Project Report on

STRENGTH IMPROVEMENT AND

PREDICTION OF CRACK IN PLASTIC
PRODUCT

Submitted in fulfillment of the requirements for the award of degree of

BACHELOR OF TECHNOLOGY
IN
MECHANICAL ENGINEERING

Submitted By:
Ankit Kumar (13117010)
Harmanpreet Singh (13117032)
Sunandan Sharma (13117070)

Under the guidance of

Dr. KAUSHIK PAL

DEPARTMENT OF MECHANICAL AND INDUSTRIAL

ENGINEERING
INDIAN INSTITUTE OF TECHNOLOGY ROORKEE
ROORKEE-247667
 CERTIFICATE

It is certified that work contained in the project report titled STRENGTH

IMPROVEMENT AND PREDICTION OF CRACK AND IN PLASTIC
PRODUCT by Ankit kumar, Harmanpreet Singh & Sunandan Sharma is authentic record
of their project work carried out in period of April 2016 to April 2017 which they have
satisfactorily completed under my supervision and that this work has not been submitted
elsewhere for a degree.

Dr. KAUSHIK PAL

MECHANICAL AND INDUSTRIAL ENGINEERING DEPARMENT
I.I.T ROORKEE
April, 2017

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 DECLARATION

We declare that this written submission represents our ideas in our own words and where
others ideas or words have been included. We have adequately cited and referenced the
original sources. We also declared that we have adhered to all principles of academic honesty
and integrity and have not misrepresented or fabricated or falsified any data/fact/source/idea
in our submission. I understand that the violation of above will cause for disciplinary action
by 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 when needed.

ANKIT KUMAR HARMANPREET SINGH SUNANDAN SHARMA

En. No. 13117010 En. No. 13117032 En. No. 13117070

Date-_________________

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 ACKNOWLEDGEMENT

We wish to express our sincere gratitude to Dr. Kaushik Pal, Mechanical and
Industrial Engineering Department, IIT Roorkee, for his invaluable guidance, motivation,
constant inspiration and co-operation for this project work. Without his guidance and co-
operation this work would have never reached its completion.
We wish to thanks the Mechanical and Industrial Engineering Department, IIT
Roorkee for giving us opportunity to work and complete the project. We also wish to take
this opportunity to thank the faculty and staff members of the department for providing us
with whatsoever help and guidance whenever and wherever needed and desired by us.

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 ABSTRACT

In our project we are improving strength of plastic product by adding some filler
material in original material then simulating injection molding process in AUTODESK
MOLDFLOW ADVISER 2015 to ensure the feasibility of manufacturing of new material we
are proposing to improve strength. Considering various parameters like pressure drop in mold,
volumetric shrinkage, frozen layer fraction, shear stress during flow the optimum filler
percentage is defined. After analyzing injection molding process, fatigue test performed on our
product to verify the improvement in product and to predict the location of crack generation and
then design is slightly modified to increase life cycle of product. ANSYS WORKBENCH 15.0 is
used to carry out fatigue analysis. Finally our main motive in this project is to increase the
durability.

Introduction
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In our project we are improving the strength of plastic
product. We have selected shell/saddle of cycle seat for
our project. We also know that the strength of any part
depends design of part, material and it also depends on
the process that how we are fabricating that part. Cycle
seat is generally manufactured by injection molding
process and pure nylon is used to manufacture saddle. In
order to improve its strength we have introduced glass
fibers at 30, 40, and 50% by weight of our part and its
Injection molding simulation is carried out using
AUTODESK MOLDFLOW ADVISER 2015 in order to obtain
different results like volumetric shrinkage, pressure drop
in mold, frozen layer fraction, temperature variance,
shear stress generated during flow of molten
thermoplastic. Then these results are compared for
different glass fiber percentage. After comparing these
results we defined feasibility of process at corresponding
percentage of filler material. We can add any material in
our analysis but the point is feasibility, if we are unable to
manufacture that product at any composition then what
is the point to say that the strength will improve after
adding certain material.
After ensuring that the product is ready to fabricate
we then performed fatigue analysis using ANSYS
WORKBENCH 15.0. Critical locations for crack generation
are predicted from fatigue test and considering that,
design is slightly modified and then again fatigue test is
performed to ensure the improvement in life cycle of our
product.

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CYCLE SADDLE:
Cycle saddle is primary part of cycle seat which bears the whole thrust. If
we want to improve the durabiblity of seat then we have to concentrate saddle of
seat. In some cycles it is covered with foam for comfort puposes.Cycle seat is
gender specific also because the pelvis bone of male is smaller as compared to
female, so seat for female cycles are broader. But in our project we are considering
cycle seat for males.

