Spur Bush Batch Project

A
MINI- PROJECT REPORT
ON
DESINGN OF SPRUE BUSH BY USING INJECTION MOULDING

Mini – Project Report Submitted in partial fulfillment of the requirement
for the award of the degree of
BACHELOR OF TECHNOLOGY
IN
MECHANICAL ENGINEERING
BY
N.VENKATA SURYA BHARADWAJ 16M51A0326.
MD.ZAMEER ALI 17M55A0322.
K.SAI KIRAN 16M51A0319.
UNDER THE GUIDENCE OF

Mr. CH NAGARAJU
DEPARTMENT OF MECHANICAL ENGINEERING
ELLENKI INSTITUTE OF ENGINEERING & TECHNOLOGY

NEAR BHEL, PATELGUDA, PATANCHERU, SANGAREDDY ( D) – 502305
AFFILIATED TO JNTU, HYDERABAD AND APPROVED BY AICTE, NEW DELHI
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ELLENKI INSTITUTE OF ENGINEERING AND TECHNOLOGY
ELLENKI INSTITUTE OF ENGINEERING & TECHNOLOGY
NEAR BHEL, PATELGUDA, PATANCHERU, SANGAREDDY ( D) – 502305
AFFILIATED TO JNTU, HYDERABAD AND APPROVED BY AICTE, NEW DELHI
DEPARTMENT OF MECHANICAL ENGINEERING
CERTIFICATE
This is to certify that the mini-project report entitled “DESINGN OF

SPRUE BUSH BY USING INJECTION MOULDING ” being submitted by
N.VENKATASURYABHARADWAJ(16M51A0326) ,MD.ZAMEERALI
(17M55A0322), K.SAI KIRAN(16M51A0319) in partial fulfillment of the
requirements for the award of Degree of Bachelor of Technology in
MECHANICAL ENGINEERING Under Jawaharlal Nehru Technological
University, Hyderabad during the period of 2019-2020.
INTERNAL GUIDE HEAD OF THE DEPARTMENT
EXTERNAL EXAMINER
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ACKNOWLEDGEMENT
It is our pleasure to acknowledge the help that we have received from

different individuals and place on our appreciation and thanks to those who
have helped us in bringing this Mini-Project work.
We express our deep sense of gratitude to our beloved chairman

Sri. E. SADASIVA REDDY , ELLENKI GROUP OF INSTITUTATIONS who
extended his co-operation in various ways throughout the course.
We express our deep sense of gratitude to our beloved Director

Sri. M. SAMBASIVA REDDY, RESEARCH AND DEVELOPMENT CENTER
AND ELLENKI INISTITUTE OF ENGINEERING & TECHNOLOGY who extended
his co-operation in various ways throughout the course.
We would like to thank Professor Dr.R.SARVANAN, PRINCIPAL

for providing us with an opportunity to do our Mini-Project.
We express special thanks Mr. CH. NAGARAJU , HEAD,
DEPARTMENT OF MECHANICAL ENGINEERING for his encouraging support

and guidance in carrying out the Mini-Project.
We express special thanks Mr. CH.NAGARAJU, ASSISTANT

PROFESSOR,DEPARTMENT OF MECHANICAL ENGINEERING for his
encouraging support and guidance in carrying out the Mini-Project.
Finally, our heartfelt gratitude and thanks to one and all who helped us
directly or indirectly to make our Mini-Project successful.
N.VENKATA SURYA BHARADWAJ 16M51A0326.
MD.ZAMEER ALI 17M55A0322.
K.SAI KIRAN 16M51A0319.
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DESIGN OF SPRUE BUSH
BY USING INJECTION
MOULDING
N VENKATA SURYA BHARADWAJ

