A plastic material is any of a wide range of synthetic or semi-synthetic organic solids that are moldable. Plastics are typically organic polymers of high molecular mass, but they often contain other substances. They are usually synthetic, most commonly derived from petrochemicals, but many are partially natural. Molding is the process of manufacturing by shaping liquid or pliable raw material using a rigid frame called a mold or matrix. This itself may have been made using a pattern or model of the final object. Cooling channels are used in mold tool to reduce the temperature of the object to help molten material to solidify quickly before the ejection. It is quite useful to increase the production rate.

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International Journal of Research and Innovation (IJRI)
DESIGN OF MOULD TOOL & COOLING CHANNEL OPTIMIZATION OF REMOTE
CONTROL TOP PANEL
V.Venkata Krishna Mohan, D.Gopichand
Mother Theresa Institute of Technology(mist) Sanketika Nagar Sathupally Khammam,India
*Corresponding Author:
V.Venkata Krishna Mohan,
Mother Theresa Institute of Technology(mist) Sanketika Nagar
Sathupally Khammam,India
Published: Sep 22, 2014
Volume No: I
Issue No. : III
Citation:V.Venkata Krishna Mohan, D.Gopichand (2014) DE-
SIGN OF MOULD TOOL & COOLING CHANNEL OPTIMI-
ZATION OF REMOTE CONTROL TOP PANEL
Problem Description
UN proper cooling effects on surface finish of the
component and warpage may occur, due to that
part dimensions may get deformed than generic/
modeld part.
Generally different types of cooling channels are
used in the field of plastic part manufacturing, it
directly effects on surface finish and warpage of the
component, even material properties also effect on
the same.
Methodology
The following methods are followed to rectify the
above problem
Plastic flow analysis will be done using various plas-
tic materials.
Thermal analysis will be done on different types of
cooling channel systems, to suggest the optimum to
ensure sufficient cooling and fill quality.
Introduction To Cad
Computer Aided Design (CAD) is a technique in
which problem solving will be done in the combina-
tion of man and machine for high precision work
flow.
Abstract
A plastic material is any of a wide range of synthetic or semi-synthetic organic solids that are moldable. Plastics are
typically organic polymers of high molecular mass, but they often contain other substances. They are usually synthetic,
most commonly derived from petrochemicals, but many are partially natural.
Molding is the process of manufacturing by shaping liquid or pliable raw material using a rigid frame called a mold or
matrix. This itself may have been made using a pattern or model of the final object.
Cooling channels are used in mold tool to reduce the temperature of the object to help molten material to solidify quickly
before the ejection. It is quite useful to increase the production rate.
The aim of this project work is to design mold structure and optimize cooling channel system to reduce effect of warpage
of remote control top panel.
Literature survey and data collection will be done to understand working process of cooling channels, effects of warpage
on plastic part’s, mold optimization.
3D model of remote control top panel will be prepared and die design calculations will be done to model the entire mold
step.
Assembly of complete mold will be prepared for further process.
Analysis will be carried out on mold cooling channel’s for evaluation and Analysis will be done on different model’s to
obtain optimum structure and cooling channel system.
Conclusion will be mode according to the obtained results
Peer Review- 1401-1402
International Journal of Research and Innovation
(IJRI)