Specifications:
for original
cycle seat saddle made up of nylon.
Cycle saddle is designed in CREO 3.0 Software.
Total part weight: 86.894 (g)
Volume: 89.6982 (cm3)

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Problem statement
Problem statement of our project is basically the
crack generation and propagation after certain time due to fatigue failure
as shown in figure below. Due to cracking near at region 1 as shown in
figure the stress then gets distributed at region 2 which futrther cause
cracking in region2 which is second most critical location for crack
propagation.

Fig: failure of cycle seat shell/saddle .

It is observed that the crack generated at location 1
is due to stress concentration. The stress concentration is
due to absence of chamfering or filleting. We have to
avoid sharp edges if we want to avoid stress
concentrations.

Injection molding process

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 Injection molding is a manufacturing process for producing parts by injecting material
into a mould cavity. Most of the thermoplastic products are fabricated using injection
molding technique.

In the process of injection molding the thermoplastic initially dried using vaccum in
order to remove moisture from raw plastic in form of beads. Then this raw material is
introduced inside injection unit of machine through hopper. Material moves in pipe of
decreasing cross section having screw rotating along its axis which moves plastic in forward
direction. Heaters are used to heat the solid plastic moving inside pipe or injection unit. Due
to decreasing cross section of pipe the plastic inside unit start melting. Some part of heat is
gained by shear heating due to forced movement by screw and remaining heat is gained from
heaters. Then molten plastic moves toward nozzle and screw then injects plastic inside mold.
Mold is divided into two parts in which one part remain fixed and second part moves on
guiding rods and clamps are used to hold two molds tightly which uses hydraulic pressure
from clamping unit . Then pushing rods also used to remove plastic part from the mold
cavity.

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Flow of project:

Improvem
ent in
Faigue design
testing

moldflow
simulation

Designin
g
original
seat

1. Designing of original seat:

seat is designed using
original dimensions of cycle seat of Xpload bike
manufactured by S.K BIKES. PRT and IGES file is
generated using CREO 3.0 software for computer aided
designing.

2. Moldflow simulation:
moldflow simulations are
performed at different conditions using AUTODESK
MOLDFLOW ADVISER 2015. This software basically
imitates the injection molding process and give various
outputs like-

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 a. Pressure drop inside mold.
b. Volumetric shrinkage of part at end of cycle
c. Shear stress warning (Quality prediction) weather
it is above recommended limit or not.
d. Frozen layer fraction at the end of filling.
e. Sink marks on part
f. Temperature variance.
g. Air traps
h. Weld lines etc.

Pressure drop:

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 The Pressure drop result uses a range of
colors to indicate the region of highest pressure drop
through to the region of lowest pressure drop. This result
indicates how much pressure is necessary to fill the
different areas of the part.
As shown in the following diagram, the color at each
place on the model represents the drop in pressure from
the injection location to that place on the model at the
moment that place was filled, that is, the pressure

required to force material to flow to that point.

The Pressure drop result is one factor that is used to
determine the Confidence of Fill result. If the pressure
drop is greater than 80 percent of the current value set
for Maximum machine injection pressure in the Analysis
Wizard Process Settings page, this causes a yellow
confidence of fill. If the pressure drop reaches 100
percent of the current Pressure Limit setting, the
Confidence of fill result for this area is red

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 If the default value of 180 MPa for the Maximum
Injection Pressure Limit is higher than the actual molding
machine capacity, the Confidence of fill result will be
better than is actually expected.
NOTE: A high pressure drop can also indicate hesitation
or some other difficulty in filling a particular area of the
part. The following options are available to improve the
result:
1. Increase the maximum injection pressure to improve
the Confidence of fill.
2. Move the polymer injection locations closer to the
problem area or add additional injection points to
improve the likelihood of all sections of a part filling.
3. Alter the part geometry; complex and thin geometry
can cause filling difficulties that require high injection
pressure to complete the filling.
4. Select a different material with a higher melt flow
rate so that less injection pressure is required to fill
the part.
5. Increase the melt temperature to reduce the
viscosity of the melt and enable the melt to flow into
the mold more easily.
NOTE: Confidence of fill is determined by both
pressure drop and melt temperature. You may need to
adjust both processing conditions before an acceptable
Confidence of fill result is obtained.

