OPTIMIZED DIE STRUCTURE DESIGN OF PLASTIC INJECTION MOULD USING FEM TECHNIQUE

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International Journal of Research and Innovation (IJRI)
OPTIMIZED DIE STRUCTURE DESIGN OF PLASTIC INJECTION MOULD USING FEM
TECHNIQUE

Choppara. Yasudas, D.Gopichand
Mother Theresa Institute of Technology(mist) Sanketika Nagar Sathupally Khammam,India
*Corresponding Author:
Choppara. Yasudas,
Mother Theresa Institute of Technology(mist) Sanketika Nagar
Sathupally Khammam,India
Published: Sep 22, 2014
Volume No: I
Issue No. : III
Citation:Choppara. Yasudas, D.Gopichand (2014) Optimized
Die Structure Design of Plastic Injection Mould Using
Fem Technique
Introduction
Air coolers also called evaporative coolers are used
for cooling purposes. They are different from air
conditioners in the sense air conditioners use refrig-
eration cycle principle whereas air coolers use the
evaporation of water principle. There are five main
evaporative cooler parts, with each of these being
composed of other parts or pieces.The first part is
the Blower which creates the airflow into and out
of the cooler.Then there are the pads which filter
and cool the air. These pads are attached to the side
grill; this grill is supported with side grill pillars and
Abstract
A die is a specialized tool used in manufacturing industries to cut or shape material mostly using a press. Like molds,
dies are generally customized to the item they are used to create. Products made with dies range from simple paper clips
to complex pieces used in advanced technology.
The Aim of this thesis work is to reduce weight and cost of the injection mold by removing unwanted materials and using
low cost materials at non-stress region areas.
A general large size model will be prepared to design the mold structure using theoretical method.
Complete level of mold parts and assembly will be prepared to conduct analysis.
Structural analysis will be conducted on mould to find stress locations and non-effective locations.
Modifications will be done on mold according to obtained results.
Analysis will be carried out on modified mold for evaluation and various materials will be applied in ANSYS at non-
stress effected areas to reduce the cost.
Conclusion will be made from the obtained results along with comparison table’s / charts.
Problem Description for Cooler Tank Die and Methodology
Mound tool is the major segment in plastic component manufacturing. The product cost and quality component by de-
pends on the mould structure cost and cooling quality only.
Chinese are manufacturing plastic components at very low cost by using low cost mould.
In our country we can do the same by reducing mould structure cost and, also quality of the product can be increased
by providing sufficient cooling effect.
The following process will guide to rectify the problems:
• Evaluating existing structures.
• Reducing unwanted materials by analyzing at clamping force conditions.
• Evaluating and optimizing cooling channel system to provide optimum cooling effect.
• By reducing the unwanted materials cost be reduced.
• By optimizing cooling channel system, quality will increased by doing reduction of plastic war pages and in-
creasing the surface quality of the product.
Review Article- 1401-1402
International Journal of Research and Innovation
(IJRI)

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a mounting stand for motor. And the final part is
bottom tank used to store water.
First, when the evaporative cooler is on, the pump
circulates water from the tank of the cooler to the
top. It filters down into the pads where some of it is
absorbed, but what isn’t absorbed is passed down
to the tank of the machine again where it will repeat
the cycle of being circulated again to the top. Some
of the water will be evaporated from the pads and
the circulating water will eventually be used up. So
tank acts as a water reservoir in order to keep the
pads damp if the pads ever dry out, the cooler will
not be able to cool the air.
We have taken up the parameters of an already pre-
pared air cooler and prepared a model for air cooler
tank. And that mould tool design is done based on
the model, by using CREO 2.0(PRO/ENGINEER)
software. After determining the values of the mould
tools, manufacturing drawings are prepared with
full details selecting the appropriate materials. Sub-
sequently, these mould tools are manufactured as
per drawing prepared and subjected to quality con-
trol tests.
Introduction TO CAD
Computer Aided Design (CAD) is a technique in
which man and machine are blended in to prob-
lem solving team, intimately coupling the best char-
acteristics of each. The result of this combination
works better than either man or machine would
work alone , and by using a multi discipline ap-
proach, it offers the advantages of integrated
team work.
Figure 1 Air cooler
MODEL OF AIR COOLER TANK
The above image shows sketch view

