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 It May Have Been Made Using A Pattern Or Model of The Final Object.

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International Journal of Research and Innovation (IJRI)
DESING OF MOULD TOOL & COOLING CHANNEL OPTIMIZATION OF
INDUSTRIAL HELMET
Bhonagiri Sudhir kumar1
, Kandathil Abraham Mathew2
,
1 Research Scholar, Department of Mechanical Engineering, Hyderabad Institute of Technology And Management, Hyderabad, India.
2 Professor, Department of Mechanical Engineering, Hyderabad Institute of Technology And Management, Hyderabad, India.
*Corresponding Author:
Bhonagiri Sudhir kumar,
Research Scholar,
Department of Mechanical Engineering,
Hyderabad Institute of Technology
And Management,Hyderabad,India.
Published: October 29, 2015
Review Type: peer reviewed
Volume: II, Issue : VI
Citation: Bhonagiri Sudhir kumar, Research Scholar (2015)
DESING OF MOULD TOOL & COOLING CHANNEL OPTIMIZA-
TION OF INDUSTRIAL HELMET.
INTRODUCTION TO HELMET
A helmet is a form of protective gear worn on the head to
protect it from injuries.
Ceremonial or symbolic helmets (e.g., English policeman's
helmet) without protective function are sometimes used.
The oldest known use of helmets was by Assyrian soldiers
in 900BC, who wore thick leather or bronze helmets to
protect the head from blunt object and sword blows and
arrow strikes in combat. Soldiers still wear helmets, now
often made from lightweight plastic materials.
In civilian life, helmets are used for recreational activi-
ties and sports (e.g., jockeys in horse racing, American
football, ice hockey, cricket, and rock climbing); danger-
ous work activities (e.g., construction, mining, riot police);
and transportation .
Materials
Types of synthetic fiber used to make some helmets:
• Aramid
• Twaron
In former times lightweight non-metallic protective mate-
rials and strong transparent materials for visors were not
available. In Greece in ancient times helmets were some-
times strengthened by covering the surface with boars'
tusks (= their canine teeth) laid flat.
INJECTION MOLD COOLING DESIGN
The design of the injection mold cooling system is very
important. The cooling time takes up 70% to 80% of in-
jection molding cycle, a well-designed cooling system can
shorten the molding time and improve the productivity
magnificently.
Poor design of cooling system will extend molding time,
increase production cost, and the injection mold tempera-
ture has great influence to the mold shrinkage, dimen-
sional stability, deformation, internal stress and surface
quality.
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 It 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 war page
of industrial helmet.
Literature survey and data collection will be done to understand working process of cooling channels, effects of war
page on plastic part’s, mold optimization.3D model of industrial helmet will be prepared by reverse engineering process
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
1401-1402

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International Journal of Research and Innovation (IJRI)
So what are the factors that matter to the cooling effec-
tive?
Plastic wall-thickness
Part with thicker wall would need longer cooling time.
Generally, the cooling time is approximately proportional
to the square and the thickness of plastic parts. If pos-
sible, propose to the part designer to minimum the wall
thickness.
Cooling system design rules:
• Ensure cooling efficiency, achieve shortest the cooling
line meanwhile get quality parts.
• Ensure uniform cooling to avoid deformation.
• Ease of manufacturing.
Some examples of injection mold cooling design, If pos-
sible, the number of cooling channels should be as many
as possible, diameter of the cooling channel should be
design as large as possible, cooling speed of A is faster
than B as figure below. Diameter of cooling channel usu-
ally are 6-12mm.
Cooling channels layout must be reasonable. When the
wall thickness of part is uniform, the distance of each
channel to the surface of parts should be even, which
means the layout of channels should follow the actual
geometry of the part, see figure A. When the thickness of
the part is un-uniform, then thicker wall area need more
cooling, see figure B, the injection mold cooling channel
can be closer to the part to enhance the cooling effect.
Usually temperature of the sprue gate area are highest, so
the cooling start from there would achieve the best cool-
ing effective, see figure below.
WARPAGE INTRODUCTION
Part warpage, either soon after molding or at some time
in-service, is a problem frequently experienced by injec-
tion molders and, at times, also by extruders. Similar to
mold shrinkage, the causes and control of warpage are
closely related to inherent material characteristics and
the laws of heat transfer. In this Technical Tip, we explain
the causes and general guidelines to minimize warpage.
It should be noted that warpage, like mold shrinkage, is
a very complex mechanism and many factors, other than
those mentioned here, have an effect on warpage. In some
cases, a specific variable may have a different effect de-
pending on other factors present.
WHAT CAUSES WARPAGE?
Warpage of thermoplastic parts can be caused by two
mechanisms: the contraction of the polymer during cool-
ing and the tendency of high-molecular-weight molecules
to "relax' if they are under stress. The first is easy to un-
derstand, as it is a common property of all solids. The
second may be compared to stretching a rubber band. As
the stress is reduced, the band returns to its original size
at a speed related to the rate of stress reduction. However,
if the band is “frozen” while stretched, it retains its shape
until the temperature increases sufficiently to allow it to
“relax” and return to its normal state.
CONTROL OF WARPAGE
As noted, there are certain polymer material character-
istics such as high molecular weight, low heat transfer
coefficients, crystallinity, contraction during cooling, etc.,
which are inherent and cannot be changed. The primary
keys to achieving low or minimal warpage are in the de-
sign of the part and mold. A thorough review of the fac-
tors that cause warpage, conducted at the design stage,
can circumvent many problems after the mold has been
constructed.
INTRODUCTION TO CAD
Computer-aided design (CAD), also known as comput-
er-aided design and drafting (CADD), is the use of com-
puter technology for the process of design and design-
documentation. Computer Aided Drafting describes the
process of drafting with a computer. CADD software, or
environments, provide the user with input-tools for the
purpose of streamlining design processes; drafting, docu-

