Publication: Numerical investigation on different sprue design on single cavity mould
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Date
2022-07
Authors
Muhammad Zulhilmi Mohd Zaki
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Abstract
Plastic may be the most divisive material in recent history. It offers a slew of great benefits that benefit people daily. It was originally a term for a product that was easily moulded and pliable. One of the processes to manufacture the plastic product is using injection moulding. Plastic injection moulding is ideal for highly detailed items. In a mass production of plastic products in injection moulding, filling time is one of the crucial factors that needs to be considered. One of the objectives of this project is to do numerical investigations on different sprue design on single sprue cavity mould. The other objective is to simulate the flow of molten plastic into the different sprue designs on single sprue cavity mould. Last objective is to optimize filling time of molten plastic, pressure, and injection velocity of single sprue injection moulding. For this project, it will be conducted using ANSYS Fluent 2020 simulation software. SolidWorks software will be used to design different sprue designs and the mould cavity. The factors that affect the injection moulding such as polypropylene, single sprue mould, range of sprue length, and finite volume method will be studied. Based on the numerical simulations of different sprue designs, the optimum value suggested by the Design Expert 12 were A (sprue length) = 63.48 mm, B = (taper angle) 0.86-degree, C (sprue opening) = 7.65 mm, D (inlet pressure) = 46.30 MPa, and E (temperature) = 486.69 K. Meanwhile, the optimum responses were velocity = 15.44 m/s, outlet pressure = 0.5652 MPa, and filling time = 1.498 s.