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The above image shows Model rare view
The above image shows Final model of cooler tank
2D DRAWINGS OF COOLER TANK
The above image shows 2d drafting views along with dimensions of cooler tank

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MOULD EXTRACTION
A die is usually made in two halves and when closed
it forms a cavity similar to the casting desired. One
half of the die that remains stationary is known
as cover die and the other movable half is called
“ejector die”.
The die casting method is used for castings of non-
ferrous metals of comparatively Low fusion tem-
perature. This process is cheaper and quicker than
permanent or sand mould casting. Most of the au-
tomobile parts like fuel pump, carburetor bodies,
Horn heater, wipers, brackets, steering wheels,
hubs and crank cases are made with this process.
Core: The core which is the male portion of the mold
forms the internal shape of the molding.
Cavity:The cavity which is the female portion of the
mold, gives the molding its external form.
CAVITY

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The above image shows cavity
CORE

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The above image shows core
Cavity Back Plates- Plates used as a support for the mold cavity block, core block.
DIE DESIGN

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Ejector Plate – Ejector plate is used for pushing ejector pins, retainer plate etc
Ejector Pins - Pins that are pushed into a mold cavity from the rear as the mold
opens to force the finished part out of the mold.
The above image is showing ejector plate and ejector pins
The above image is showing ejector pin

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Retainer Plate - The plate on which demountable pieces, such as mold cavities,
ejector pins, retainer pins are mounted during molding.
Retainer Pins – Retainer pins are used to push the retainer plate
The above image is showing retainer pin

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Guide Bush Guide Pillar
The above image is showing guide bush and guide pillar
Guide Sleeves
The above image is showing guide bush and guide pillar
2D drawings
The above image is showing cavity back plate and retaining plate

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DIE ASSEMBLY
The above image is showing die assembly

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INTRODUCTION TO ANSYS
ANSYS is general-purpose finite element analysis
(FEA) software package. Finite Element Analysis
is a numerical method of deconstructing a complex
system into very small pieces (of user-designated
size) called elements. The software implements
equations that govern the behaviour of these ele-
ments and solves them all; creating a comprehen-
sive explanation of how the system acts as a whole.
These results then can be presented in tabulated,
or graphical forms. This type of analysis is typically
used for the design and optimization of a system far
too complex to analyze by hand. Systems that may
fit into this category are too complex due to their
geometry, scale, or governing equations.
ANSYS is the standard FEA teaching tool within
the Mechanical Engineering Department at many
colleges. ANSYS is also used in Civil and Electrical
Engineering, as well as the Physics and Chemistry
departments.
MATERIAL PROPERTIES AND BOUNDARY CON-
DITIONS
MATERIAL: EN 38
Material Properties: Youngs Modulus (EX) :
20900N/mm2
Poissons Ratio (PRXY) : 0.27
Density
:0.000007876kg/mm3
Hardness, Brinell 179 - 235
Hardness, Knoop 229
Hardness, Rockwell B 93
Hardness, Rockwell C 15
Hardness, Vickers 217
Bulk Modulus 140 GPa 20300 ksi
Typical for steel
Machinability 55 %
Shear Modulus 80.0 GPa
Carbon, C 0.32 - 0.38 %
Iron, Fe 97.15 - 98.08 %
Manganese, Mn 1.45 - 2.05 %
Phosphorous, P <= 0.035 %
Silicon, Si 0.15 - 0.35 %
Sulfur, S <= 0.040 %
MILD STEEL (MS)
Physical Properties Metric
Density 7.87 g/cc
Mechanical Properties Metric
Hardness, Brinell 126
Hardness, Knoop 145
Hardness, Rockwell B
Hardness, Vickers 131
Tensile Strength, Ultimate 440 MPa
Tensile Strength, Yield 370 MPa
Elongation at Break 15 % 15 %
Reduction of Area 40 %
Modulus of Elasticity 205 GPa
Bulk Modulus 140 GPa
Poissons Ratio 0.29
Machinability 70 %
Shear Modulus 80.0 GPa
Thermal Properties Metric
Specific Heat Capacity 0.486 J/g-°C
Thermal Conductivity 51.9 W/m-K
Component Elements Properties Metric
Carbon, C 0.14 - 0.20 %
Iron, Fe 98.81 - 99.26 %
Manganese, Mn 0.60 - 0.90 %
Phosphorous, P <= 0.040 %
Sulfur, S <= 0.050 %
c22 material properties
Density 8.22 g/cc
Tensile Strength, Ultimate 765 MPa
Tensile Strength, Yield 380 MPa@Strain
0.200 %
Modulus of Elasticity 139 GPa
Boron, B <= 0.0080 %
Carbon, C 0.10 %
Chromium, Cr 22 %
Cobalt, Co 1.5 %
Iron, Fe 18 %
Manganese, Mn <= 1.0 %
Molybdenum, Mo 9.0 %
Nickel, Ni 47 %
Silicon, Si <= 1.0 %
Tungsten, W 0.60 %
OHNS
Oil Hardened Non-shrinking Steel
Density 7.83 g/cc
Modulus of Elasticity214 GPa
Component Elements Properties Metric
Carbon, C 0.94 %
Chromium, Cr 0.50 %
Iron, Fe 96.56 %
Manganese, Mn 1.2 %
Silicon, Si 0.30 %
Tungsten, W 0.50 %
CONSTRAINED AT BOTTOM
FORCE ON TOP 741.255 TONS