MD. ZAMEER ALI
K SAI KIRAN
CONTENT
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ABSTRACT …..1
CHAPTER-1
1. INTRODUCTION TO INJECTION MOULDING …..2 - 4
1.1. Introduction ….. 2
1.2. Capabilities ….. 3
CHAPTER-2
2. PROCESS CYCLE …..5 - 17
2.1. Equipment ….. 7
2.2. Injection Unit ….. 7
2.3. Clamping Unit ….. 9
2.4. Machine Specifications ….. 10
2.5. Tooling ….. 11
2.6. Mold Base ….. 12
2.7. Mold Channels ….. 13
2.8. Mold Design ….. 14
2.9. Materials ….. 16
CHAPTER-3
3. COST DRIVERS ….18 - 21
3.1. Material Cost ….. 18
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3.2. Production Cost ….. 18
3.3. Tooling Cost ….. 19
3.4. Tolerances and Surfaces ….. 20
3.5. Lubrication and Cooling ….. 20
3.6. Power Requirements ….. 21
CHAPTER-4
4. INTRODUCTION TO SPRUE BUSH …..22 - 23
CHAPTER-5
5. SPRUE DESIGN …..24 - 35
5.1. Sprue Bush Design Rule ….. 27
5.2. Sprue Bush Cooling And Construction ….. 28
5.3. Basic Rule Design ….. 32
5.4. Manufacturing Process of Sprue Bush ….. 35
CONCLUSION …..36
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ABSTRACT
The molten plastic injected from the injector nozzle will go through a Sprue (Sprue
bush), a runner, and a gate and fill up in the cavity.
As the temperature of molten plastic is lowered while going through the Sprue and
runner, the viscosity will rise; therefore, the viscosity is lowered by shear heat generated
when going through the gate to fill the cavity.
Sprue bush design is important, because Sprue bush is part that contact first time with
melted plastic, bad design of Sprue bush can make plastic product broken, especially Sprue
broken and runner broken.
In our project we study the design and manufacturing of Sprue bush used in injection
moulding.
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CHAPTER-1
INTRODUCTION TO INJECTION MOULDING
1.1. INTRODUCTION:-
Injection molding is the most commonly used manufacturing process for the
fabrication of plastic parts. A wide variety of products are manufactured using injection
molding, which vary greatly in their size, complexity, and application. The injection molding
process requires the use of an injection molding machine, raw plastic material, and a mold.
The plastic is melted in the injection molding machine and then injected into the mold, where
it cools and solidifies into the final part.
Injection molding overview
Injection molding is used to produce thin-walled plastic parts for a wide variety of
applications, one of the most common being plastic housings. Plastic housing is a thin-walled
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enclosure, often requiring many ribs and bosses on the interior. These housings are used in a
variety of products including household appliances, consumer electronics, power tools, and as
automotive dashboards. Other common thin-walled products include different types of open
containers, such as buckets. Injection molding is also used to produce several everyday items
such as toothbrushes or small plastic toys. Many medical devices, including valves and
syringes, are manufactured using injection molding as well.
1.2. CAPABILITIES:-
Typical Feasible
Thin-walled: Cylindrical
Shapes: Flat
Thin-walled: Cubic
Thin-walled: Complex
Envelope: 0.01 in³ - 80 ft³

Part size:
Weight: 0.5 oz - 55 lb
Elastomer
Materials: Thermoplastics
Thermo sets
1 - 32
Surface finish - Ra: 4 - 16 μin
μin
± 0.002
Tolerance: ± 0.008 in.
in.
Max wall thickness: 0.03 - 0.25 in. 0.015 -
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Typical Feasible
0.5 in.
1000 -
Quantity: 10000 - 1000000
1000000
Lead time: Months Weeks
Can form complex shapes and fine details.
Excellent surface finish.
Good dimensional accuracy.

