OPTIMIZED MANUFACTURING PROCESSES FOR COOLER TANK

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OPTIMIZED MANUFACTURING PROCESSES FOR
COOLER TANK
MAGULURI NAGARJUNA [1] E. KAVITHA [2] ANOOSHA PEYYALA [3]
1Research Scholar, Department of Mechanical Engineering, P V P SIDDHARTHA
INSTITUTE of TECHNOLOGY,(PVPSIT),kanuru Vijayawada, Andhra Pradesh ,India
2Assistant Professor, Department of Mechanical Engineering, P V P SIDDHARTHA
3Assistant Professor, Department of Mechanical Engineering, P V P SIDDHARTHA
ABSTRACT:
This project deals with the modeling of cooler tank parametric
model as per the client requirement. Finding the best manufacturing
process preparing mould base for the same, analyzing different
manufacturing process by doing CNC program by changing milling
parameters (feed, speed, cutters….).So that optimum parameters for
manufacturing will be suggested which is useful to reduce the costs and
efforts. Plastic flow analysis will be conducted to check the material flow
and filling. So that reduction in the pre-machining cost will be done by
rectifying the problem. FEM Based analysis will be conducted on mould
structure to reduce weight of the mould. And thermal analysis will be
conducted to suggest optimized cooling channel design. Modeling, mould
base preparation, manufacturing, cnc programming will be done
Submitted on: 25-02-14 /Accepted on: 04-03-14 /published on: 15-03-14
INTERNATIONAL JOURNAL OF RESEARCH AND INNOVATION (IJRI))
1401-1402 VOL.1, ISSUE.2, MAR-APR. 2014
AVAILABLE ONLINE: WWW.IJRIPUBLISHERS.COM

INTRODUCTION:
Air coolers also called
evaporative coolers are used for cooling
purposes. They are different from air
conditioners in the sense air
conditioners use refrigeration 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 a mounting stand for
motor. And the final part is bottom
tank used to store water.
Figure 1 Air cooler
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 prepared air
cooler and prepared a model for air
cooler tank. And that mould tool design
is done based on the model, by using
Pro/engineer software. After
determining the values of the mould
tools, manufacturing drawings are
prepared with full details selecting the
appropriate materials. Subsequently,
these mould tools are manufactured as
per drawing prepared and subjected to
quality control tests.
INTRODUCTION TO CAD
Computer Aided Design (CAD) is
a technique in which man and machine
are blended in to problem solving team,
intimately coupling the best
characteristics of each. The result of
this combination works better than
either man or machine would work
alone , and by using a multi discipline
approach, it offers the advantages of
integrated team work.
The advances in Computer
Science and Technology resulted in the
emergence of very powerful hardware
and software tool. It offers scope for use
in the entire design process resulting in
improvement in the quality of design.
The emergency of CAD as a field of
specialization will help the engineer to
acquire the knowledge and skills
needed in the use of these tools in an
efficient and effective way on the design
process.
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 encompasses a wide
variety of computer based
methodologies and tools for a spectrum
of engineering activities planning,
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 PRO/ENGINEER
Pro/ENGINEER is a feature based,
parametric solid modeling program. As
such, it's use is significantly different
from conventional drafting programs. In
conventional drafting (either manual or
computer assisted), various views of a
part are created in an attempt to
describe the geometry. Each view
incorporates aspects of various features
(surfaces, cuts, radii, holes,
protrusions) but the features are not
individually defined. In feature based
modeling, each feature is individually
described then integrated into the part.
The other significant aspect of
conventional drafting is that the part
geometry is defined by the drawing. If it
is desired to change the size, shape, or
location of a feature, the physical lines
on the drawing must be changed (in
each affected view) then associated
dimensions are updated. When using
parametric modeling, the features are
driven by the dimensions (parameters).
To modify the diameter of a hole, the
hole diameter parameter value is
changed. This automatically modifies
the feature wherever it occurs - drawing
views, assemblies, etc. Another unique
attribute of Pro/ENGINEER is that it is
a solid modeling program. The design
procedure is to create a model, view it,
assemble parts as required, then
generate any drawings which are
required. It should be noted that for
many uses of Pro/E, complete drawings
are never created. A typical design cycle
for a molded plastic part might consist
of the creation of a solid model, export
of an SLA file to a rapid prototyping
system (stereo lithography, etc.), use of
the SLA part in hands-on verification of
fit, form, and function, and then export
of an IGES file to the molder or
toolmaker. A toolmaker will then use
the IGES file to program the NC
machines which will directly create the
mold for the parts. In many such
design cycles, the only print created will
be an inspection drawing with critical
and envelope dimensions shown.
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 overview
rather than giving specific details on
the individual functionality of the
product.
Pro/Engineer is a software application
within the CAID/CAD/CAM/CAE
category, along with other similar
products currently on the market.
Engineering Design
Pro/Engineer 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 disciplines such as
industrial and standard pipe work and
complete wiring definitions. Tools are
also available to support collaborative
development.
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
environment in the form of tooling
design and simulated CNC machining
and output.
Tooling options cover specialty tools for
molding, die-casting and progressive
tooling design.

