selecting there which is also depending upon the mold type right for example if we are choosing pinpoint gate it means we are we are selecting the three plate mold right understood I hope you I hope confusing right quite confusing and one one minute okay so just just see this all the step okay Runner design and the gate design okay now again once you design the runner and the gate design you have to prepare the complete mold base and mold base is it clear once mold base designed you have to prepare the child Parts what is the meaning of child Parts tell me like locating ring locating ring is and rest button and tell me return pin tell me guide player and the guide bush these all are nothing but this is the child parts of the mold right okay okay then calculate and calculate and the design the guide play and the guide Bush then if we required air winds then we have to we have to design the air winds also into the multicavity understood you understood about the all points are quite understood right yes I don't uh I don't think that you have understood all the all the points completely right right so as I told you design mold type ejection system though once we uh discuss with the customer so it means it can be two plate mold it can be three plate mold or or for example or instead of the two two plate or the three plate customer need something different then it the customer maybe go for the hot run mod also right okay the hot runner system is other things so first of all we are dealing with the cun mold which is the two plate and three plate mold okay understood depending depending on the upon the ejection system also H mold type can be different for example uh ejection system though generally we are using pin pin pin ejection or the blade ejection okay but if we are choosing the steeper plate ejection though mold will become steeper plate mold but this is nothing but a type of mold understood now this is the flowchart or the steps which you should use or designer should use during the design first of all for example you are you are designing mold for any type of component first this is the first step which you have to take which is the Tage calculation now again tell me dep Tage calculation depending upon which thing tell me component component projected area and injection pressure Tage is nothing but it is the force depending upon the available available injection molding machine we have to verify the Tage understood and now this is the first step for for any mold design right second desde the mold type as I told you in previous slide that design decide the mold type okay again decide the ejection system depending upon the ejection system or the type of gate or type uh discussion on the customer right depending upon the disc discussion of the customer uh we have to decide the mold type what type of mold we are designing right multicavity layout if we are dealing with the multicavity we have to prepare the multicavity lay out right understood okay Runner and the gate design once the runner and gate design completed then cor and cavity extraction cor and cavity extraction then the mold based design once mold base design guide pillar and the child part design okay then the final touch to the C design Final Touch to the complete C design I hope you understood about these [Music] points this is all the basic things this is all the basic this which is which is important right this is all the steps if you if you start the design step by step there will be less chances for error understood okay so basically here we have discussed about the uh mole type the basically if we are dealing with the multicavity mode design so basically first of all we have to understood the runner and the C design right or wrong sorry Runner and the gate design right so first of all we have to understood the runner and gate Des we have covered the r road gate design or not tell me in previous lecture we have seen that no no sir right first of all we have to cover this point right see a runner design or the calculation right now tell me first of all for example this is the plastic component we have just for an example this is the plastic component we have if we are dealing with the multi cavity as I told you and if we are dealing with the multicavity that means we have to use a runner system we have to use a feed system you can say that right okay here the question is that how to decide all this thing like Runner sub Runner or the getting system right okay see here so basically there are two types of uh you can say that we can categorize the runner into two two category right Runner layout and the runner diameter and for example if we are designing the runner so we have to understood the runner layout and the runner diameter also and the for the runner diameter we have to take the calculation right see so Runner layout means this is the path what is the meaning of this is the path which path for example this is the center point right so this is the path from where material will go into the impression so this is the path okay and the what is the runner diameter it is the material flow area material flow area is it clear what is the meaning of this meaning of this that this is the this diameter right this is diameter understood yes sir okay now see here see this is the feed System complete feed system H in which you can see that here what is this this is what is this tell me SC SC what is this [Music] yes this is the sorry this is the main Runner and this is the sner right this is nothing but this is the gate which is the entry point for the material into the impression right okay what is this it is also known as cold sludge you know cold sled this is known as cold Sledge you can see that right this this one okay is it for need part this sir yeah this is very important for example for controlling the uh proper flow for example material go from this side right and uh there is no brake system for the material right so basically for the proper flowing into this from this uh from this channel so there there will be the this is the extra area so for that we material get rest for some time right for the smooth flow you can say that right okay see this is the isometric of the feed system right now again as I told you what it what is the feed system there feed system is nothing but it is the combination of ispr primary Runner and secondary Runner and the gate right now see here this is the center in center you can say that this is the sprew right and this is the primary Runner this is the secondary Runner or this will be the yet yellow portion is the gate right understood okay so this all the combination is known as feed system and for the codner system we have to design this so need to calculate in feed system if we are calculating the feed system so basically these are the point first of all we have to calculate the sprew aperture whole diameter second one is primary Runner diameter third one is secondary Runner diameter okay now okay so we have to calculate this all this right so sprw aperture hole a what is the sprw aperture hole tell me first of all for example this is the screw Bush right this is the sprew okay now this sprew has a hole like this right okay why scw has a hole like this tell me tell me for the material right this is the entry point where your machine nozzle will be placed right understood or not right yes sir H this is this so this is the machine nozle if I'm talking about that this diameter if I'm talking about this diameter this initial diameter which is the aperture hole the aperture hole is diameter diameter is depending upon the nozle diameter okay so this no nozle diameter uh can be 2. 5 di can be 3 mm D can be 3. 5 D can be 4 mm D okay so this aperture hold should be greater than this diameter right why it it should not be misaligned right for the safety purpose or nothing for the safety purpose it should not be misaligned for example right this is nothing but this is the D1 here okay though D oh no this is the D1 here right okay though D1 can be small injection for the smell injection machine like it has it has diameter about 2.