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STRUCTURAL ANALYSIS OF STANDARD MOULD
The above image is the imported model of composite shaft. Modeling was done in Pro-E
and imported with the help of IGES (Initial Graphical Exchanging Specification).
Meshed Model
The above image showing the meshed modal. Default solid Brick element was used to
mesh the components. The shown mesh method was called Tetra Hydra Mesh.
Meshing is used to deconstruct complex problem into number of small problems based
on finite element method.

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The above image is showing the loads applied on a mold
The above image shows the displacement, value is 0.007979mm

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The above image shows the stress, value is 5.61561N/mm2
Structural Analysis of Reduced Thickness

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Structural Analysis of Reduced Thickness Two

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Thermal Analysis For Standard Mould
The above image is the imported model of composite shaft. Modeling was done in Pro-E
and imported with the help of IGES (Initial Graphical Exchanging Specification).

18
The above image showing the meshed modal. Default solid Brick element was used to
mesh the components. The shown mesh method was called Tetra Hydra Mesh.
Meshing is used to deconstruct complex problem into number of small problems based
on finite element method.
The above image shows the melted material temperatureThe above image shows the melted material temperature

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The above image shows the cooling channel temperature
The above images shows the contact area with air

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Results
The above image shows the nodal temperature
The above image shows the thermal gradient

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The above image shows the Thermal flux
Thermal Analysis For Modified Cooling ChannelThermal Analysis For Modified Cooling Channel
Nodal temperature
The above image shows the nodal temperature

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The above image shows the thermal gradient
The above image shows the Thermal flux

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MANUFACTURING PROCESS
By designed the mould tool for air cooler
tank, with the parameters now we can manufacture
the air cooler tank according to the dimensions. The
flow chart of the manufacturing process of the air
cooler tank is given below.
Raw material
Hot die steels are most commonly used mould tool
materials. they have Excellent toughness, ductility
and harden ability .Used for vary large dies espe-
cially in thickness greater than 200mm .Also used
for hot and warm forging and in extrusion tooling
such as intricate dies and also dummy block ,lin-
ers, etc.
Surface grinding
After selecting raw material surface grinding is
done, Surface Grinding is a widely used process of
machining in which a spinning wheel covered in
rough particles cuts chips of metallic or non metal-
lic substance making them flat or smooth.
Heat treatment
To increase the strength of the material it is heat
treated. Heat treatment is an important operation
in the manufacturing process of machine parts and
tools. Heat Treatment is the controlled heating and
cooling of metals to alter their physical and me-
chanical properties without changing the product
shape.
Heat Treatment is often associated with increasing
the strength of material, but it can also be used to
alter certain manufacturability objectives such as
improve machining, improve formability, restore
ductility after a cold working operation. Thus it is
a very enabling manufacturing process that can
not only help other manufacturing process, but can
also improve product performance by increasing
strength or other desirable characteristics.
CNC machining
In modern CNC systems, end-to-end component
design is highly automated using CAD/CAM pro-
grams. The programs produce a computer file that
is interpreted to extract the commands needed to
operate a particular machine, and then loaded into
the CNC machines for production. Since any par-
ticular component might require the use of a num-
ber of different tools - drills, saws, etc. - modern
machines often combine multiple tools into a sin-
gle "cell". In other cases, a number of different ma-
chines are used with an external controller and hu-
man or robotic operators that move the component
from machine to machine. In either case the com-
plex series of steps needed to produce any part is
highly automated and produces a part that closely
matches the original CAD design. After undergoing
CNC machining process the mold tool i.e. core and
cavity are shown in following figures.
Cavity