MODEL OF AIR COOLER TANK
Sketch
First sketch of part
2D DRAWINGS OF COOLER TANK

INJECTION MOULDING
Injection moulding is a manufacturing
process for producing parts from both
thermoplastic and thermosetting plastic
materials. Material 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. After a
product is designed, usually by an
industrial designer or an engineer,
molds are made by a mold maker (or
toolmaker) from metal, usually either
steel or aluminium, and precision-
machined to form the features of the
desired part. Injection molding is widely
used for manufacturing a variety of
parts, from the smallest component to
entire body panels of cars.
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, automotive
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 design moldable parts.
Injection molding machine
Equipment
Injection molding machines consist of a
material hopper, an injection ram or
screw-type plunger, and a heating unit.
They are also known as presses, they
hold the molds in which the
components are shaped. Presses are
rated by tonnage, which expresses the
amount of clamping force that the
machine can exert. This force keeps the
mold closed during the injection
process. Tonnage can vary from less
than 5 tons to 6000 tons, with the
higher figures used in comparatively
few manufacturing operations. The
total clamp force needed is determined
by the projected area of the part being
molded. This projected area is
multiplied by a clamp force of from 2 to
8 tons for each square inch of the
projected areas. As a rule of thumb, 4
or 5 tons/in2 can be used for most
products. If the plastic material is very
stiff, it will require more injection
pressure to fill the mold, thus more
clamp tonnage to hold the mold closed.
The required force can also be
determined by the material used and
the size of the part, larger parts require
higher clamping

Mold
Mold or die are the common terms
used to describe the tooling used to
produce plastic parts in molding.
Traditionally, molds have been
expensive to manufacture. They were
usually only used in mass production
where thousands of parts were being
produced. Molds are typically
constructed from hardened steel, pre-
hardened steel, aluminium, and/or
beryllium-copper alloy. The choice of
material to build a mold from is
primarily one of economics, steel molds
generally cost more to construct, but
their longer lifespan will offset the
higher initial cost over a higher number
of parts made before wearing out. Pre-
hardened steel molds are less wear
resistant and are used for lower volume
requirements or larger components.
The steel hardness is typically 38-45 on
the Rockwell-C scale. Hardened steel
molds are heat treated after machining.
These are by far the superior in terms
of wear resistance and lifespan. Typical
hardness ranges between 50 and 60
Rockwell-C (HRC). Aluminium molds
can cost substantially less, and when
designed and machined with modern
computerized equipment, can be
economical for molding tens or even
hundreds of thousands of parts.
Beryllium copper is used in areas of the
mold which require fast heat removal or
areas that see the most shear heat
generated... The molds can be
manufactured by either CNC
Machining
Molds are built through two main
methods: standard machining and
EDM. Standard Machining, in its
conventional form, has historically been
the method of building injection molds.
With technological development, CNC
machining became the predominant
means of making more complex molds
with more accurate mold details in less
time than traditional methods.
The electrical discharge machining
(EDM) or spark erosion process has
become widely used in mold making. As
well as allowing the formation of shapes
which are difficult to machine, the
process allows pre-hardened molds to
be shaped so that no heat treatment is
required. Changes to a hardened mold
by conventional drilling and milling
normally require annealing to soften
the steel, followed by heat treatment to
harden it again. EDM is a simple
process in which a shaped electrode,
usually made of copper or graphite, is
very slowly lowered onto the mold
surface (over a period of many hours),
which is immersed in paraffin oil. A
voltage applied between tool and mold
causes spark erosion of the mold
surface in the inverse shape of the
electrode.
Injection process
With Injection Molding, granular plastic
is fed by gravity from a hopper into a
heated barrel. As the granules are
slowly moved forward by a screw-type
plunger, the plastic is forced into a
heated chamber, where it is melted. As
the plunger advances, the melted
plastic is forced through a nozzle that
rests against the mold, allowing it to
enter the mold cavity through a gate
and runner system. The mold remains
cold so the plastic solidifies almost as
soon as the mold is filled.
Time Function
The time it takes to make a product
using injection molding can be
calculated by adding:
Twice the Mold Open/Close Time (2M)
+
Injection Time (T)
+
Cooling Time (C)
+

