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1
Injection Molding
CONSEQUENCE OF IMBALANCED
RUNNER SYSTEMS
2
Injection Molding
INCOMPRESSIBLE CONTINUITY
EQUATION FOR LIQUIDS
Cartesian coordinates: x, y, z
dVx dVy dVz
+ + =0
dx dy dz
Cylindrical coordinates: r, θ, z
1 d 1 dvθ dvz
(rvr ) + + =0
r dr r dθ dz
Spherical coordinates: r, θ, φ
1 d 2 1 d 1 dvφ
2
(r vr ) + (vθ sin θ) + =0
r dr r sin θ dθ r sin θ dφ
~ · ~v = 0
All are simply ∇
3
Injection Molding
Example: use Hagen-Poiseuille Law to balance the runners
8µLQ
Hagen-Poiseuille Law: ∆P =
πR4
Suppose: RAB = RBC = RCD = RDG ≡ R
2
QBC = Q
3
1
QCD = Q
3
1
QBE = QCF = QDG = Q
6
All lengths are equal, define K ≡ 8µL/π
4
Injection Molding
Pressure drops are additive:
KQBC KQCF
∆PBF = 4
+ 4
RBC RCF
2 KQ KQ
= 4
+ 4
3 R 6RCF
1 1
First Result: ∆PBG = ∆PBF ⇒ 4
=
6RCF 2R4
R
RCF = = 0.76R
31/4
KQ
∆PBE = 4
6RBE
1 7
Second Result: ∆PBE = ∆PBG ⇒ 4
=
6RBE 6R4
R
RBE = = 0.61R
71/4
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Injection Molding
EXTREME EXAMPLE OF RUNNER
BALANCING
6
Injection Molding
CONVENTIONAL INJECTION MOLDING
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Injection Molding
INJECTION MOLDING DEFECTS
Weld lines
Figure 7: Cold flow fronts recombine to make a visible line that can be
mechanically weak.
Figure 8: Use of ribs instead of a solid section. Solid section (left) and thin
section (right). 10% shrink can be expected.
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Injection Molding
MATERIAL AND INJECTION PRESSURE
9
Injection Molding
HOT-RUNNER SYSTEMS
10