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International Journal of Research and Innovation (IJRI)
Computer Aided Design is an interactive process,
where the exchange of information between the
designer and the computer is made as simple and
effective as possible. Computer aided design en-
compasses a wide variety of computer based meth-
odologies and tools for engineering activity plan-
ning, analysis, detailing, drafting, construction,
manufacturing, monitoring, management, process
control and maintenance. CAD is more concerned
with the use of computer-based tools to support the
entire life cycle of engineering system.
Introduction To Creo Parametric 2.0 (Creo 2.0)
CREO PARAMETRIC is one of the most popular PLM
software founded by Parametric Technology Corpo-
ration which consists of CAD/CAM/CAE. So that
designer can easily check their part/product design
compatibility with FEM and CAM segments and
also they can check plastic flow for injection mold-
ings parts to reduce production/component errors.
CREO PARAMETRIC is completely feature based
modeling tool with ribbon mode which is very easy
to understand by the users.
Summary of capabilities
Like any software it is continually being developed
to include new functionality. The details below aim
to outline the scope of capabilities to give an over-
view rather than giving specific details on the indi-
vidual functionality of the product.
Engineering Design
Creo parametric 2.0 offers a range of tools to enable
the generation of a complete digital representation
of the product being designed. In addition to the
general geometry tools there is also the ability to
generate geometry of other integrated design disci-
plines such as industrial and standard pipe work
and complete wiring definitions. Tools are also
available to support collaborative development.
A number of concept design tools that provide up-
front Industrial Design concepts can then be used
in the downstream process of engineering the prod-
uct. These range from conceptual Industrial design
sketches, reverse engineering with point cloud data
and comprehensive freeform surface tools.
Manufacturing
By using the fundamental abilities of the software
with regards to the single data source principle, it
provides a rich set of tools in the manufacturing en-
vironment in the form of tooling design and simu-
lated CNC machining and output.
Tooling options cover specialty tools for molding,
die-casting and progressive tooling design.
Modeling of remote
The above image shows the 2d sketch of remote using trimmed circles and arcs

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International Journal of Research and Innovation (IJRI)
The above image shows the fillets using round option
The above image shows the completed image of remote
The above image shows 2d drafting of remote

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International Journal of Research and Innovation (IJRI)
Injection Moulding
In manufacturing processes Injection moulding
plays a crucial role for producing plastic compo-
nents by using thermo plastic and thermo setting.
After completion of product design as per client re-
quirement done by an engineer, molds are prepared
by tool maker. For less number of components Alu-
minum is the better option. For large production
better to use steel alloys to maintain good surface
finish, dimensional stability. Maximum of compo-
nents are made by thermo plastic which are recy-
cled (or) reusable.
plasticsMaterial is fed into a heated barrel, mixed,
and forced into a mold cavity where it cools and
hardens to the configuration of the mold cavity
Commonly open top components are produced in
injection molding which is having minimum thick-
ness of 0.5mm, for good quality of product the wall
thickness should be more than 2mm.
For remote control panel better to use recycled poly-
propelene due to good impact resistence, low cost
and eco-friendly and it has good structural stability.
Process Characteristics
• Utilizes a ram or screw-type plunger to force
molten plastic material into a mold cavity
• Produces a solid or open-ended shape which has
conformed to the contour of the mold
• Uses thermoplastic or thermoset materials
• Produces a parting line, sprue, and gate marks
• Ejector pin marks are usually present
Injection molding is used to create many things
such as wire spools, packaging, bottle caps, auto-
motive dashboards, pocket combs, and most other
plastic products available today. Injection molding
is the most common method of part manufacturing.
It is ideal for producing high volumes of the same
object. Some advantages of injection molding are
high production rates, repeatable high tolerances,
and the ability to use a wide range of materials, low
labour cost, minimal scrap losses, and little need to
finish parts after molding. Some disadvantages of
this process are expensive equipment investment,
potentially high running costs, and the need to de-
sign moldable parts.
Design
Molds separate into two sides at a parting line, the
A side, and the B side, to permit the part to be ex-
tracted. Plastic resin enters the mold through
a sprue in the A plate, branches out between
the two sides through channels called runners, and
enters each part cavitythrough one or more spe-
cialized gates. Inside each cavity, the resin flows
around cores and conforms to the cavity geom-
etry to form the desired part. The amount of
resin required to fill the sprue, runner and cavities
of a mold is a shot. When a core shuts offagainst
an opposing mold cavity or core, a hole results in
the part. Air in the cavities when the mold closes
escapes through very slight gaps between the
plates and pins, into shallow plenums called
vents. To permit removal of the part, its features
must not overhang one another in the direction
that the mold opens, unless parts of the mold are
designed to move from between such overhangs
when the mold opens. Sides of the part that appear
parallel with the direction of draw are typically draft
with to ease release of the part from the mold, and
examination of most plastic household objects will
reveal this. Parts with bucket-like features tend to
shrink onto the cores that form them while cool-
ing, and cling to those cores when the cavity is
pulled away. The mold is usually designed so that
the molded part reliably remains on the ejector side
of the mold when it opens, and draws the runner
and the sprue out of the side along with the parts.
The part then falls freely when ejected from the side.
Tunnel gatestunnel sharply below the parting sur-
face of the B side at the tip of each runner so that
the gate is sheared off of the part when both are
ejected. Ejector pins are the most popular method
for removing the part from the side core, but air
ejection, and stripper plates can also be used de-
pending on the application. Most ejector plates are
found on the moving half of the tool, but they can
be placed on the fixed half if spring loaded. For
thermoplastics, coolant, usually water with cor-
rosion inhibitors, circulates throughpassageways
bored through the main plates on both sides of the
mold to enable temperature control and rapid part
solidification.
Plastic Advisor In Creo Parametric
Problems found after tooling development are al-
ways expensive and frustrating. For plastic part
design and manufacture, there is a better way. By
simulating the plastic-filling process for injection-
molded parts, Pro/ENGINEER Plastic Advisor ena-
bles engineers to design for manufacturability, un-
cover problems, and propose remedies, reducing
development time and expense.
CREO Plastic Advisor simulates mold filling for in-
jection molded plastic parts. Advanced features
provide valuable manufacturability insight - in-
sight that can significantly reduce late-cycle design
changes and mold reengineering costs.
CREO Plastic Advisor simulates mold filling for in-
jection molded plastic parts. Advanced features
provide valuable manufacturability insight - in-
sight that can significantly reduce late-cycle design
changes and mold reengineering costs.
Features & Benefits
• Animates plastic injection fill process and auto-
matically creates Web reports within Pro/ENGI-
NEER browser