Advantages:
High production rate.
Low labor cost.
Scrap can be recycled.
Limited to thin walled parts.
Disadvantages: High tooling and equipment cost.
Long lead time possible.
Applications: Housings, containers, caps, fittings.
CHAPTER-2
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PROCESS CYCLE
The process cycle for injection molding is very short, typically between 2 seconds and
2 minutes, and consists of the following four stages:
1. Clamping - Prior to the injection of the material into the mold, the two halves
of the mold must first be securely closed by the clamping unit. Each half of the mold is
attached to the injection molding machine and one half is allowed to slide. The
hydraulically powered clamping unit pushes the mold halves together and exerts
sufficient force to keep the mold securely closed while the material is injected. The time
required to close and clamp the mold is dependent upon the machine - larger machines
(those with greater clamping forces) will require more time. This time can be estimated
from the dry cycle time of the machine.
2. Injection - The raw plastic material, usually in the form of pellets, is fed into
the injection molding machine, and advanced towards the mold by the injection unit.
During this process, the material is melted by heat and pressure. The molten plastic is
then injected into the mold very quickly and the buildup of pressure packs and holds the
material. The amount of material that is injected is referred to as the shot. The injection
time is difficult to calculate accurately due to the complex and changing flow of the
molten plastic into the mold. However, the injection time can be estimated by the shot
volume, injection pressure, and injection power.
3. Cooling - The molten plastic that is inside the mold begins to cool as soon as it
makes contact with the interior mold surfaces. As the plastic cools, it will solidify into the
shape of the desired part. However, during cooling some shrinkage of the part may occur.
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The packing of material in the injection stage allows additional material to flow into the
mold and reduce the amount of visible shrinkage. The mold can not be opened until the
required cooling time has elapsed. The cooling time can be estimated from several
thermodynamic properties of the plastic and the maximum wall thickness of the part.
4. Ejection- After sufficient time has passed, the cooled part may be ejected from
the mold by the ejection system, which is attached to the rear half of the mold. When the
mold is opened, a mechanism is used to push the part out of the mold. Force must be
applied to eject the part because during cooling the part shrinks and adheres to the mold.
In order to facilitate the ejection of the part, a mold release agent can be sprayed onto the
surfaces of the mold cavity prior to injection of the material. The time that is required to
open the mold and eject the part can be estimated from the dry cycle time of the machine
and should include time for the part to fall free of the mold. Once the part is ejected, the
mold can be clamped shut for the next shot to be injected.
After the injection molding cycle, some post processing is typically required. During
cooling, the material in the channels of the mold will solidify attached to the part. This excess
material, along with any flash that has occurred, must be trimmed from the part, typically by
using cutters. For some types of material, such as thermoplastics, the scrap material that
results from this trimming can be recycled by being placed into a plastic grinder, also called
regrind machines or granulators, which regrinds the scrap material into pellets. Due to some
degradation of the material properties, the regrind must be mixed with raw material in the
proper regrind ratio to be reused in the injection molding process.
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2.1. EQUIPMENT:-
Injection molding machines have many components and are available in different
configurations, including a horizontal configuration and a vertical configuration. However,
regardless of their design, all injection molding machines utilize a power source, injection
unit, mold assembly, and clamping unit to perform the four stages of the process cycle.
2.2. INJECTION UNIT:-
The injection unit is responsible for both heating and injecting the material into the
mold. The first part of this unit is the hopper, a large container into which the raw plastic is
poured. The hopper has an open bottom, which allows the material to feed into the barrel.
The barrel contains the mechanism for heating and injecting the material into the mold. This
mechanism is usually a ram injector or a reciprocating screw. A ram injector forces the
material forward through a heated section with a ram or plunger that is usually hydraulically
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powered. Today, the more common technique is the use of a reciprocating screw. A
reciprocating screw moves the material forward by both rotating and sliding axially, being
powered by either a hydraulic or electric motor. The material enters the grooves of the screw
from the hopper and is advanced towards the mold as the screw rotates. While it is advanced,
the material is melted by pressure, friction, and additional heaters that surround the
reciprocating screw. The molten plastic is then injected very quickly into the mold through
the nozzle at the end of the barrel by the buildup of pressure and the forward action of the
screw. This increasing pressure allows the material to be packed and forcibly held in the