Ejection Time (E)
Where T is found by dividing:
Mold Size (S) / Flow Rate (F)
Total time = 2M + T + C + E
T = V/R
V = Mold cavity size (in3)
R = Material flow rate (in3/min)
The total cycle time can be calculated
using t cycle = t closing + t cooling + t ejection
The closing and ejection times, can last
from a fraction of a second to a few
seconds, depending on the size of the
mold and machine. The cooling times,
which dominate the process, depend on
the maximum thickness of the part.
Lubrication and Cooling
Obviously, the mold must be cooled in
order for the production to take place.
Because of the heat capacity,
inexpensiveness, and availability of
water, water is used as the primary
cooling agent. To cool the mold, water
can be channeled through the mold to
account for quick cooling times.
Usually a colder mold is more efficient
because this allows for faster cycle
times. However, this is not always true
because crystalline materials require
the opposite of a warmer mold and
lengthier cycle time
Applications
Injection molding is used to create
many things such as milk cartons,
containers, bottle caps, automotive
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, high tolerances are repeatable,
wide range of materials can be used,
low labour cost, minimal scrap losses,
and little need to finish parts after
molding. Some disadvantages of this
process are expensive equipment
investment, running costs may be high,
and parts must be designed with
molding consideration.
Mold Design
The mold consists of two primary
components, the injection mold (A
plate) and the ejector mold (B plate).
Plastic resin enters the mold through a
sprue in the injection mold, the sprue
bushing is to seal tightly against the
nozzle of the injection barrel of the
molding machine and to allow molten
plastic to flow from the barrel into the
mold, also known as cavity .The sprue
bushing directs the molten plastic to
the cavity images through channels
that are machined into the faces of the
A and B plates. These channels allow
plastic to run along them, so they are
referred to as runners. The molten
plastic flows through the runner and
enters one or more specialized gates
and into the cavity geometry to form the
desired part.
The amount of resin required to fill the
sprue, runner and cavities of a mold is
a shot. Trapped air in the mold can
escaped through air vents that are
grinded into the parting line of the
mold. If the trapped air is not allowed
to escape, it is compressed by the
pressure of the incoming material and
is squeezed into the corners of the
cavity, where it prevents filling and
causes other defects as well. The air
can become so compressed that it
ignites and burns the surrounding
plastic material. To allow for removal of
the molded part from the mold, the
mold 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
(utilizing components called Lifters).
Sides of the part that appear parallel
with the direction of draw (The axis of
the cored position (hole) or insert is
parallel to the up and down movement
of the mold as it opens and closes) are
typically angled slightly with (draft) to
ease release of the part from the mold.
Insufficient draft can cause deformation
or damage. The draft required for mold
release is primarily dependent on the
depth of the cavity: the deeper the
cavity, the more draft necessary.
Shrinkage must also be taken into
account when determining the draft
required. If the skin is too thin, then the
molded part will tend to shrink onto the
cores that form them while cooling, and
cling to those cores or part may warp,
twist, blister or crack when the cavity is
pulled away. The mold is usually
designed so that the molded part
reliably remains on the ejector (B) side
of the mold when it opens, and draws
the runner and the sprue out of the (A)
side along with the parts. The part then
falls freely when ejected from the (B)
side. Tunnel gates, also known as
submarine or mold gate, is located
below the parting line or mold surface.
The opening is machined into the
surface of the mold on the parting line.
The molded part is cut (by the mold)
from the runner system on ejection
from the mold. Ejector pins, also known
as knockout pin, is a circular pin
placed in either half of the mold
(usually the ejector half) which pushes
the finished molded product, or runner
system out of a mold.
The standard method of cooling is
passing a coolant (usually water)
through a series of holes drilled
through the mold plates and connected
by hoses to form a continuous pathway.
The coolant absorbs heat from the mold
(which has absorbed heat from the hot
plastic) and keeps the mold at a proper
temperature to solidify the plastic at
the most efficient rate.
To ease maintenance and venting,
cavities and cores are divided into
pieces, called inserts, and sub-
assemblies, also called inserts, blocks,
or chase blocks. By substituting
interchangeable inserts, one mold may
make several variations of the same
part.
More complex parts are formed using
more complex molds. These may have
sections called slides, that move into a
cavity perpendicular to the draw
direction, to form overhanging part
features. When the mold is opened, the
slides are pulled away from the plastic
part by using stationary “angle pins” on
the stationary mold half. These pins
enter a slot in the slides and cause the
slides to move backward when the
moving half of the mold opens. The part
is then ejected and the mold closes. The
closing action of the mold causes the
slides to move forward along the angle
pins.
Injection mold design
Injection mold drawing