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International Journal of Research and Innovation (IJRI)
• Access library of common plastic materials and
automatically select from typical injection-molding
machine parameters
• Identify optimal injection locations to reduce cycle
time and improve product appearance
• Identify potential mold-filling problems such as
short shots, air traps, and weld lines
• Improve design quality and reduces manufactur-
ing cycle times and rework of molds
Materials
Polypropylene (pp)
Acrylonitrile Butadiene System (ABS)
High Density Polyethylene (HDPE)
Polyvinyl Chloride (PVC)
Polybutylene terepthalate (PBT)
Plastic Flow analysis of remote control panel using polypropylene (pp)
The above image shows fill time
The above image shows confidence of fill

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International Journal of Research and Innovation (IJRI)
The above image shows injection pressure
The above image shows pressure drop
The above image shows flow front temp

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International Journal of Research and Innovation (IJRI)
The above image shows quality prediction
The above image shows surface temp variance
Plastic Flow analysis of remote control panel using Acrylonitrile Butadiene System (ABS)
The above image shows fill time

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International Journal of Research and Innovation (IJRI)
The above image shows injection pressure
The above image shows pressure drop
The above image shows surface temp variance

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International Journal of Research and Innovation (IJRI)
Plastic Flow analysis of remote control panel using High Density Polyethylene (HDPE)
The above image shows fill time
The above image shows injection pressure
The above image shows pressure drop

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International Journal of Research and Innovation (IJRI)
The above image shows surface temp variance
Plastic Flow analysis of remote control panel using Polyvinyl Chloride (PVC)
The above image shows fill time
The above image shows injection pressure

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International Journal of Research and Innovation (IJRI)
The above image shows pressure drop
The above image shows surface temp variance
Plastic Flow analysis of remote control panel using polybutylene terepthalate (PBT)
The above image shows fill time

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International Journal of Research and Innovation (IJRI)
The above image shows injection pressure
The above image shows pressure drop
The above image shows surface temp variance

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International Journal of Research and Innovation (IJRI)
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.
Parting Line Creation
The above image shows the parting surface
Core and cavity preparation
The above image shows the work piece creation

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International Journal of Research and Innovation (IJRI)
The above image shows the cavity part
The above image shows the core part
Mold Tool Design For Remote Control Top Panel
The above image shows cavity