mold. Once the material has solidified inside the mold, the screw can retract and fill with
more material for the next shot.
Injection molding machine - Injection unit
2.3. CLAMPING UNIT:-
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Prior to the injection of the molten plastic into the mold, the two halves of the mold
must first be securely closed by the clamping unit. When the mold is attached to the injection
molding machine, each half is fixed to a large plate, called a platen. The front half of the
mold, called the mold cavity, is mounted to a stationary platen and aligns with the nozzle of
the injection unit. The rear half of the mold, called the mold core, is mounted to a movable
platen, which slides along the tie bars. The hydraulically powered clamping motor actuates
clamping bars that push the moveable platen towards the stationary platen and exert sufficient
force to keep the mold securely closed while the material is injected and subsequently cools.
After the required cooling time, the mold is then opened by the clamping motor. An ejection
system, which is attached to the rear half of the mold, is actuated by the ejector bar and
pushes the solidified part out of the open cavity.
Injection molding machine - Clamping unit
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2.4. MACHINE SPECIFICATIONS:-
Injection molding machines are typically characterized by the tonnage of the clamp
force they provide. The required clamp force is determined by the projected area of the parts
in the mold and the pressure with which the material is injected. Therefore, a larger part will
require a larger clamping force. Also, certain materials that require high injection pressures
may require higher tonnage machines. The size of the part must also comply with other
machine specifications, such as shot capacity, clamp stroke, minimum mold thickness, and
platen size.
Injection molded parts can vary greatly in size and therefore require these measures to cover
a very large range. As a result, injection molding machines are designed to each
accommodate a small range of this larger spectrum of values. Sample specifications are
shown below for three different models (Babyplast, Powerline, and Maxima) of injection
molding machine that are manufactured by Cincinnati Milacron.
Babyplast Powerline Maxima
Clamp force (ton) 6.6 330 4400
Shot capacity (oz.) 0.13 - 0.50 8 - 34 413 - 1054
Clamp stroke (in.) 4.33 23.6 133.8
Min. mold thickness (in.) 1.18 7.9 31.5
Plate size (in.) 2.95 x 2.95 40.55 x 40.55 122.0 x 106.3
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Injection molding machine
2.5. TOOLING:-
The injection molding process uses molds, typically made of steel or aluminum, as the
custom tooling. The mold has many components, but can be split into two halves. Each half
is attached inside the injection molding machine and the rear half is allowed to slide so that
the mold can be opened and closed along the mold's parting line. The two main components
of the mold are the mold core and the mold cavity. When the mold is closed, the space
between the mold core and the mold cavity forms the part cavity. that will be filled with
molten plastic to create the desired part. Multiple-cavity molds are sometimes used, in which
the two mold halves form several identical part cavities.
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Mold overview
2.6. MOLD BASE:-
The mold core and mold cavity are each mounted to the mold base, which is then
fixed to the platens inside the injection molding machine. The front half of the mold base
includes a support plate, to which the mold cavity is attached, the sprue bushing, into which
the material will flow from the nozzle, and a locating ring, in order to align the mold base
with the nozzle. The rear half of the mold base includes the ejection system, to which the
mold core is attached, and a support plate. When the clamping unit separates the mold halves,
the ejector bar actuates the ejection system. The ejector bar pushes the ejector plate forward
inside the ejector box, which in turn pushes the ejector pins into the molded part. The ejector
pins push the solidified part out of the open mold cavity.
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Mold base
2.7. MOLD CHANNELS:-
In order for the molten plastic to flow into the mold cavities, several channels are
integrated into the mold design. First, the molten plastic enters the mold through the sprue.
Additional channels, called runners, carry the molten plastic from the sprue to all of the
cavities that must be filled. At the end of each runner, the molten plastic enters the cavity
through a gate which directs the flow. The molten plastic that solidifies inside these runners is
attached to the part and must be separated after the part has been ejected from the mold.
However, sometimes hot runner systems are used which independently heat the channels,
allowing the contained material to be melted and detached from the part. Another type of
channel that is built into the mold is cooling channels. These channels allow water to flow
through the mold walls, adjacent to the cavity, and cool the molten plastic.
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Mold channels
2.8. MOLD DESIGN:-
In addition to runners and gates, there are many other design issues that must be
considered in the design of the molds. Firstly, the mold must allow the molten plastic to flow
easily into all of the cavities. Equally important is the removal of the solidified part from the
mold, so a draft angle must be applied to the mold walls. The design of the mold must also
accommodate any complex features on the part, such as undercuts or threads, which will