1. Locating Ring
2. Sprue Bushing
3. Top Clamping Plate
4. Angle Pin
5. Socket Head Bolt
6. A Plate
7. Guide Lock
8. Wedge Lock
9. Retainer
10. Dowel Pin
11. Wear Plate
12. Support Plate
13. Slide
14. Core Pin
15. Socket Head Bolt
16. Baffle
17. '8' Plate
18. Ejector Retainer Plate
19. Ejector Pin
20. Stop Pin
21. Ejector Plate
22. Ejector Housing
23. Return Spring
24. Return Pin
25. Cooling Channel
26. Ejector Shaft
Clamping Unit in Injection
molding machine
The clamping unit holds the mold
together, opens and closes it
automatically, and ejects the finished
part. The mechanism may be of several
designs, mechanical, hydraulic or
hydro mechanical.
Clamping Units.
Clamping designs are of three types:
toggle, hydraulic, and hydro
mechanical. Toggle clamps include
various designs. An actuator moves the
crosshead forward, extending the toggle
links to push the moving platen toward
a closed position. At the beginning of
the movement, mechanical advantage is
low and speed is high; but near the end
of the stroke, the reverse is true. Thus,
toggle clamps provide both high speed
and high force at different points in the
cycle when they are desirable. They are
actuated either by hydraulic
Figure 59 Clamping unit
Hydraulic clamps are used on higher-
tonnage injection-molding machines,
typically in the range 1300 to 8900 kN
(150 to 1000 tons). These units are also
more flexible than toggle clamps in
terms of setting the tonnage at given
positions during the stroke. Hydro
mechanical clamps are designed for
large tonnages, usually above 8900 kN
(1000 tons.

Injection Molding Cycle & Process
The injection molding process occurs
cyclically. Typical cycle times range
from 10 to 100 seconds and are
controlled by the cooling time of the
thermoplastic or the currying time of
the thermosetting plastic. The plastic
resin in the form of pellets or powder is
fed from the hopper and melted. In a
reciprocating screw type injection
molding machine, the screw rotates
forward and fills the mold with melt,
holds the melt under high pressure,
and adds more melt to compensate for
the contraction due to cooling and
solidification of the polymer. This is
called the hold time. Eventually the
gate freezes, isolating the mold from the
injection unit, the melt cools and
solidifies. Next the screw begins to
rotate and more melt is generated for
the next shot. In the soak time the
screw is stationary and the polymer
melts by heat conduction from the
barrel to the polymer. The solidified
part is then ejected and the mold closes
for the next shot.
Step #1 - The
uncured rubber
is fed into the
machine in the
form of a
continuous
strip.
Step #2 - The
uncured rubber
is worked and
warmed by an
auger screw in
a temperature
controlled
barrel.
Step #3 - As
the rubber
stock
accumulates in
the front of the
screw, the
screw is forced
backwards.
When the screw
has moved
back a specified
amount, the
machine is
ready to make a
shot.
Step #4 - With
the mold held
closed under
hydraulic
pressure, the
screw is pushed
forward. This
forces the
rubber into the
mold, similar to
the action of a
hypodermic
syringe.
Step #5 -
While the
rubber cures
in the heated
mold, the
screw turns
again to refill.
Step #6 - The
mold opens and
the part can be
removed. The
machine is
ready to make
the next shot,
as soon as the
mold closes.