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International Journal of Research and Innovation (IJRI)
mentation, and manufacturing processes. CADD output
is often in the form of electronic files for print or machin-
ing operations. The development of CADD-based soft-
ware is in direct correlation with the processes it seeks to
economize; industry-based software (construction, manu-
facturing, etc.) typically uses vector-based (linear) envi-
ronments whereas graphic-based software utilizes raster-
based (pixilated) environments.
MODEL OF INDUSTRIAL HELMET
The above image shows sketcher
The above image shows adding ribs
The above image shows final model of industrial helmet
MOULD FLOW ANALYSIS
Mould flow, 3D solids-based plastics flow simulation that
allows plastics part designers to determine the manu-
facturability of their parts during the preliminary design
stages and avoid potential downstream problems, which
can lead to delays and cost overruns. Following are the
benefits:
• Optimize the part wall thickness to achieve uniform fill-
ing patterns, minimum cycle time and lowest part cost
Identify and eliminate cosmetic issues such as sink
marks, weld lines and air traps.
• Determine the best injection locations for a given part
design
Mould flow analysis gives you the ability to maintain the
integrity of your product designs. It provides you the tools
to quickly optimize part designs and check the impact
of critical design decisions on the manufacturability and
quality of the product early in the design process.
PLASTIC FLOW ANALYSIS OF INDUSTRIAL HELMET
USING MATERIAL POLYPROPYLENE (PP)
Plastic flow analysis
The Flow Analysis summary page gives an overview of the
model's analysis, including information about actual in-
jection time and pressure and whether weld lines and air
traps are present. In addition, the dialog uses the Confi-
dence of Fill result to assess the mould ability of the part.
The above image shows Plastic flow analysis
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.
The above image shows 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.

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The above image shows Confidence of fill
The above image shows Fill time
The above image shows Confidence of fill
The above image shows cooling quality
PLASTIC FLOW ANALYSIS OF INDUSTRIAL HELMET
USING MATERIAL HIGH-DENSITY POLYETHYLENE
(HDPE)
The above image shows Flow front temperature
The above image shows Quality indication
PP ABS HDPE
Injection
Time:
2.73 sec 3.18 sec 4.05 sec
Injection
Pressure:
61.91 MPa 98.57 MPa 106.90 MPa
Surface
Temperature
Variance
Range
-14.45 deg.C
to 19.34
deg.C
-21.44 deg.C
to 21.29
deg.C
-21.44 deg.C
to 21.29
deg.C
Freeze Time
Variance
Range
-2.38 sec to
4.33 sec
-2.41 sec to
4.53 sec
-2.41 sec to
4.53 sec
Cycle Time: 18.34 sec 21.65 sec 15.58 sec
MOULD EXTRACTION
The above image shows parting surface

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International Journal of Research and Innovation (IJRI)
The above image shows core
The above image shows cavity
INTRODUCTION TO ANSYS
ANSYS is general-purpose finite element analysis (FEA)
software package. Finite Element Analysis is a numeri-
cal method of deconstructing a complex system into very
small pieces (of user-designated size) called elements.
The software implements equations that govern the be-
haviour 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 com-
plex 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 Me-
chanical Engineering Department at many colleges. AN-
SYS is also used in Civil and Electrical Engineering, as
well as the Physics and Chemistry departments.
THERMAL ANALYSIS ON INDUSTRIAL HELMET WITH
STRAIGHT COOLING CHANNELS WITH WATER AS
COOLANT
The above image shows imported model
The above image shows meshed model
The above image shows load applied
The above image shows temperature
The above image shows total heat flux