require additional mold pieces. Most of these devices slide into the part cavity through the
side of the mold, and are therefore known as slides, or side-actions. The most common type
of side-action is a side-core which enables an external undercut to be molded. Other devices
enter through the end of the mold along the parting direction, such as internal core lifters,
which can form an internal undercut. To mold threads into the part, an unscrewing device is
needed, which can rotate out of the mold after the threads have been formed.
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Mold - Closed
Mold - Exploded view
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2.9. MATERIALS:-
There are many types of materials that may be used in the injection molding process.
Most polymers may be used, including all thermoplastics, some thermosets, and some
elastomers. When these materials are used in the injection molding process, their raw form is
usually small pellets or a fine powder. Also, colorants may be added in the process to control
the color of the final part. The selection of a material for creating injection molded parts is
not solely based upon the desired characteristics of the final part. While each material has
different properties that will affect the strength and function of the final part, these properties
also dictate the parameters used in processing these materials. Each material requires a
different set of processing parameters in the injection molding process, including the
injection temperature, injection pressure, mold temperature, ejection temperature, and cycle
time. A comparison of some commonly used materials is shown below.
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CHAPTER-3
COST DRIVERS
3.1. MATERIAL COST:-
The material cost is determined by the weight of material that is required and the unit
price of that material. The weight of material is clearly a result of the part volume and
material density; however, the part's maximum wall thickness can also play a role. The
weight of material that is required includes the material that fills the channels of the mold.
The size of those channels, and hence the amount of material, is largely determined by the
thickness of the part.
3.2. PRODUCTION COST:-
The production cost is primarily calculated from the hourly rate and the cycle time.
The hourly rate is proportional to the size of the injection molding machine being used, so it
is important to understand how the part design affects machine selection. Injection molding
machines are typically referred to by the tonnage of the clamping force they provide. The
required clamping force is determined by the projected area of the part and the pressure with
which the material is injected. Therefore, a larger part will require a larger clamping force,
and hence a more expensive machine. Also, certain materials that require high injection
pressures may require higher tonnage machines. The size of the part must also comply with
other machine specifications, such as clamp stroke, platen size, and shot capacity.
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The cycle time can be broken down into the injection time, cooling time, and resetting time.
By reducing any of these times, the production cost will be lowered. The injection time can
be decreased by reducing the maximum wall thickness of the part and the part volume. The
cooling time is also decreased for lower wall thicknesses, as they require less time to cool all
the way through. Several thermodynamic properties of the material also affect the cooling
time. Lastly, the resetting time depends on the machine size and the part size. A larger part
will require larger motions from the machine to open, close, and eject the part, and a larger
machine requires more time to perform these operations.
3.3. TOOLING COST:-
The tooling cost has two main components - the mold base and the machining of the
cavities. The cost of the mold base is primarily controlled by the size of the part's envelope. A
larger part requires a larger, more expensive, mold base. The cost of machining the cavities is
affected by nearly every aspect of the part's geometry. The primary cost driver is the size of
the cavity that must be machined, measured by the projected area of the cavity (equal to the
projected area of the part and projected holes) and its depth. Any other elements that will
require additional machining time will add to the cost, including the feature count, parting
surface, side-cores, lifters, unscrewing devices, tolerance, and surface roughness.
The quantity of parts also impacts the tooling cost. A larger production quantity will require a
higher class mold that will not wear as quickly. The stronger mold material results in a higher
mold base cost and more machining time.
One final consideration is the number of side-action directions, which can indirectly affect
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the cost. The additional cost for side-cores is determined by how many are used. However,
the number of directions can restrict the number of cavities that can be included in the mold.
For example, the mold for a part which requires 3 side-action directions can only contain 2
cavities. There is no direct cost added, but it is possible that the use of more cavities could
provide further savings.
3.4. TOLERANCES AND SURFACES:-
Molding tolerance is a specified allowance on the deviation in parameters such as
dimensions, weights, shapes, or angles, etc. To maximize control in setting tolerances there is
usually a minimum and maximum limit on thickness, based on the process used. Injection