MOULD CALCULATIONS
Clamping Tonnage
Fc = Pc×Ap×n
Fc = clamping tonnage .( tons)
Pc = Cavity pressure = 550 Kg/ cm2
=55 kg/ cm2
Ap = projected area = 1.3477369 m2 =
13477.369 cm2
n = no. of cavity =1
Fc = 55 kg/cm2×13477.369 cm2×1
= 741255.295 kg = 741.255 tons
Available tonnage = 1103
As per machine standards = 1103 tons
=
1103×0.85
= 937.55 tons
741.255T<937.55T
J1000AD (JAD series)
Mold height = 500 to 1200 mm
Based on the shot capacity
Shot weight = 635×density of PA-
6/density of PS
= 635×(1.45/1.05)
= 876.3 gm
Considering the Factor of safety 85%
only
= 876.3×0.85 = 744.855
Cooling calculations
Q = Heat to be transferred per hour by
plastic Material
Q = Mp×a Cal /hr
Mp = Mass of plastic Material injected
into mold per hour in gms/hr
a = heat content of plastic in Cal/gm =
50
Mp = Shot weight × no.of cycles per/hr
No.of cycles per /hr
59.90sec/comp filling time = 60 sec
Ejection time = 30 sec
3600sec/hr/90 per/comp = 40 comp
Mp = 744.855×40 = 29794.2
Q = 29794.2×130
Q = 387324.6 Cal/hr
Qw = Rate of heat to be extracted by
water in Cal/hr
K = the constant to allow heat transfer
efficiency
Mw = Mass of water circulated in gms /
hr
Qw = Mw × K(tout –tin) 50
For direct cooling method = 0.64
Indirect method = 0.50
Qw = Mw × K(tout –tin)
= Q/2
Mw = 1716000/2×0.64×5
= 268125 gm/hr
= 268.125 lit/hr

MOULD EXTRACTION
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
CORE

DIE DESIGN
Cavity Back Plates - Plates used as a
support for the mold cavity block, core
block.
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.
Ejector Pin
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.
Retainer Pin
Guide bush
Guide Pillar
Guide Sleeves
2D drawings:

DIE ASSEMBLY

MOULD FLOW ANALYSIS
Physical
Properties
Metric
Density 0.920 g/cc
Linear Mold
Shrinkage
0.012 cm/cm
Melt Flow 11 g/10 min
Ash 10 %
Mechanical
Properties
Metric
Hardness, Rockwell
R
68
Tensile Strength at
Break
18.0 MPa
Tensile Strength,
Yield
22.0 MPa
Elongation at Break 168 %
Elongation at Yield 5.0 %
Tensile Modulus 1.20 GPa
Flexural Strength 25.0 MPa
Flexural Modulus 1.00 GPa
Izod Impact,
Notched
1.28 J/cm
Thermal
Properties
Metric
Deflection
Temperature at 0.46
MPa (66 psi)
52.8 °C
Deflection
Temperature at 1.8
MPa (264 psi)
87.8 °C
PLASTIC ADVISOR in PRO/ENGINEER
Problems found after tooling
development are always 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 enables engineers to
design for manufacturability, uncover
problems, and propose remedies,
reducing development time and
expense.
Features & Benefits
• Animates plastic injection fill
process and automatically creates
Web reports within Pro/ENGINEER
browser
• 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
manufacturing cycle times and
rework of molds
4-INJECTIONS:
Plastic flow analysis
The Flow Analysis summary page
gives an overview of the model's
analysis, including information about
actual injection time and pressure and
whether weld lines and air traps are
present. In addition, the dialog uses the
Confidence of Fill result to assess the
mould ability of the part.
Fill Time - This result shows the
flow path of the plastic through the
part by plotting contours which join
regions filling at the same time.
These contours are displayed in a
range of colors from red, to indicate
the first region to fill, through to

blue to indicate the last region to
fill.
Fill time
Confidence of Fill - The confidence of
fill result displays the probability of a
region within the cavity filling with
plastic at conventional injection
molding conditions. This result is
derived from the pressure and
temperature results.
Confidence of fill
Injection pressure
Flow Front Temperature - The flow
front temperature result uses a
range of colors to indicate the region
of lowest temperature (colored blue)
through to the region of highest
temperature (colored red). The
colors represent the material
temperature at each point as that
point was filled. The result shows
the changes in the temperature of
the flow front during filling.
Quality indication
Weld Line - This result indicates the
presence and location of weld and weld
lines in the filled part model. These are
places where two flow fronts have
converged. The presence of weld and
weld lines may indicate a weakness or
blemish.

