International Journal of Research and Innovation (IJRI)

International Journal of Research and Innovation

(IJRI)
DESIGN OF MOULD TOOL & COOLING CHANNEL OPTIMIZATION OF REMOTE
CONTROL TOP PANEL
Peer Review- 1401-1402
V.Venkata Krishna Mohan, D.Gopichand
Mother Theresa Institute of Technology(mist) Sanketika Nagar Sathupally Khammam,India

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 parts, 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 channels for evaluation and Analysis will be done on different models to
obtain optimum structure and cooling channel system.
Conclusion will be mode according to the obtained results
*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) DESIGN OF MOULD TOOL & COOLING CHANNEL OPTIMIZATION 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 plastic 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 combination of man and machine for high precision work
flow.
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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 encompasses a wide variety of computer based methodologies and tools for engineering activity 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 Creo Parametric 2.0 (Creo 2.0)
CREO PARAMETRIC is one of the most popular PLM
software founded by Parametric Technology Corporation 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 moldings 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 individual 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 disciplines 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 upfront Industrial Design concepts can then be used
in the downstream process of engineering the product. 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 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.

Modeling of remote

The above image shows the 2d sketch of remote using trimmed circles and arcs

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

International Journal of Research and Innovation (IJRI)

Injection Moulding
In manufacturing processes Injection moulding
plays a crucial role for producing plastic components by using thermo plastic and thermo setting.
After completion of product design as per client requirement done by an engineer, molds are prepared
by tool maker. For less number of components Aluminum is the better option. For large production
better to use steel alloys to maintain good surface
finish, dimensional stability. Maximum of components are made by thermo plastic which are recycled (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 thickness of 0.5mm, for good quality of product the wall
thickness should be more than 2mm.
For remote control panel better to use recycled polypropelene 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, 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.
Design
Molds separate into two sides at a parting line, the
A side, and the B side, to permit the part to be extracted. 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 specialized gates. Inside each cavity, the resin flows
around cores and conforms to 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. 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 cooling, 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 surface 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 depending 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 corrosion 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 always expensive and frustrating. For plastic part
design and manufacture, there is a better way. By
simulating the plastic-filling process for injectionmolded parts, Pro/ENGINEER Plastic Advisor enables engineers to design for manufacturability, uncover problems, and propose remedies, reducing
development time and expense.
CREO Plastic Advisor simulates mold filling for injection molded plastic parts. Advanced features
provide valuable manufacturability insight - insight that can significantly reduce late-cycle design
changes and mold reengineering costs.
CREO Plastic Advisor simulates mold filling for injection molded plastic parts. Advanced features
provide valuable manufacturability insight - insight that can significantly reduce late-cycle design
changes and mold reengineering costs.
Features & Benefits
Animates plastic injection fill process and automatically creates Web reports within Pro/ENGINEER 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 manufacturing 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

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

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

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

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 nonferrous metals of comparatively Low fusion tem-

perature. This process is cheaper and quicker than

permanent or sand mould casting. Most of the automobile 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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International Journal of Research and Innovation (IJRI)

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 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.

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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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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International Journal of Research and Innovation (IJRI)

The above image shows temperature

The above image shows total heat flux

The above image shows thermal error

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International Journal of Research and Innovation (IJRI)

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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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

Results
Result table for plastic flow analysis
PP

ABS

HDPE

PVC

PbT

Fill time

0.96

1.38

1.19

2.57

1.50

Injection pressure

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 temperature variance

4.98

4.98

4.98

4.98

4.98

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International Journal of Research and Innovation (IJRI)

Result table for optimized cooling channels

Linear

Spiral

Zigzag horizontal

Zigzag vertical

Total deforma- 0.019266

tion

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

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 varying plastic materials.

tronic version) ISSN 1503-8181 Doctoral theses at

NTNU, 2008:113
4]. B. Sidda Reddy 1,*, J. Suresh Kumar2, Vijaya
Kumar Reddy2 and G. Padmanabhan3 1 Department of Mechanical Engineering, R. G. M. College
of Engineering & Technology, Nandyal, Kurnool
(Dt), A.P-518 501, India. 2 Mechanical Engineering,
J.N.T University, Hyderabad, India. 3 Mechanical
Engineering, S.V. University College of Engineering,
S.V. University, Tirupati, A.P. India
5]. Omar A. Mohamed, S.H. Masood, AbulSaifullah
Faculty of Engineering and Industrial Science, Swinburne University of Technology, Hawthorn, Melbourne, Australia Corresponding Email: smasood@
swin.edu.au

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.

6]. Mohammad Aashiq M1, Arun A.P1, Parthiban

M2 1 PGD IN TOOL & DIE DESIGN ENGINEERINGPSG IAS 2 ASST.PROFESSOR DEPARTMENT OF
MECHANICAL ENGINEERING-PSG CT Coimbatore
641004, India

Thermal analysis is done in ansys work bench by

varying cooling channel systems to analyze thermal
behavior.

7]. JiajunShen An Engineering Project Submitted

to the Graduate Faculty of Rensselaer Polytechnic
Institute

As per thermal analysis spiral system is showing

good quality in providing sufficient cooling effect to
the part.

Authors

As per above analysis results this project work concludes 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 Institute of Polymer Processing and Production Management, Czestochowa University of Technology, al.
ArmiiKrajowej 19c, 42-200 Czstochowa, PolandCorresponding author: E-mail address: postawa@
kpts.pcz.czest.pl
2]. Hong-Seok Park and Xuan-Phuong Dang University of Ulsan South Korea Z. Shayfull*1, M.F.
Ghazali1, M. Azaman1, S.M. Nasir1, N.A. Faris2
1School of Manufacturing Engineering, Universiti
Malaysia Perlis, Malaysia 2Politeknik Sultan Abdul
HalimMuadzam Shah (POLIMAS), Malaysia shayfull@unimap.edu.my
3].Lars-Erik Rnnar ISBN 978-82-471-8270-3
(printed version) ISBN 978-82-471-8284-0 (elec-

vadlamannati venkata krishna mohan

25 Years 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
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