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1.
International Research Journal
of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 06 Issue: 05 | May 2019 www.irjet.net p-ISSN: 2395-0072 © 2019, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 7071 Analysis of Ceiling Cable Holder Base Nitish Kumar Mishra1, Professor Vaibhav Bankar2 1Department of Mechanical Engineering, Vidarbha Institue of Technology Nagpur, Maharashtra (INDIA) 2Head of Department of Mechanical Engineering, Vidarbha Institue of Technology Nagpur, Maharashtra (INDIA) -------------------------------------------------------------------------***-------------------------------------------------------------------------- Abstract:- Injection moulds are classified into two types based on runner design (i.e.) Cold runner moulds and Runner less moulds (i.e.) hot runner moulds. In cold runner moulds, for multi-cavity and multi-point injection moulds, there is wreckage of material in runner area. Also wastage of material is more than component weight. To overcome the above problem, the technique used is hot Runner moulds. Hot runner mould is one of the improved manufacturing technique for multi-cavity type moulds. This types of moulds are commonly used for large production rate. While producing plastic components using normal/standard multi- cavity mould, we are facing the problems like partial filling, cavities in components, less product quality, injection pressure and temperature reduction and warpage etc. Thus we are redesigning the holder base by doing some modification in and this will be beneficial for our using purpose. We are doing, mould flow analysis using software Solidworks. KEYWORDS: - mould, core-cavity, warpage, etc. 1. INTRODUCTION In Injection molding, a high pressure fluid polymer is injected to the impression formed in the mold by using injection molding machine. The injection cycle starts when the mold closes, followed supervene by the injection of polymer into the mold cavity. Once the cavity is filled, then the part is sufficiently cool, the mold opens and the part is ejected. CAE software is used for mold flow analysis. Firstly the specified product is designed using 3D mechanical software. After the product and mold preparation import the models into mold flow software for analysis and simulation. It can show the result of injection molding for plastic in designed cavity, find the different problems in them and modify. It proved that numerical simulation technology in injection molding played a key role in quickening new plastic product development, increasing plastic quality and reducing the cost. 2. OBJECTIVES The prime objective is to design the Injection Mould tool to produce good quality Component and economically and also:- 3. Design and Analysis of Ceiling cable Holder Base 4. To improve the aesthetic view and reduce material wastage. 5. Provide strength to the holder base. 6. Applying a shrinkage to the part material, geometry and moulding conditions. 7. Make conceptual design of mould. 3. MODEL STUDY AND MODELLING OF COMPONENT Model study includes identifying the problems in Component, following are the problems involved in component Proper ejection method required to eject the component. Extra material wastage due to rectangular shape. Looks odd when fitted with the holder, as shape of holder is circular. Less attractive aesthetic view. Warpage occurs on flat surface
2.
International Research Journal
of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 06 Issue: 05 | May 2019 www.irjet.net p-ISSN: 2395-0072 © 2019, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 7072 Figure No.1 Existing Component Component is modeled using the software SOLIDWORK Component has a circular in structure with following dimensions: Figure No.2 Dimension of Holder Base. Other details of model are given below:- Component name: Holder Base Component material: PP (polypropylene) Shrinkage: 1.5 Moulding type: Four Cavity injection mould tool Figure No.3 3D model of Knob. 4. MOULD FLOW ANALYSIS It is required to do the mould flow analysis for the particular component to know the proper filling and any other defects coming during the filling process of the component. To locate the proper gating system and melt temperature of the material in which injection process takes place. Following are some images of analysis. Figure No.4 Analysis of Filling Time Figure No.5 Analysis of Cooling Time Figure No.6 Analysis of Temperature at the End of Fill
3.
International Research Journal
of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 06 Issue: 05 | May 2019 www.irjet.net p-ISSN: 2395-0072 © 2019, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 7073 Figure No.7 Analysis of Ease of Fill Figure No.8 Analysis of shear stress at the end of fill. Figure No.9 Analysis of shear rate at the end of fill. Figure No.9 Analysis of velocity vector at the end of fill. Graph No. 1 X Direct. Clamping Force Vs Time Graph No. 2 Y Direct. Clamping Force Vs Time
4.
International Research Journal
of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 06 Issue: 05 | May 2019 www.irjet.net p-ISSN: 2395-0072 © 2019, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 7074 Graph No. 3 Z Direct. Clamping Force Vs Time 5. CONCLUSION In this project, we carried out the Analysis of Ceiling Cable Holder Base. The complete injection mould tool is analyzed for fabricating holder base by using solidwork. The plastic flow analysis is carried out using solidwork. All the results viz. fill time, temperature at the end of fill, weld lines, air traps, Ease of fill prediction are analyzed and it has not shown any error in the mould flow analysis. 6. REFERENCES [1] S.Karthikeyan, S.Jayabal, S.kalyanasundaram, C Boopathi, “Influence of Cooling Channel Position and Form on Polymer Solidification and Temperature in Injection Molding Die”, International Journal For Research In Applied Science & Engineering Technology (IJRASET), Volume 3 Issue III, March 2015. [2] Book on Injection mould design by R.G.W.PYE [3] B.Iftekhar Hussain, Mir Safiulla, Mohamed Ali, G.Suresh, "Injection Mould Tool Design of Power Box Side Panel", International Journal of Innovative Research in Science, Engineering and Technology, Vol. 3, Issue 2, February 2014. [4] NikMizamzulMehat, Shahrul Kamaruddin, and Abdul Rahim Othman, "Modeling and Analysis of Injection Moulding Process Parameters for Plastic Gear Industry Application”, Hindawi Publishing Corporation ISRN Industrial Engineering Volume 2013, Article ID 869736. [5] Jithin k1, Kannakumar k2, "Process Parameter Optimization of Injection Mold Using Concurrent Approach”, IJISET - International Journal of Innovative Science, Engineering & Technology, Vol. 3 Issue 12, December 2016 [6] Bown, J., “Injection Moulding of Plastic Components”, McGraw-Hill [7] Book on Injection mould design by R.G.W.PYE. [8] Pravin popatrao Shinde, S S Patil, Swapnil S Kulkarni “Design & Development of Plastic Injection mould for auto components” in International Journal of Advanced Engineering Research and Studies, Vol. 4 Issue 1 Oct-Dec. 2014, Pages 27-30. [9] L.M. Galantucci, R Spina, “ Evaluation of filling conditions of injection moulding by integrating numerical simulation and experimental tests” in ELSEVIER-Journal of Material processing & Technology, 141(2003) Pages 266- 275. [10] Sharifah Imihezri Syed Shahruddin, Mohd. Sapuan Salit,Edi Syams Zainudin, “A review of the effect of Moulding parameters on the Performance of polymeric composite injection Moulding” Turkish J Engg. Env. Sci., 30, 2006, Pages 23-34. [11] Eranna H, “Development of Pneumatically operated compression Moulding Machine” in International Journal of Engineering Research, Vol.2 Issue 4 oct. 2014, Pages 62- 67. [12] Poonam G Shukla, Gaurav p Shukla, “Design & Fabrication of Pneumatically operated injection Moulding Machine, in International Journal of Engineering & innovative Technology (IJEIT), Vol. 2, Issue 7, January 2013, Pages 98-101.
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