Weld line
Air Traps - The air trap result shows
the regions where the melt stops at a
convergence of at least 2 flow fronts or
at the last point of fill, where a bubble
of air becomes trapped. The regions
highlighted in the result are positions of
possible air traps.
Air traps
COOLING QUALITY - The Cooling
Quality analysis calculates the entire
time that is needed for all areas of the
part to freeze completely, and plots
variations from that time value. When
a result indicates that an area has a
greater freeze time than normal, that
area will require more cooling to
compensate for the heat that is
concentrated in that area.
The Freeze Time Variance is greater
than normal
The Cooling Quality Analysis Adviser
highlights areas in which the freeze
time variance is greater than normal.
Adv. cooling quality
The Surface Temperature
Variance is higher than normal
warns that the surface temperature
variance in a particular area of the
model is higher than the average.
Adv. temperature variance
Sink Marks - This result indicates the
presence and location of Sink Marks
(and Voids) likely to be caused by
features on the opposite face of the

surface. Sink Marks typically occur in
moldings with thicker sections, or at
locations opposite ribs, bosses or
internal fillets. The result does not
indicate Sink Marks caused by locally
thick regions.
Sink mark
5-INJECTIONS:
Plastic flow analysis - The Flow
Analysis summary page gives an
overview of the model's analysis,
including information about actual
injection time and pressure and
whether weld lines and air traps are
present. In addition, the dialog uses the
Confidence of Fill result to assess the
mould ability of the part.
Fill Time - This result shows the flow
path of the plastic through the part by
plotting contours which join regions
filling at the same time. These contours
are displayed in a range of colors from
red, to indicate the first region to fill,
through to blue to indicate the last
region to fill. A short shot is a part of
the model that did not fill, and will be
displayed as translucent. By plotting
these contours in time sequence, the
impression is given of plastic actually
flowing into the mould.
Fill time
Confidence of Fill - The confidence of
fill result displays the probability of a
region within the cavity filling with
plastic at conventional injection
molding conditions. This result is
derived from the pressure and
temperature results.
Confidence of fill

Injection pressure
Flow Front Temperature - The flow
front temperature result uses a
range of colors to indicate the region
of lowest temperature (colored blue)
through to the region of highest
temperature (colored red). The
colors represent the material
temperature at each point as that
point was filled. The result shows
the changes in the temperature of
the flow front during filling.
Quality indication
Weld Line - This result indicates the
presence and location of weld and weld
lines in the filled part model. These are
places where two flow fronts have
converged. The presence of weld and
weld lines may indicate a weakness or
blemish.
Weld line
Air Traps - The air trap result shows
the regions where the melt stops at a
convergence of at least 2 flow fronts or
at the last point of fill, where a bubble
of air becomes trapped. The regions
highlighted in the result are positions of
possible air traps.

Air traps
COOLING QUALITY - The Cooling
Quality analysis calculates the entire
time that is needed for all areas of the
part to freeze completely, and plots
variations from that time value. When
a result indicates that an area has a
greater freeze time than normal, that
area will require more cooling to
compensate for the heat that is
concentrated in that area.
The Freeze Time Variance is greater
than normal
highlights areas in which the freeze
time variance is greater than normal.
Adv. cooling quality
The Surface Temperature
Variance is higher than normal
warns that the surface temperature
variance in a particular area of the
model is higher than the average.
Adv. temperature variance
Sink Marks - This result indicates the
presence and location of Sink Marks
(and Voids) likely to be caused by
features on the opposite face of the
surface. Sink Marks typically occur in
moldings with thicker sections, or at
locations opposite ribs, bosses or
internal fillets. The result does not
indicate Sink Marks caused by locally
thick regions.

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 behavior of
these elements and solves them all;
creating a comprehensive 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.
With virtual prototyping techniques,
users can iterate various scenarios to
optimize the product long before the
manufacturing is started. This enables
a reduction in the level of risk, and in
the cost of ineffective designs. The
multifaceted nature of ANSYS also
provides a means to ensure that users
are able to see the effect of a design on
the whole behavior of the product, be it
electromagnetic, thermal, mechanical
etc.
Steps involved in ANSYS:
In general, a finite element solution can
be broken into the following these
categories.
1. Preprocessing module: Defining the
problem
The major steps in preprocessing are
given below
- defining key points
/lines/areas/volumes
- define element type and material
/geometric /properties
- mesh lines/areas/volumes/are
required
The amount of detail required will
depend on the dimensionality of the
analysis (i.e. 1D, 2D, axis, symmetric)
2. Solution processor module: assigning
the loads, constraints and solving. Here
we specify the loads, constraints and
finally solve the resulting set of
equations.
3. Post processing module: further
processing and viewing of results
In this stage we can see:
List of no coupled-field analysis dal
displacement
Elements forces and moments
Deflection plots
Stress contour diagrams
Overview of coupled-field analysis
A coupled-field analysis is an analysis
that takes into account the interaction
(coupling) between two or more
disciplines (fields) of engineering. A
piezoelectric analysis, for example,
handles the interaction between the
structural and electric fields: it solves
for the voltage distribution due to
applied displacements, or vice versa.
Other examples of coupled-field
analysis are thermal-stress analysis,
thermal-electric analysis, and fluid-
structure analysis.
Some of the applications in which
coupled-field analysis may be required
are pressure vessels (thermal-stress
analysis), fluid flow constrictions,
induction heating (magnetic-thermal
analysis), ultrasonic transducers, and
magnetic forming (magneto-structural
analysis)

