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Runner Sizing
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Page 1 of 5
Introduction
Estimating cooling time and optimizing runner
geometry have significant effects on the final mold design
of an injection mold. Cooling time analysis not only helps
the designer to predict the cycle time but it also helps in
determining the number of cooling channels, flow rate of
coolant required, and the final layout of the cooling
circuit. Though the Ballman-Shusman equation is accurate
it still needs to be solved using coefficients for the thermal
and processing conditions for a given material. Hence an
easier rule that can predict the cooling time within 1020% of the exact value can be very useful for the mold
designer. The suspected origination and performance of
one commonly used rule is subsequently analyzed.
Runner size on the other hand plays a critical role not
only in the final quality of the molding but also in the
overall economics of the process. Though large size
runners ease the forward movement of melt, they also lead
to a large scrap volume which needs to be regrinded hence
increasing the overall cost of the final product. Other
disadvantages with large runners are increase in the
cooling time and clamping pressure because of large
cross-sectional and projected area respectively. Runners
can be sized with the help of software tools to minimize
the total volume. Alternatively, mold designers often use a
rule to size downstream runners based on the dimension
of the primary runner diameter. The performance of this
commonly used rule is subsequently analyzed.
tc = 2 H 2
(1)
tc =
H2
2
ln
8 TM TC
2
TE TC
(2)
tc = K t 2
where
K=
1
2
ln
8 TM
2
TE
(3)
Tm
Tm
(4)
Page 2 of 5
Primary
(6)
P =
1 + 3n
n R3
2KL n
Q
R
(7)
Page 3 of 5
Conclusion
Mold designers often use design rules for cooling
time estimation and runner sizing. The two rules have
been analyzed and found to provide a simple and often
reasonable approach for mold design. In fact, both design
rules were found to have very low expected error on
average. The term expected error is used here to
represent the average error across many different mold
design applications. While the expected error may be low,
these design rules can provide very high errors on an
application by application basis.
Specifically, the cooling times for predicted with the
cooling time rule for acetal and HDPE were near the exact
values of those predicted with the Ballman-Shuchman
equation. However, the cooling times predicted for PC
and PA6 were under predicted, while those for PS were
over predicted. For this reason, the common rule for
cooling time estimation can be quickly used for noncritical estimates, but more advanced analysis should be
used for determination of mold cavitation and cooling
system design.
Similar performance was observed between the
results predicted with the runner sizing rule and the
optimal runner designs developed with the HagenPouiselle equation. In general, the runner sizing rule
provide designs that had volumes that were just a few
percent above the optimal designs. When examining
cooling times, however, the runner sizing rule was far
from optimal. Accordingly, mold designers should
perform appropriate analysis on an application by
application basis rather than blindly following previous
practice or general design rules.
References
[1]
[2]
[3]
[4]
[5]
[6]
Page 4 of 5
[7]
[8]
[9]
[10]
6.35
5.83
5.83
8.07
5.71
5.71
ln
Polycarbonate
HDPE
Polyacetal
Polystyrene
Nylon 66
Length
L1
L2
L3
8 TM
2
TE
4.72
4.15
3.89
4.19
4.50
Tm
Tm
V1
V2
V3
V
Q
Q/2
Q/2
Constant of Proprtionality,K
Pressure
drop
P1
P2
P3
P
HDPE
Polyacetal
Polystyrene
Nylon 66
Page 5 of 5
optimised
rule
12000
volume(mm 3)
10000
8000
6000
4000
2000
0
20
40
60
80
100
120
cooling time(s)
Figure 6: Pressure dependent volume and cooling time
1.09
40
1.07
1.06
1.05
1.04
1.03
1.02
0
10
12
14
16
LPrimary/Lsecondary
Vrule / Voptimum
1.08
35
30
25
20
15
10
5
0
10
15
20
25
30
35
40
6000
t (ru le )/ t (o p tim is e d )
1.6
1.2
1
0.8
0.6
0.4
0.2
0
0
10
12
Lprimary/Lsecondry
14
16
5000
4000
3000
2000
1000
0
0
1000
2000
3000
4000
5000
6000