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Core
Air cooler tank

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MANUFACTURING PROCESS
CORE ROUGHING
CUTTING TOOL
PLAY PATH
VERICUT
ROUGHING PROGRAM
%G71 O0001
N0010T1M06
S5000M03
G00X10.Y-10.
G43Z0.H01

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ROUGHING PROGRAM
G71
O0001
N0010T1M06
S5000M03
G00X111.616Y-139.396
G43Z0.H01
G01X111.854Y-140.92Z-1.753F200.
X112.545Y-142.3Z-2.34
X113.625Y-143.402Z-2.684
X114.989Y-144.124Z-2.874
X116.508Y-144.395Z-2.94
X116.616Y-144.396
G03X116.616Y-144.396I0.J5.
G02X120.025Y-146.076I0.J-4.3
G01X120.153Y-146.242
G03X123.68Y-146.474I1.865J1.433
X116.616Y-149.396I-7.064J7.078
G02X120.228Y-151.363I0.J-4.3
G01X120.353Y-151.557
G03X123.997Y-152.454I2.298J1.484
X116.616Y-154.396I-7.381J13.058
G02X120.313Y-156.501I0.J-4.3
CAVITY
ROUGHING

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Displacement in
mm
Stress In N/mm2
Standard mold 0.007979 5.61561
Reduced thickness 0.008118 5.6919
Reduced thickness
two
0.008713 10.5942
Structural analysis
Thermal gradient Thermal
flux
Nodal temperature
Standard mold 240.348 12.4981 513
Modified cooling 260.207 13.5308 513
Thermal analysis
CONCLUSION
• In this project, designed an air cooler water
tank as per the parameters; tank capacity is
15 liters, width 380mm, length 420mm, and
height 260mm.
• Core and Cavity is extracted for the tank.
• Die design is prepared for the same.
• The modeling, core-cavity extraction and die
design is done in creo 2.0.
• CNC program is generated for core and cavity
to conducting milling operation.
• Static and thermal analysis is conducted on
mould structure for weight reduction and for
optimized cooling channels.
• As per the analytical results reduction of
spacer housing thickness and reduction of core
back support is also performing well, so bet-
ter to use reduced thick 2 model for cast and
weight reduction.
• Optimized location is the better option for ther-
mal behavior because of high flux and gradient
rates.
BIBLIOGRAPHY
1) Machine design, T.V.Sundararajamoorthy
2) Machine design, R.S.Khurmi/J.K.Guptha
(S.CHAND)
3) Design data book:P.S.G.College of Technology
(Kalaikathirachchagam),
4) Www. google.com “online”
5) Design of machine element:V.B.Bandari (TATA
McGraw-hill
6) Injectionmould design: R.G.W. PYE (East-West
press Pvt. Ltd
Authors
Choppara. Yasudas
20 Year’s Teching Experience In Govt Polytechnic
College
D.Gopichand
Qualification: m.tech
Designation: assistant profressor
Experience :4 yr in teaching & 2 yr experience in
InfoTech as design engineer

OPTIMIZED DIE STRUCTURE DESIGN OF PLASTIC INJECTION MOULD USING FEM TECHNIQUE

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OPTIMIZED DIE STRUCTURE DESIGN OF PLASTIC INJECTION MOULD USING FEM TECHNIQUE