molding typically is capable of tolerances equivalent to an IT Grade of about 9–14. The
possible tolerance of a thermoplastic or a thermoset is ±0.008 to ±0.002 inches. Surface
finishes of two to four micro inches or better can be obtained. Rough or pebbled surfaces are
also possible.
Molding Type Typical [in] Possible [in]
Thermoplastic ±0.008 ±0.002
Thermoset ±0.008 ±0.002
3.5. LUBRICATION AND COOLING:-
Obviously, the mold must be cooled in order for the production to take place. Because
of the heat capacity, low cost, 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
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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: a
warmer mold and lengthier cycle time.
3.6. POWER REQUIREMENTS:-
The power required for this process of injection molding depends on many things and
varies between materials used. Manufacturing Processes Reference Guide states that the
power requirements depend on "a material's specific gravity, melting point, thermal
conductivity, part size, and molding rate." Below is a table from page 243 of the same
reference as previously mentioned that best illustrates the characteristics relevant to the
power required for the most commonly used materials.
Material Specific gravity (g/cm3) Melting point (°F) Melting point (°C)
Epoxy 1.12 to 1.24 248 120
Phenolic 1.34 to 1.95 248 120
Nylon 1.01 to 1.15 381 to 509 194 to 265
Polyethylene 0.91 to 0.965 230 to 243 110 to 117
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CHAPTER-4
INTRODUCTION TO SPRUE BUSH
The sprue bush is defined as that part if the mold in which the sprue is formed. In
practice the sprue bush is the connecting member between the machine nozzle and the mold
face, and provides suitable aperture through which the material can travel on its way to the
impression or the start of the runner system in multi-impression molds.
The sprue bush is fairly highly stressed in some appliance and should therefore be
made from a 1.5% nickel chrome steel and should always be hardened. Note that while
initially the nozzle may have been set up correctly, an increase in the injection cylinder
temperature will cause a fairly high force to be applied to the sprue bush because of the
expansion of the injection cylinder.
The internal aperture of the sprue bush has between 2˚ and 4˚ included taper, which
facilitates removal of the sprue from the mold at the end of molding cycle.
There are two basic design of sprue bush which differ only with respect to the form
of seating between the sprue bush and nozzle of the machine. Both designs are shown
(Figure3-9a, c). The first of these is a sprue bush with a spherical recess which is used in
conjunction with a spherical front ended nozzle as illustrated (Figure3-9a). The second has a
perfected flat rear face, the seating between it and it corresponding nozzle being shown
(Frigure3-9a).
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Providing the alignment between the nozzle and the bush apertures is perfect, a leak-
free joint is achieved with the spherical seating. It should be noted that the radius on the
nozzle is slightly less than that in the bush, which ensures both parts are in physical contact at
the apertures. However, if the nozzle and sprue bush are slightly out of line (due perhaps to
wear on platen bushes), a gap will result and leakage behind the mold will develop (Figure3-
9b). This drawback is not present if slight misalignment occurs at the seating of the sprue
bush and lat-faced nozzle (Figure3-9d). As can be seen, no leakage can occur if the two
apertures are slightly out of the line and no restriction to flow will occur either, providing that
the sprue bush has an aperture slightly larger than that of the nozzle. An allowance of 0.8mm
on diameter is usually made.
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CHAPTER-5
SPRUE DESIGN
Sprue is located at the entrance of molds.It allows the melt plastic material to flow
into the runner or cavity.A sprue bush is inserted on the cavity plate or runner. When direct
gate is used, the plastic part will be left with a trace by the sprue. To keep the sprue bush in
place, while being under pressure, a step design is usually used to fix it on a locating ring.
The hole inside the sprue bush is usually conic in shape. The smaller end of the hole is a
curve. the large taper the hole has, the easier the sprue to pop out. Sprue bush and nozzle may
come in contact on a planesurface; it facilitates a right location and tight fit.
For theplastic Molds Design, the following principles are applied to sprue bush
design: First, usually the radius of the sprue bush should be larger than the radius of the
nozzle about 1mm. And the smaller diameter of the cone -shaped hole should be larger than
the nozzle’s diameter by 0.5~1mm.Third, minimize its length. Firth, polish the cone-shape
hole along its length’s direction.
Cold-slug well usually locates at the end of the sprue.That is, at the end of
the runner and on the core-retainer plate, on directly opposite side of the sprue.Its purpose is
to store cold slug created intermittently by the nozzle due to heat loss and low temperature.
Cold slugs could clog or slow down the material flow in runner and cavity and cause cold
scars or cold marks on the plastic part. During the opening, the well can pull the slug off the
sprue bush. Thus the diameter of a cold-slug well should be larger than the larger diameter of
the sprue,while its length should be about the same as the larger diameter of the sprue, to
promote the material flow. A sprue puller consists of cold-slug well and ejector pin. There is