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).
Material: EN 38
Element Type:
Solid 20 nodes 95
Material Properties:
Young’s Modulus (EX) :
20900N/mm2
Poissons Ratio (PRXY :
0.27
Density :
0.000007876kg/mm3
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.
Loads 1000000*9.81=9810000
AREA 621152mm2
Pressure – 15.79N/mm2
The above image is showing the loads
applied on a mold
Solution
Solution – Solve – Current LS – ok
Post Processor
General Post Processor – Plot Results
– Contour Plot - Nodal Solution – DOF
Solution – Displacement Vector Sum
The above image shows the
displacement, value is 0.007979mm

The above image shows the stress,
value is 5.61561N/mm2
REDUCED THICKNESS
REDUCED THICKNESS TWO
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).
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.
Loads
Molten material Temp 513k
Mould temp 313
The above image shows the melted
material temperature
The above image shows the cooling
channel temperature
The above images shows the contact
area with air
Results
The above image shows the nodal
temperature

The above image shows the thermal
gradient
The above image shows the Thermal
flux
THERMAL ANALYSIS FOR MODIFIED
COOLING CHANNAL
Nodal temp
The above image shows the nodal
temperature
The above image shows the thermal
gradient
The above image shows the Thermal
flux
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
especially in thickness greater than
200mm .Also used for hot and warm
forging and in extrusion tooling such as
intricate dies and also dummy block
,liners, 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-metallic 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 mechanical
properties without changing the product
shape.
CNC machining
In modern CNC systems, end-to-end
component design is highly automated
using CAD/CAM programs. 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 particular
component might require the use of a
number of different tools - drills, saws,
etc. - modern machines often combine
multiple tools into a single "cell". In
other cases, a number of different
machines are used with an external
controller and human or robotic
operators that move the component
from machine to machine. In either
case the complex 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
Core
Air cooler tank
MANUFACTURING PROCESS
CORE ROUGHING
WORKPIECE
CUTTING TOOL
PLAY PATH
VERICUT

FINISHING
VERICUT
CAVITY
ROUGHING
FINISHING

ANALYSIS RESULT TABLE
Structural analysis
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
Thermal analysis
Thermal
gradient
Thermal
flux
Nodal
temperatur
e
Standar
d mold
240.34
8
12.498
1
513
Modified
cooling
260.20
7
13.530
8
513
TIME FOR MACHAINING (milling)
PROCESSES
Cavity roughing process
=209397.32sec
Finishing process time
= 17337.18sce
Total time 63hrs
Core roughing process time
=586735.8se
Core finishing time
=16011.62sec
Total time
=167hrs
Overall cost: 230(hours)*300(per hour)
= Rs 69,000
Weight and cost table for existing
model
INDEX
MATERIA
L NAME
QUANTIT
Y &
PRICE
COST
bolts
C22
carbon
steel
alloy
1.516KG
X275 Rs
416.00 /-
plates
MS tool
grade
754.67
KG X175
Rs
1,32,067.00
/-
Die set
(core&
cavity)
HARDND
STEEL
884.69K
G X 375
Rs
331758.75/
-
Guide
pins
OHNS
7.508 X
325 Rs
2460.00/-
GUIDE
SLEEVE
S
GUIDE
SLEEVE
S
6NOS X
500Rs
3000.00/-
GUIDE
PILLERS
GUIDE
PILLERS
6 X
1300Rs 7800/-
WATER
INLET
KNOBS
WATER
INLET
KNOBS
12 X150
Rs 3600/-
TOTAL
4,81,102.00/-
Weight and cost table for reduced
thickness 1
INDEX
MATERIA
L NAME
QUANTIT
Y &
PRICE
COST
Bolts C22
carbon
steel
alloy for
bolts
1.516KG
X275 Rs
416.00 /-
Plates
MS tool
grade
700.40
KG X175
Rs
1,22,570.00
/-
Die set
(core&
cavity)
HARD
AND
STEEL
884.69K
G X 375
Rs
331758.75/
-
Guide
pins
OHNS
7.508 X
325 Rs
2460.00/-
GUIDE
SLEEVE
S
GUIDE
SLEEVE
S
6NOS X
500Rs
3000.00/-
GUIDE
PILLERS
GUIDE
PILLERS
6 X
1300Rs 7800/-
WATER
INLET
KNOBS
WATER
INLET
KNOBS
12X150
Rs
3600/-
TOTAL
4,71,604.75/-