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 Volumetric shrinkage:
The Volumetric shrinkage at ejection result
shows the volumetric shrinkage for each area expressed as a
percent of the original modeled volume. Volumetric shrinkage at
ejection is the decrease in local volume from the end of the
cooling stage to when the part has cooled to the ambient
reference temperature (the default value is 25C/77F).

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NOTE: The packing phase includes both packing time and cooling
(holding) time.

When viewing the volumetric shrinkage at ejection result, watch

for the following:

Localized areas of high shrinkage can result in internal voids

or sink marks when the part cools.

Shrinkage values should be uniform throughout the part.

This is important for good packing of the material, ensuring
good structural and visual integrity of the part. Use a
packing profile to make the shrinkage more uniform.

Negative volumetric values indicate expansion rather than

shrinkage. Avoid negative shrinkage on ribs because this can
cause ejection problems.

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 Check that values are in the expected range for the material,
noting the following

Materials that shrink isotropically have a linear shrinkage

that is approximately one third of the volumetric shrinkage.
For molded materials, the linear shrinkages in the thickness,
flow, and transverse directions depend on the effects of
relaxation and orientation.

For shell-like geometries, the shrinkage in the thickness

direction should be higher than the shrinkage in the plane of
the part. Shrinkage in the thickness direction is likely to be
greater than one third of the volumetric shrinkage, and in-
plane shrinkage should be less than one third of the
volumetric shrinkage. Many mold features act as constraints
on in-plane shrinkage. When fiber-filled materials are used,
the orientation of the fibers in the plane of the part will limit
shrinkage in this direction. Shrinkage in the thickness
direction is relatively unconstrained.

Quality prediction
The Quality prediction result is used to estimate the quality of the
mechanical properties and appearance of the part. This result is
derived from the pressure, temperature, and other results.

The colors displayed in the Quality prediction result indicate the

following:

1. Will have high quality.

2. May have quality problems
3. Will definitely have quality problems

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Quality prediction color code

The Quality prediction result will

not be available if there is a short
shot. Fix the cause of the short
shot before analyzing this result

Check the Confidence of fill result

to see how likely it is that the part
will fill.

All green The part quality should be acceptable.

Some The part quality may not be acceptable. As the percentage of

yellow yellow increases, the part quality will decrease.

Some The part quality is more likely to be unacceptable. As the

yellow and percentages of yellow and red increase, the part quality will
red decrease.

Frozen layer fraction

The Frozen layer fraction at end of fill result represents the
thickness fraction of the frozen layer at the end of filling.

It ranges from 0.0 to 1.0. A higher value indicates a thicker frozen

layer (or thinner flow layer) and higher flow resistance. A polymer
is considered frozen when the temperature falls below the
transition temperature. During filling, the frozen layer should
maintain a constant thickness for those areas with continuous
flow, because the heat loss to the mold wall is balanced by the
hot melt coming from upstream. Once the flow stops, the heat

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loss through the thickness is completely dominant in that area. A
rapid increase in the thickness of the frozen layer results.

Frozen-layer fraction has very significant effects on the flow

resistance. The viscosity exponentially increases with decreasing
temperature. The thickness of the flow layer is also reduced as
the thickness of the frozen layer increases

The fluidity is proportional to the cubic power of the part

thickness. A 50% reduction in part thickness reduces the fluidity
by a factor of eight (or increases the flow resistance by a factor of
eight). Moreover, a 50% reduction in thickness in runners reduces
the fluidity by a factor of 16. It is not surprising that excessive
high pressure is required to fill parts in which hesitation occurs
early in the filling stage. The flow layer becomes very thin in
areas of hesitation, which are filled last.

The frozen layer fraction generally will be very low near the
injection location and the end of fill. The maximum frozen layer
fraction at the end of fill should be less than 0.200.25. Higher
values will make the part difficult to pack out. Areas of the mold
that are filled early in the cycle, but have little subsequent flow,
normally have the highest frozen
layer fraction.

None of the part should have a

frozen layer fraction higher than
0.200.25 at the end of fill. A
faster injection time will reduce
the frozen layer fraction.

Sink marks on part

These sink mark results indicate
the presence and location of sink marks and voids likely to be
caused by features on the opposite face of the surface. Sink
marks typically occur in moldings with thicker sections, or at
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locations opposite ribs, bosses, or internal fillets. These results do
not indicate sink marks caused by locally thick regions.

Because sink marks are a visual defect rather than a structural

defect, the result should be evaluated against the part's visual
design specifications.