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an ejector pin at the bottom of the cold-slug well. The ejector pin is fixed on an ejector
retainer plate and co-actuated with the ejection system.
The molten plastic injected from the injector nozzle will go through a sprue (sprue
bush), a runner, and a gate and fill up in the cavity.
As the temperature of molten plastic is lowered while going through the sprue and
runner, the viscosity will rise; therefore, the viscosity is lowered by shear heat generated
when going through the gate to fill the cavity.
So learn Sprue bush design is important, because sprue bush is part that contact first
time with melted plastic, bad design of sprue bush can make plastic product broken,
especially sprue broken and runner broken.
Picture below shown mold basic construction with sprue.
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3D model of sprue bush with 2 bolts
This type is commonly use in small mold size, until 350 ton injection machine is still
used.
The other construction is 4 bolts, this sprue bush type commonly use in large mold
type and mass production, more than 200 ton.
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Sprue bush with ring attachment, this type use when top plate thickness is width, but
some designer prefer use large chamfer in top plate so with first model sprue bush is still can
be attached.
5.1. SPRUE BUSH DESIGN RULE:-
1. Ball radius of sprue must larger than ball radius nozzle, so don't forget to check
diameter of nozzle of injection machine, or you can look at injection machine catalog. For
example when ball radius of nozzle of injection machine is 10 mm use ball radius sprue bush
11 until 13 mm.
2. Hole diameter inner must be larger than hole diameter nozzle, diameter nozzle is
variating base on machine injection type and manufacture, is about 2 mm until 5 mm. use 0.5
mm more larger than hole diameter of nozzle.
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3. Check your plate thickness; make sure that length of sprue bush fit with the plate
thickness.
5.2. SPRUE BUSH COOLING DESIGN AND CONSTRUCTION:-
Some times sprue bush need cooling to cut the cycle time of injection process, when
diameter of sprue is large cooling in sprue bush is important. Somefabrication of mold part
has their own sprue bush that containing cooling pipe. Like picture below
From those picture some standard part mold company have their own methods to make inner
cooling at the sprue bush, we can by cutting in some part that weld together again, or by other
method.
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the other way to make cooling in sprue is like picture below
by those type of sprue we change the entrance and exit flow by using stopper buffle, for
example like picture below
or you can make the flow straight, the other cooling method in sprue is like picture below, by
Page | 35
using this type is easy to attach the O ring, because in and out flow from below side that
contact with moldbase.Because when assembling of ring to moldbase is more easy by attach
the O ring in Moldbase then put the sprue bush than attach the O ring in sprue bush and
assembling it together in moldbase.
Locating ring is simple part but, very important when mold base attach to injection machine,
ok here the construction of locating ring after assembled in mold base.
Page | 36
then after attach in injection mold, the position of locating ring is like below
Page | 37
5.3. BASIC RULE DESIGN: -
1. When design locating ring, first rule is look at your injection machine catalog or hand
book, and find the dimension of locating ring.
Like picture below
From picture above we know that locating ring diameter is 200 mm and diameter of nozzle is
52 mm, so you’re locating ring outer diameter must same with those injection machine
locating ring hole.
Page | 38
2. Don’t worry about the tolerance, at the injection machine tolerance always about
minus 0.01-0.1 mm, then the locating ring tolerance if we buy in standard mold part company
is about minus 0.01-0.05. 3D Modeling various locating ring below is some picture of
locating ring that was sketch using Google sketch Up, now i provide two type of locating
ring. To choose right locating ring in mould is depend on injection machine nozzle, locating
hole diameter, nozzle length in other factor.
Page | 39
Second type
Third type this type have large chamfer from top to bottom in inner hole, those chamfer
provide shape so nozzle can touch the sprue more precise and easier.
Page | 40
5.4. MANUFACTURING PROCESS OF SPRUE BUSH:-
Material used for sprue bush is OHNS.
Cut off a suitable length and diameter of rod from a raw material byusing the power
saw. After that one end of the rod is fixed on spindle and otherend of the rod is centered on
tail stock on turning. Makea step turning by using turning tool. Then drill a hole of 6mm dia.
using drilling operation.
Then the bush is hardened to 62-64HRC and surface finishing is done using buffing
tool.Then the hole is enlarged to 20mm dia. at the top using CNC Wire Cut machine. Mirror
polishing is done. Then the bush is chrome plated to increase surface hardness and provide
corrosion resistance.
Page | 41
CONCLUSION
The sprue bush is defined as that part if the mold in which the sprue is formed. In
practice the sprue bush is the connecting member between the machine nozzle and the mold
face, and provides suitable aperture through which the material can travel on its way to the
impression or the start of the runner system in multi-impression molds.
In our project we have studied about sprue bush, its design and manufacturing
process.
Page | 42
Page | 43