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International Journal of Research and Innovation (IJRI)
THERMAL ANALYSIS ON INDUSTRIAL HELMET WITH
ZIGZAG COOLING CHANNELS WITH WATER AS COOL-
ANT
The above image shows temperature
The above image shows total heat flux
THERMAL ANALYSIS ON INDUSTRIAL HELMET WITH
SPIRAL COOLING CHANNELS WITH WATER AS COOL-
ANT
The above image shows temperature
The above image shows total heat flux
water glycol
Straight Zigzag spiral Straight Zigzag Spiral
tempera-
ture
200 200 200 200 200 200
total heat
flux
5.9198e-
14
6.8771e-
15
4.7871e-
14
1.3172e-
14
6.8771e-
15
6.9655e-
15
Direc-
tional
heat flux
in X
5.0854e-
14
4.9278e-
15
4.6474e-
14
7.3145e-
15
4.9278e-
15
5.8607e-
15
Direc-
tional
heat flux
in Y
8.2583e-
15
3.9391e-
15
4.6989e-
14
3.0377e-
15
3.9391e-
15
5.1032e-
15
Direc-
tional
heat flux
in Z
2.9329e-
14
4.2854e-
15
2.0568e-
14
3.5655e-
15
4.2854e-
15
5.0786e-
15
GRAPHS FOR ANALYSIS RESULTS

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International Journal of Research and Innovation (IJRI)
CONCLUSION
• In this project, we have designed an Industrial Helmet
as per the parameters.
• Core and Cavity is extracted for the Helmet.
• 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 Helmet, We are using
mould flow analysis for finding the material filling, pres-
sure distribution during injection molding 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 prob-
lems, and propose remedies, reducing development time
and expense.
• ASPER THE ANALYSIS GLYCOL SPIRAL WILL PROVIDE
GOOD THERMAL TRANSPORTATION WHICH REDUCES
WARPAGE TO THE COMPONENT WHILE DOING MANU-
FACTURING.
• ASPER THE MOULD FLOW ANALYSIS RESULTS PP MA-
TERIAL IS BETTER WHILE CONSIDERING MANUFAC-
TURING PARAMETERS LIKE PRESSURE, FLOW QUAL-
ITY AND FILL TIME.
• By using this process manufacture of Helmet can be
done without any failures….
REFERENCES
1)Improving thermal properties of industrial safety hel-
mets Yeh-Liang Hsu*, Chi-Yu Tai, Ting-Chin Chen
Department of Mechanical Engineering, Yuan Ze Univer-
sity, Chung Li 320, Taoyuan, Taiwan, ROC
2) Design and Analysis of Industrial Helmet
1Anil Kumar. K, 2Y. Suresh babu M.Tech 1,2Depart-
ment of Mechanical Engineering, Rajiv Gandhi Memo-
rial College of Engineering & Technology, Affiliated to
J.N.T.University Anantapur, Nandyal,
3)Design and Analysis of Industrial Safety Helmet using
Natural Fibers
Rajasekar.K PG Student, Department of Mechanical En-
gineering, Narayanan.L Assistant Professor, Department
of Mechanical Engineering
4)The Damping of Off-Central Impact for Selected Indus-
trial Safety Helmets Used in Poland
Ryszard Korycki, Department of Technical Mechanics,
Technical University of £o´dz´, Poland
5)INTERNATIONAL JOURNAL OF OCCUPATIONAL SAFE-
TY AND ERGONOMICS
6) Improving Thermal Comfort in Industrial Safety Helmet
using Phase Change Material
7) GOWTHAM VIGNESWARAN1, L. ARULMURUGAN2
K.S.Rangasamy College of Technology,
8)Design and Analysis of Multi-Funtional Helmet for the
Industries
A.V. PRADEEP *, R. SURYA KIRAN ** *(Department of
Mechanical Engineering, Sankethika Vidya Parishad, Vi-
sakhapatnam-45,India)
9)Fabrication of Industrial Safety Helmet by using Hybrid
Composite Materials
B.Murali, D.Chandramohan, S.K.Nagoor Vali and
B.Mohan,Department of Mechanical Engineering,Veltech
,Avadi,Chennai, India
Author
Bhonagiri Sudhir kumar,
Research Scholar,
Department of Mechanical Engineering,
Hyderabad Institute of Technology And Management,
Hyderabad,India.
Kandathil Abraham Mathew,
Professor ,
Department of Mechanical Engineering,
Hyderabad Institute of Technology And Management,
Hyderabad,India.