Weight and cost table for reduced
thickness 2
INDEX
MATERIA
L NAME
QUANTIT
Y &
PRICE
COST
bolts
C22
carbon
steel
alloy
1.516KG
X275 Rs
416.00 /-
plates
MS tool
grade
646.60
KG X175
Rs
1,13,155.00
/-
Die set
(core&
cavity)
HARD
AND
STEEL
884.69K
G X 375
Rs
331758.75/
-
Guide
pins
OHNS
7.508 X
325 Rs
2460.00/-
GUIDE
SLEEVE
S
GUIDE
SLEEVE
S
6NOS X
500Rs
3000.00/-
GUIDE
PILLERS
GUIDE
PILLERS
6 X
1300Rs 7800/-
WATER
INLET
KNOBS
WATER
INLET
KNOBS
12 X150
Rs 3600/-
TOTAL
4,62,189.75/-
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 PRO/ENGINEER.
• Mould Flow Analysis is done on
water tank
• Mould flow analysis for finding
the material filling, pressure
distribution, air traps, wild lines
formed during injection
moulding process.
• Mould Flow Analysis is done
using “Plastic Advisor” which is a
module in Pro/Engineer.
• By simulating the plastic-filling
process for injection-molded
parts, Pro/ENGINEER Plastic
Advisor enables engineers to
design for manufacturability,
uncover problems, and propose
remedies, reducing development
time and expense.
• By using this process
manufacture of air cooler tank
can be done without any
failures….
• 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 better to use reduced thk
2 model for cast and weight
reduction.
• Optimized location is the better
option for thermal behavior
because of high flux and gradient
rates.
• By reducing plate sizes company
can reduce upto Rs.19,000/-
450000
460000
470000
480000
490000
#REF!
reduced thk 1
reduced thk 2

Refarence
1)Machine design ,T.V. Sundararaja
moorthy
2) Machine design, R.S.Khurmi
/J.K.Guptha (S.CHAND)
3) Design data book: P.S.G.College of
Technology (Kalaikathirachchagam),
4) Design of machine element:
V.B.Bandari ( TATA McGraw-hill)
5) Injection mould design: R.G.W. PYE
(East-West press Pvt. Ltd)
[6] On Optimization of Injection Molding
Cooling Lars-Erik Rännar Thesis for the
degree doktor ingeniør Trondheim, April
2008 Norwegian University of Science
and Technology Faculty of Engineering
Science and Technology Department of
Engineering Design and Materials
[7] Multidisciplinary optimization of
injection molding systems Irene
Ferreira • Olivier de Weck •Pedro
Saraiva. José Cabral Struct Multidisc
Optim (2010) 41:621–635DOI
10.1007/s00158-009-0435-
[8] Injection Mold Design and
Optimization of Battery Air vent Rahul
S. Khichadi M.Tech student, VACOE
Ahmednagar, Maharashtra, India-
414201
[9] Effective Run-In and Optimization of
an Injection Molding Process Stefan
Moser. Moser Process Consulting,
Germany
[10] Recent Methods for Optimization of
Plastic Injection Molding Process - A
Literature Review Rashi A.Yadav
Reserach Scholar, Principal S.V.Joshi,
Asst. Prof. N.K.Kamble
Production Engineering Department
D.Y.Patil College of Engineering,
Akurdi, Pune – 44 MH. India
Authors
MAGULURI NAGARJUNA
(M.Tech (Machine Design))
Research scholar from,
department of mechanical
engineering,
P V P SIDDHARTHA INSTITUTE
Of TECHNOLOGY, kanuru,
Vijayawada, Krishna dist,
Andhra Pradesh ,India
Email ID:
yadeedya319@gmail.com
E. Kavitha
Assistant Professor
Mechanical Engineering
M.Tech (CAD/CAM)
Teaching Experience: 6 years
(in PVPSIT College, kanuru)
Andhra Pradesh, India
kavithavarikola@gmail.com
Anoosha Peyyala
Mechanical Engineering,
Assistant Professor
M.Tech - Mechanical
Teaching Experience: 3 years
(in PVPSIT College, kanuru)
Andhra Pradesh, India
anoosha.peyyala@gmail.com

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