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A

MINI- PROJECT REPORT

DESINGN OF SPRUE BUSH BY USING INJECTION MOULDING

for the award of the degree of

MD.ZAMEER ALI 17M55A0322.

K.SAI KIRAN 16M51A0319.

UNDER THE GUIDENCE OF

DEPARTMENT OF MECHANICAL ENGINEERING

ELLENKI INSTITUTE OF ENGINEERING & TECHNOLOGY

DEPARTMENT OF MECHANICAL ENGINEERING

This is to certify that the mini-project report entitled “DESINGN OF

INTERNAL GUIDE HEAD OF THE DEPARTMENT

It is our pleasure to acknowledge the help that we have received from

We express our deep sense of gratitude to our beloved chairman

We express our deep sense of gratitude to our beloved Director

We would like to thank Professor Dr.R.SARVANAN, PRINCIPAL

We express special thanks Mr. CH. NAGARAJU , HEAD,

DEPARTMENT OF MECHANICAL ENGINEERING for his encouraging support

We express special thanks Mr. CH.NAGARAJU, ASSISTANT

N.VENKATA SURYA BHARADWAJ 16M51A0326.

MD.ZAMEER ALI 17M55A0322.

K.SAI KIRAN 16M51A0319.

N VENKATA SURYA BHARADWAJ

1. INTRODUCTION TO INJECTION MOULDING …..2 - 4

1.1. Introduction ….. 2

1.2. Capabilities ….. 3

2. PROCESS CYCLE …..5 - 17

2.1. Equipment ….. 7

2.2. Injection Unit ….. 7

2.3. Clamping Unit ….. 9

2.4. Machine Specifications ….. 10

2.5. Tooling ….. 11

2.6. Mold Base ….. 12

2.7. Mold Channels ….. 13

2.8. Mold Design ….. 14

2.9. Materials ….. 16

3. COST DRIVERS ….18 - 21

3.1. Material Cost ….. 18

3.3. Tooling Cost ….. 19

3.4. Tolerances and Surfaces ….. 20

3.5. Lubrication and Cooling ….. 20

3.6. Power Requirements ….. 21

4. INTRODUCTION TO SPRUE BUSH …..22 - 23

5. SPRUE DESIGN …..24 - 35

5.1. Sprue Bush Design Rule ….. 27

5.2. Sprue Bush Cooling And Construction ….. 28

5.3. Basic Rule Design ….. 32

5.4. Manufacturing Process of Sprue Bush ….. 35

bush), a runner, and a gate and fill up in the cavity.

when going through the gate to fill the cavity.

broken and runner broken.

INTRODUCTION TO INJECTION MOULDING

it cools and solidifies into the final part.

Injection molding overview

syringes, are manufactured using injection molding as well.

Envelope: 0.01 in³ - 80 ft³

Max wall thickness: 0.03 - 0.25 in. 0.015 -

Lead time: Months Weeks

Can form complex shapes and fine details.

Excellent surface finish.

Good dimensional accuracy.

Low labor cost.

Scrap can be recycled.