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International Journal of Research and Innovation (IJRI)
The above image shows core
The above image shows mould assembly
The above image shows exploded view

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2D Drafting For Mold Tool Design
BILL OF MATERIALS

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Optimized Cooling Channels For Remote Control Top Panel
The above image shows linear
The above image shows horizontal
The above image shows vertical

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International Journal of Research and Innovation (IJRI)
The above image shows spiral
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.
Warpage Analysis Of Remote Control Top Panel Using Coupled Field Analysis
Linear type cooling system
The above image shows imported model of remote control top panel with linear cooling system

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International Journal of Research and Innovation (IJRI)
The above image shows meshed model
The above image shows total deformation
The above image shows temperature

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International Journal of Research and Innovation (IJRI)
The above image shows total heat flux
The above image shows thermal error
Spiral type cooling system
The above image shows total deformation

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The above image shows temperature
The above image shows total heat flux
The above image shows thermal error

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Zigzag horizontal type cooling system
The above image shows total deformation
The above image shows temperature
The above image shows total heat flux

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International Journal of Research and Innovation (IJRI)
The above image shows thermal error
Zigzag vertical type cooling system
The above image shows total deformation
The above image shows temperature

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International Journal of Research and Innovation (IJRI)
The above image shows total heat flux
The above image shows thermal error
PP ABS HDPE PVC PbT
Fill time 0.96 1.38 1.19 2.57 1.50
Injection pres-
sure
19.30 36.31 34.31 65.43 61.24
Pressure drop 19.30 36.31 34.31 65.43 61.24
Flow front
temperature
240.01 230.04 210.07 170.15 247.18
Surface tem-
perature vari-
ance
4.98 4.98 4.98 4.98 4.98
Result table for plastic flow analysis
Results

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Linear Spiral Zigzag hori-
zontal
Zigzag vertical
Total deforma-
tion
0.019266 0.0096524 0.019223 0.019331
Temperature 200 200 200 200
Total heat flux 8.2928e-12 8.3161e-12 9.6433e-12 9.7462e-12
Thermal error 1.3267e-18 1.3616e-18 3.7358e-18 3.7255e-18
Result table for optimized cooling channels
Conclusion
This project work deals with design of mold tool
and cooling channel optimization of remote control
top panel to suggest optimum material and cooling
channel system to reduce warpage of the product.
Initially literature survey and data collection was
done to understand the methodology and material
selection.
Remote control top panel was modeled and designed
mold tool for the same using parametric software
creo-2.0 (pro-engineer).
Mold flow analysis was conducted on part by vary-
ing plastic materials.
As per flow analysis P.P (polypropylene) is showing
good characteristics in confidence of fill and quality
with in low pressure and less drop, but it requires
little bit high temperature than other materials.
Thermal analysis is done in ansys work bench by
varying cooling channel systems to analyze thermal
behavior.
As per thermal analysis spiral system is showing
good quality in providing sufficient cooling effect to
the part.
As per above analysis results this project work con-
cludes that remote control with P.P (polypropylene)
material along with spiral cooling channel system
gives good quality product due to its quality of filling
and sufficient cooling effect.
References
1]. P. Postawa*, D. Kwiatkowski, E. Bociaga Insti-
tute of Polymer Processing and Production Manage-
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kpts.pcz.czest.pl
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1School of Manufacturing Engineering, Universiti
Malaysia Perlis, Malaysia 2Politeknik Sultan Abdul
HalimMu’adzam Shah (POLIMAS), Malaysia shay-
full@unimap.edu.my
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NTNU, 2008:113
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of Engineering & Technology, Nandyal, Kurnool
(Dt), A.P-518 501, India. 2 Mechanical Engineering,
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5]. Omar A. Mohamed, S.H. Masood, AbulSaifullah
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6]. Mohammad Aashiq M1, Arun A.P1, Parthiban
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7]. JiajunShen An Engineering Project Submitted
to the Graduate Faculty of Rensselaer Polytechnic
Institute
Authors
vadlamannati venkata krishna mohan
25 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