Generally, if the thickness of the rib is less than or equal to 60

percent of the main wall section, there is not likely to be any
significant sink marks.

If it is not possible to remove or reduce a sink mark, you can

conceal it. This can be done by adding a design feature, such as a
series of serrations on the area where it occurs.

The following solutions can reduce the occurrence of sink marks:

Alter the part design to avoid thick sections and reduce the
thickness of any features that intersect with the main
surface.

Relocate the gate to or near the problem areas. This enables

these sections to be packed before the thinner sections
between the gate and the problem areas freeze.

Increase the size of gates and runners to delay the gate

freeze-off time. This enables more material to be packed into
the cavity.

Decreasing the melt and mold temperature may be

sufficient. Alternatively, a less viscous melt can be used.
Temperature variance result

The Temperature variance result highlights areas where the part

geometry and the cooling system will cause the surface

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temperature to be different from the average part temperature,
which is taken at the end of the cycle.

Red indicates areas that are hotter than average and blue
indicates areas that are colder than average.

Red areas in the Cooling quality result may stem from large
variations in surface temperature. If this is the case, use the
Temperature variance result and the following suggestions to
investigate the cause.

Temperature variance significantly

negative Possible problems

Increase the thickness in the area to May cause a functional problem

reduce the rate of cooling. with the design, and may increase
the time it takes to freeze.

If the problem is caused by hesitation, May cause a functional problem

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address the causes of the hesitation. with the design.

Consider using hotter coolant in this

region when designing the mold.

Temperature variance significantly

positive Possible problems

Reduce part thickness locally. May cause a functional problem

with the design.

Consider adding more cooling

channels and/or using colder
coolant in this region when
designing the mold.

Air traps:
An air trap occurs where the melt traps and compresses a bubble
of air or gas between two or more converging flow fronts, or
between the flow front and the cavity wall. Typically, the result is
a small hole or a blemish on the surface of the part. In extreme
cases, the compression increases the temperature to a level that
causes the plastic to degrade or burn.

Air traps are often due to converging flow fronts caused by

racetrack or hesitation effects, or by non-uniform or non-linear fill
patterns. Even when the part has balanced flow paths, inadequate
venting can cause air traps to occur at the ends of flow paths.

The Air traps result shows a thin, continuous line wherever

an air trap is likely to occur. For 3D models, it displays a solid
colored area wherever an air trap is likely to occur.

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 The air trap plot is used to determine the probability of an air
trap occurring at a particular location. A higher value indicates a
higher probability that an air trap will occur, and a lower value
indicates a lower probability that an air trap will occur.

The Air traps result can reveal the following problems in your
part:

Burn marks caused by air in an air trap, which ignites under

pressure and burns the plastic

Short shots caused by the incomplete filling of the part; if an air

trap is not vented and not compressed quickly enough to cause a
burn mark, it may cause a short shot or leave bubbles of air or
gas in the plastic part.

Other surface blemishes caused by air traps.

The following methods can be used to prevent air traps:

Use flow leaders or deflectors.

Increase the injection speed to eliminate air traps caused by

converging flow fronts and hesitation.

Decrease the injection speed to reduce air traps caused by

poor venting, and to prevent burn marks.

Decrease the part wall thickness ratio to reduce

racetracking.

Move the injection locations so that the air traps form in

areas that are easy to vent, such as the parting plane.
Weld Lines

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The Weld lines result displays the angle of convergence as two
flow fronts meet. The presence of weld lines may indicate a
structural weakness and/or a surface blemish. The term weld
line is often used to mean both weld and meld lines. The only
difference between them is the angle at which they are formed.
Weld lines are formed at lower angles than meld lines. Weld lines
can cause structural problems and make the part visually
unacceptable, but they are unavoidable when the flow front splits
and comes together around a hole, or if the part has multiple
gates.

Consider the processing conditions and position of the weld lines

to determine whether the weld lines will be high quality. Weld and
meld lines should be avoided, particularly weld lines in areas that
require strength or a smooth appearance.

Processing conditions help to determine the quality of weld or

meld lines. Weld line strength is influenced by the temperature at
which the weld line is formed and the pressure exerted on the
weld until the part freezes, pressure is 0 at the weld line. Typically
a good weld will occur if the temperature of the melt at the
weld line as it forms is no more than 20C below the injection
temperature.

Weld lines can be moved by changing the fill pattern to make the
flow fronts meet at a different place. To move weld lines:

Alter the gate locations

Change the thickness of the part.

