INTEGRATING FLOW SIMULATION FOR INJECTION MOULDING

Injection moulding is one of the manufacturing techniques to produce mass production of engineering components made of typical polymer materials. The mould and part design of plastic parts for injection moulding is a complicated process, considerations for producing a part ranging from cost and speed of production to structural, ergonomics and aesthetic requirements. One of the routines problem faced by a designer while designing the tool for good quality parts is the process of cavity balancing. This entails controlling the plastic flow in the filling phase such that the melt front reaches the boundaries of the mould at the same time. The Plastic flow analysis is done using Mould Flow analysis software. It is necessary to provide a flow-way in injection moulding to connect the nozzle to the each impression; this flow-way is termed as feed system, normally feed system consisting of sprue, runner and gate. Gate location can have a drastic effect on a part that could result in incorrect parts. The analysis was carried out to study the location of gate which reduces filling time and flow visualization improves the part quality considering bezel part as an example, this case study is done by mouldflow analysis tool, to ensure the concepts mentioned above