5 mm 3 mm 4 mm for the big machine it will it it can be it will be 6 mm 8 mm or the 10 mm diameter right okay what is the whole the whole diameter of the aperture what is the aperture whole diameter nozal di plus 0. 8 to 1 mm and extra we have to take understood okay as if I'm talking about screw aperture hold diameter to it is it diameter is depending upon the injection molding machine nozle okay understood now for example this is the screw we have okay here see this is the sprew here see this is the sprew now for example this is the nozle of the machine right now if I'm I'm talking about this diameter which is the D1 I'm showing the showing by the D1 is it clear so for example this is the D this is the D right so this d d is depending upon this nozle depend upon this nozle for example is nozle diameter and plus 0. 8 to 1 mm if I will replace the nozal diameter with 2.

5 so then what will be the value take the 1 3. 5 right the D will be the 3. 5 understood this is very important okay see here okay the example nozal diameter is 3 mm then the screw D equal to 3.

8 or the 4 mm you can take H now primary diameter for selecting the primary diameter we have to we have understood we have to understand this formula okay which is the t equal to w^ 0. 5 * L to^ 0. 25 / 3.

7 H where you can see that W is nothing is the mass of the component and multiply by number of cavities plus 10% for the runner uh mass of the component how we how we can uh calculate the mass of the component tell me for every component mass will be different right or wrong for every material mass will be different like for example ABS what is the density for the ABS tell me 1. 2 1. 05 for the hom yes for the vergin material right for pp9 0.

90 G per CM cube right in gam per CM cube right or wrong understood okay this is very important see here okay so depending upon the density as I told you mass will be different okay now L is nothing but it is the runner length now you understood about this as I mention you about the multi cavity layout right so Runner length is depending upon the multicavity layout for example if we are taking the four cavity component right just for example this is the four cavity component okay so as I told you for example I'm taking the runner like this so it can be about 10 mm diameter right or wrong so from this point to this point it is about 20 it is about 20 again right or wrong tell me tell me okay now for example if the component from this point to this point again it is about 20 and it is about 20 okay okay now for example component width is about to 50 mm 50 mm and again here component width will be the 50 mm okay understood T understood or not tell me 50 and again this will be the 50 then what to here you can see that this is the center Center plus 5 m you can say right so here 25 + 25 + 20 how much tell me this will be the 25 right from the center right 25 and this will be the 25 and this will be the 20 how much 70 70 70 right and from 20 and 20 this will be the 40 40 and this again will be the 40 right and I will take the cold Sledge which is about 5 mm okay 5 mm here and 5 mm here so it will become 10 mm right then what will be the length tell me what will be the L here 71 6 0 so this is nothing but this will be this will become L now as I told you to L is depending upon the multi cavity layout and what type of multicavity layout we are designing there understood why we are taking this this method because we want to we want to waste we want we don't want to waste material and we don't want to M waste plastic material that's why we are taking the minimum distance which is the manufacturing possibility that's why understood okay so it is the main Runner diameter formula by which you can decide the runner diameter understood now so where where you get that 3. 7 value uh 3. 7 is just like a constant value constant value for example uh depend you can say that depending upon the some uh research right that is that finding that the 3.

7 is the value which is used for the for equate the equation right or wrong for example like like like H2 H2 + O2 right yeah so for example we are we are making the H2 right so what we are doing this here two and this will two what we are doing this with this we are taking the extra two here and extra two here also right why for making this two right just like this this is the constant value which is depending upon the experiments you can say that right number of experiment done on the plastic material so that's why this formula will be here understood so okay so here you understood about the this that W is nothing but W is the mass of the component multiply by number of cavities right plus 10% of the runner 10% for the runner we have to take and the L is nothing but it is the runner length underst what is the 10 10% of the runner length or what oh no no 10% not length 10% 10% we have to take for the runner for example here uh mass of the component and the number of cavities if we calculated that it will become for example 50 g okay then what will be the 10% of 50 g 5 G so we can consider that 5 G we have to take we have to take for the runner system understood minimum I'm taking here understood or not this this runner system or the feed system has weight also right has weight some have weight some some weight right so we have to add the the weight of this feed system also so that's why we are taking 10% 10% of that just assuming understood here we are taking the component mass and the number of cavities but we are not taking the feed system about the feed system right or wrong for the for the feed system we have to take few percentage of that right or wrong that's why we are getting 10 percentage that's understood or not understood Okay so so here calculation calculation for example W is the mass of the component and the number of cavities plus 10% Runner right 10% for the runner you can say that right L is the runner length first of all for example we have a component material PP H now we are calculating the W here see here example PP density is 0.