To improve the quality of weld lines:

Increase the melt temperature, injection speed, or packing

pressure. This will enable the flow fronts to weld to each
other more effectively.

Increase the diameters of gates and runners to make it

easier to pack the part.

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 Move injection locations to make weld lines form closer to
the gates. The weld line is then created with a higher flow
front temperature and is packed with more pressure.

Optimize the design of the runner system.

Reduce runner dimensions and maintain the same flow rate.

Shear heating can then be utilized to increase the melt
temperature at the flow front.

The Weld Lines result helps you identify the following problems:

Structural problems: The part may be more likely to fracture

or deform at a weld line, especially if the weld line is of a low
quality. This weakness is a more serious problem in areas of
the part that are subject to stress.

Visual defects: A weld line can cause a line, notch, or color

change on the surface of the part. If the weld line is
positioned on a non-critical part surface, such as the bottom,
this may not be a problem.

Fill Time
The Fill time result shows the position of the flow front at regular
intervals as the cavity fills. The following diagrams show the
contour colors that represent the flow of plastic into the part. All
regions with the same color are filled simultaneously. The result is
dark blue at the start of the injection, and the last areas to fill are
red.

The flow pattern is balanced in a part with a good fill time result,
which means the following:

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 1. All flow paths finish at the same time and reach the edges of
the model simultaneously. In the previous diagram, each flow
path should end with red contours.

2. The contours are evenly spaced and indicate the speed at

which the polymer is flowing. Widely-spaced contours
indicate rapid flow; narrow contours indicate that the part is
filling slowly.

Temperature at flow front result

The Temperature at flow front result, which is produced by a Fill
analysis, shows the temperature of the polymer when the flow
front reaches a specified point in the center of the plastic cross-
section. As shown in the following diagram, the Temperature at
flow front result uses a range of colors to indicate the region of
lowest temperature in blue through to the region of highest
temperature in red. The colors represent the material
temperature at each point as that point was filled. The result
shows the changes in the temperature of the flow front during
filling.

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The flow front temperature should not drop more than 2C to 5C
during the filling phase. Larger changes often indicate that the
injection time is too low, or there are areas of hesitation. If the
flow front temperature is too low in a thin area of the part,
hesitation may result in a short shot. In areas where the flow front
temperature increases by several degrees, material degradation
and surface defects may occur. Minimize the flow front
temperature variation in the filling phase to under 2-5C. Smaller
temperature variations cause fewer problems. If the Confidence of
fill result is poor, use the Temperature at flow front result to see
whether the problems are caused by low melt temperatures.

NOTE: Confidence of fill is determined by both material melt

temperature and injection pressure. It may be necessary to adjust
the processing conditions of both before an acceptable
Confidence of fill result is obtained.

Try changing the following settings to improve the result, using

the information in the table below to check whether a change has
introduced other problems.

Problem Change Possible problems

Temperature Decrease injection May cause excess shear in the gate if

too low time. it is restrictive. Too much shear will
cause degradation and surface
defects.

Increase the melt May increase cycle time.

temperature. May cause material
degradation. Keep the temperature
within the temperature limits
specified in the material
information in the database.
Increase mold May increase cycle time.
temperature.
Increase the May cause a functional problem with

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 thickness in the the design and increase cost.
area to permit flow.
Move the gate May cause hesitation or other
away from areas problems elsewhere in the part.
with hesitation.
Temperature Increase the May cause hesitation.
too high injection time.

Cooling time variance result.

The Cooling time variance result shows the difference between
the time it takes for polymer to freeze in any region of the part
and the average time it takes to freeze in the entire part.

The average time to freeze is calculated on the basis of the

surface area and the existing cooling channels. Areas that are
plotted as positive values, which appear in red, take longer to
freeze than the average time to freeze. Areas that are plotted as
negative values, which appear in blue, freeze more quickly than
the average time to freeze. Zero values in this result indicate the
average time to freeze.

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Red areas demonstrate higher temperatures than the average
part temperature, a sign indicating that the area will need more
cooling.

Taken together, the Temperature variance and Cooling time

variance results indicate places on the part that might require
redesigning, such as changing the thickness of a wall or the
inclusion of cooling devices in the mold (such as a bubbler), or
positioning cooling away from fast cooling areas.

Cycle time predictions are based on 90 percent of the part

thickness being frozen, which is the normal threshold for part
ejection. The Cooling time variance result is based on the time
required for every part of the model to freeze completely. Using
this result, you can decide whether to extend the estimated cycle
time so that critical areas of the part are properly solidified before
ejection.

