KLSs

GOGTE INSTITUTE OF TECHNOLOGY

UDYAMBAG, BELGAUM

HOT RUNNER SYSTEMS

Under the Guidance of Shri. M. D. DESHPANDE Professor Department Of Mechanical Engineering, GIT.
Submitted by AKASH SHETTANNAVAR USN No: 2GI08ME006
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CONTENTS
1.

2.
3. 4. 5. 6. 7.

Introduction What does a hot runner do? Main benefits of hot runner systems Working principle Materials Merits and Demerits References

1.Introduction
A hot runner system is an assembly of heated components in plastic injection moulds that inject plastic in to the cavities of the mould. A hot runner system usually includes a heated manifold and a number of heated nozzles. Hot runners are fairly complicated systems as they have to maintain plastic material within them in molten state, while the rest of the injection mould is being cooled in order to solidify the products quickly.
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2.What does a hot runner do?

Maintains plastic material in molten state. Hot runner moulds use molten plastic and inject it in to the cavity. The ideal hot runner system delivers moulded parts of uniform density, free from runners, flash and gates. Thus has taken moulding to whole new level.

3. Main Benefits of Hot Runner System

Reduces cycle time. Eliminates the cold runner that would be scrap or require regrind. Improves part consistency and quality. Reduced gate mark. Reduces injection pressure. Sequential filling and family of parts are made possible by using valve gates. Increases process control for fine tuning mould and part.

4.Working Principle

Selecting a Hot Runner System When selecting a hot runner system, the part section wall, the part shape, and the time required for filling the part are the first considerations, and then gate selection, gate design, material and mould design. Material Category For materials with large percentages of filler (for example>15%) or very low melt flow index, the material classification moves up a grade (, i.e., easy to medium or medium to difficult) Parts with very thin wall sections or very long flow lengths need a larger than normal nozzle and gate to achieve proper filling, this may require increasing the nozzle by one or two series. Gate selection When designing an injection mould, the size and location of the gate is one of the most important considerations for correct moulding of the part. Incorrect gate position can result in uneven filling, over packing and dimensional instability. The most common gate type is direct gating, which offers the simplest construction and high reliability.
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Gate Profile Considerations The gate size ensures a good thermal gate is achieved and minimizes the pressure drop across the gate, while maintaining its structural integrity. The gate size affects the following: Flow Rate. Pressure drop through the system. Cycle Time. Thermal gate shut off after filling. Cosmetic impact of the gate on the part. Cooling in the gate area.

Gate Design Considerations

When deciding on a specific gate design, the following factors must be considered; Shot size of the part. Material to be moulded. Viscosity. Additives. Glass Fibre. Flame Retardant. Cosmetic appearance of the gate. Thickness of part walls. Longest flow length of the part. Required cycle time
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5.Materials
A.I.S.I HRC C Si Mn Cr Mo V S P APPLICATION

P-20

48-50

0.35 0.2

1.3

1.8

0.15 *

0.04

0.03

BOLSTERS, INSERTS

H11

50-52 0.36 0.9

0.3

4.5

1.1

0.25

0.03

0.03

PROBE HEAD & CAVITY INSERTS

CAVITY INSERTS

H13

50-52

0.37 0.9

0.5

4.8

1.2

0.9

0.03

0.03

HCHCr 58-60

1.8

0.2

0.1

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GUIDE PILLAR &GUIDE BUSHES

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Heat Treatment
The process is as follows Parts are warmed to 400C. It is then heated in two stages of 650C and 850C (holding time of the parts in the stages depends on the cross section). It is then heated to a hardening temperature of 1000C. It is then quenched in oil at 550C-600C.

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6.Merits

Material cost savingno runners to regrind or reprocess. Low cost least expensive for large volume production. Smaller machines reduced shot volume into runners. Automated processing- runners do not need to be separated from the parts.

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Demerits

Higher maintenance cost because susceptible to Break downs Leakages Heating element failure Wear caused by filling elements Elaborate temperature control required. Higher initial start-up costs than for cold runner systems.

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7. References

www.synventive.com www.hasco.com www.moldmasters.com Elementary Mold Design by R.J.W.Pie Spear system Hand book, Seiki Corporation, Japan. Hasco standard Hot Runner systems catalog, Hasco India Pvt Ltd,Germany.

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THANK YOU

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