There are a number of part design options available to improve

the uniformity of the part freeze time. Alterations usually have
side effects so after making changes, you should check to see if
other problems have been caused.

Cooling time variance

significantly low Possible problems

Increase thickness in the May cause a functional problem with the part.
area to increase time to
freeze.

May increase cycle time.

Increase the melt
temperature. May cause material degradation. Keep the
temperature within the temperature limits
specified for the material in the database.

Cooling time variance

significantly high Possible problems

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Decrease thickness in the May cause functional problems with the design or
area to decrease time to reduce structural strength.
freeze.

Cooling quality result

The Cooling quality result shows you where heat tends to stay in a
part due to its shape and thickness.

The part is considered to be located in the center of a block of

metal, or a theoretical mold, without any cooling circuits and held
there for a fixed period of time. The result shows the way heat will
leave the hot part naturally and flow towards the extremities of
the block.

This result is derived from the cooling time variance and

temperature variance results.

The Cooling quality result graphically depicts a part with green,

yellow, and red areas. The green areas indicate a high amount of
cooling; the yellow areas indicate a medium amount of cooling;
and the red areas indicate a low amount of cooling. This result is a
combination of the Cool analysis Temperature variance result,
which is mainly affected by shape, and Cool analysis cooling time
variance result, which is mainly affected by thickness. The
following graphic result shows that most of the part can be cooled
effectively, but there could be problems with the thin center and
the thin ribs.

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If cooling quality is low in a thin area of the part due to the
Temperature variance result or Cooling time variance result being
significantly lower than the average, hesitation or a short shot
may occur, and the result will show a red area. Thicker walls or a
higher melt temperature may be necessary.
For the same reason, the cooling quality may be low in an area
where weld lines are more obvious and the part is structurally
weaker.
In areas where the cooling quality is low due to the temperature
or cooling time variance being significantly higher than normal,
surface defects and warpage can occur unless significant cooling
is introduced to your mold design or the product redesigned.
Ensure the temperature at the flow front is always within the
recommended temperature range for the polymer you are using.
Yellow or red cooling quality results can be caused by the
following:
Cooling time variance results that are significantly shorter or
longer than the average time to freeze

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 Temperature variance result values that are too low or too
high
When a part has a yellow or red Cooling quality result, examine
the Cooling time variance and Temperature variance results to
investigate the cause.

Comparison of polymers

After comparing various thermoplastic in given diagram we have

selected Nylon (PA6) as a matrix in our simulation in consideration of its
good strength and light weight. it is also cost effective for In order to
further improve its properties we have used glass fibers as filler
materials.

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 PBT and PET are generally of high cost so nylon is giving good strength
at lower cost.
We have to select the ductile material from above diagram because
ductile material can with stand high cycles under fatigue loading.
Polypropylene is rejected due to its considerably low strength as
compared to nylon or polyamides.
SIMULATION RESULTS IN AUTODESK MOULDFLOW
ADVISOR
Material used: in original seat nylon polymer is
used but in order to improve its strength we have
added glass fibers.
glass fibers are varied according to weight %age.
At room temperature 300K
Composite Elastic Actual Tensile
modulus Strength (Mpa)
(Mpa)
Nylon pure 2280 63.3
Nylon (30% 7950 150
fibers)
Nylon (40% 9850 180
fibers)
Nylon (50% 13600 203
fibers)
Random 234483 350.15
glass fiber
equivalent

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 And other properties like thermal conductivity,
thermal expansion, viscosity are available in library
of MOLDFLOW
Cost effectiveness:
By using glass fiber as filler cost can be
reduced.
Price of Nylon = 180-200 Rs/Kg
Glass Fiber=100-120 Rs/Kg
so as we increase glass fiber percentage the
product will become cheaper and stronger.
In our mold flow simulation material is selected
initially and two results (Gate Suitability, Flow
Resistance) are evaluated by MOLDFLOW software .

Gate Suitability: According to gate suitability results blue

region is best location for placing gate.

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Flow Resistance: From this result blue region that we
obtained have least resistance to flow of fluid.

By combining the results of gate suitability and flow

resistance suitable gating location is obtained. Yellow arrow
shown in figure shown below is injection location.

By considering this injection location further analysis is performed at different:

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 Mold temperature
Melt temperature
Glass fiber weight percentage

so variation of different parameters are obtained from MOLDFLOW.

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ANSYS analysis.
Fatigue analysis is performed by varying fillet
radius at point of crack in original cycle seat

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