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Gates and Runners
Gates and Runners
Gates and Runners
Chapter 10
Professor Joseph Greene
All rights reserved
Copyright 2000
Overview
• Gate Location and Number per Cavity
• Hot Runner Gate Types and Configurations
• Cold Runner Gate Types and Configurations
• Cold Runner Ejection and Pullers
• Cold Runner Molds
Gate Location and Number per Cavity
• Rule 1: One gate per cavity should be sufficient
– Avoids undesirable weld lines in the product
• One Gate per cavity
– Outside Center Gating (OSCG)
• Used with hot runner or three-plate mold, OSCG should be located so that
an approximately equal volume of plastic will flow about the same distance
toward the outside rim of the product
• Venting is generally not a problem since plastic is flowing toward the
parting line
• Main problem is with core shift or core deflection
– C/L of cavity may not coincide with the C/L of the core
» Result is that one side of the cavity space is filled faster than the other,
exerting a side pressure on the core and bending it.
– C/Ls coincide, but the gate is offset just enough to produce a result similar to
the above.
Gate Location and Number per Cavity
– Core shift is more serious with
• Thin-walled products, where higher injection pressures are needed
• Products with very little draft angle, where products get jammed between
cavity and bent core. This prevents pulling out of the cavity, causing
scratches or damages to the cavity walls
• Visible and measurable effect of core shift is uneven walls in the product.
– Causes warpage due to differential shrinkage.
• Thinner side may not fill
– Solutions
• Proper selection of practical tolerances,
• Well designed, long, and correctly preloaded tapers for alignment
• Selection of stiffer (expensive) materials, e.g., tugnsten-carbide cores)
• Gate selection (type and location) has the most effect on core shift
Fig 10.1 Gate
Gate Gate Gate
C/L Vent
Vent P/L Vent P/L Vent P/L P/L
Gate Location and Number per Cavity
• One Gate per cavity
– Inside Center Gating (ISCG)
• Used in hot runner or three-plate molds
• Same gate location considerations apply as with OSCG
• Venting problems are the same
• Added complication is the ejection of the gate
• Should be used ONLY in special cases when it is necessary to avoid the
gate vestige (mark) on the visible side of the product (plates, bowls, etc.)
– Side Gating Near Top
• Hot runner edge gating (HREG) or Tunnel gate (TG)
• Product design my not allow for vestige on either side of part (lenses)
• Side location is better than gating near the rim for thin walled parts
• Plastic will usually fill the bottom first & then flow toward the rim (OSCG)
C/L
Ejection Cooling P/L
Vent Vent Gate
ISCG Gate Vent P/L
Gate Location and Number per Cavity
• One Gate per cavity
– Side Gating Near Top
• Recommended that the side gate be located so that the plasic stream will not
flow freely into the top surface
• It should be directed to hit the core, at least partially.
• The stream could be directed against a core pin in the top surface near the
gate. This creates turbulence in the plastic flow and avoids streak marks.
• Venting is critical because may travel so that it encircles a portion of the
cavity space and traps the air in the bottom.
– Ejector pins are natural vents
– Otherwise use vent pins or vent inserts (Chap 11)
Gate
Vent P/L
Gate Location and Number per Cavity
• One Gate per cavity
– Outside Gating Near Rim (Fig 10.6)
• Used in HREG, two-plate and TG
• Used in basic, general purpose molding, usually flat products
• Not recommended for containers, particularly thin-walled products due to
existence of weld lines and air entrapment.
• Venting is very important, especially through the ejector pins
– Gating of an Elongate Product
• May have HR, HREG, three plate, two plate, or TG (Fig 10.7)
• Rule is to locate the gate so that the plastic will flow the whole length of the
product to avoid formation of weak area across from gate. (Fig 10.8)
• Weak area is similar to weld line as flow splits.
Flow Direction
HR or 3-plate
Vent through pin Fig 10.6 Vent through pin Fig 10.7
Gate Location and Number per Cavity
• One Gate per cavity
– Gating with a Live Hinge
• Used in HR, three-plate, and two-plate molds
• Live hinge is usually with PP is a very thin passage from one protion (ox) to
the matching other portion (cover), producing a hinge.
• Usually gate is located in the large portion, and the smaller portion is filled
through the hinge.
• Gating in both parts could produce a weal weld line at the hinge which
could break after a few cycles of use.
Gate
HR or 3-plate
Gate Live Hinge
P/L P/L
Weak spot
Fig 10.8
Fig 10.7
Gate Location and Number per Cavity
• Two or More Gates per Cavity_ Large Products
– Sometimes two or more gates are required for large parts where flow
distance from single gate would be too long
• automotive products, bottle crates, etc.
– Problems with multiple gating
• Freeze-up of gates
– Not a problem with cold runners because gate is ejected with part
– Hot runners that use open gates have the plastic pressure to open gate, which is
partially frozen at the end of the previous cycle.
– If pressure at the gates is uneven, or if one cavity is cooler than the other, the cavity
will be filled from the gate that is easier to fill and not from the other
• Minimum distance between gates
– Hot runners requires a necessary distance because of physical dimensions of hot
runner components
• Weld lines and venting
– Weld lines occur when two flow fronts meet creating a weak point.
– Strength of weld line can be improved by venting trapped air between fronts
– Trapped air can cause burning of plastic
Gate Location and Number per Cavity
• Two or More Gates per Cavity_ Slender Products (Fig 10.11)
– Conditions are similar to other slender (cylindrical) products
explained earlier, except that the cavity is filled from open end of
the product from two or more gates.
– Restrictive to two-plate molds using edge or tunnel gates
• Plastic enters on opposite sides of the cavity space and rises toward the end.
• Forces on core are balanced and the rising plastic holds the core steady,
even if it is very slender.
• Two gates are placed 180° and three gates are placed 120°
• A Continuous gate could be used to reduce weld lines effects or a solid ring
which must be removed later.
• Venting is very important, especially on the end farthest from the gate.
Vent
P/L
Gate Gate
Cooled Core
Hot Runner Gate Types and Configurations
• Annular Gates
– Design recommendations for HREG
• Bubble should be as large as possible to create a plastic pool that will not easily
freeze.
• Land should be small in the order of 0.5 to 1.0 mm. The smaller the better but
limits are set by the strength of the steel.
• Land must be smaller than the wall thickness of the product opposite the gate so
that the slug can be easily pushed out into the cavity on the next shot.
• Gap between the land and the gate should be as small as possible
– (0.03 - 0.05mm) to bring the heat conducting nozzle (and heat) to the plastic close
to the gate area.
– Nozzle should not contact the cooled cavity.
• Reaction force from the plastic injected through the gate must be well supported
to prevent deflection of the nozzle away from the gate.
– Two gates can be located in the well at 180° to feed two cavities, or
– Three small or four small cavities can be located at 120° or 90°
– For one cavity, there must be mechanical support opposite to the gate, or
– Nozzle design must be stiff enough to withstand the deflecting force.
Hot Runner Gate Types and Configurations
• Valved Gates
• Principle of valved gates is that
the gate opening and/or closing is achieved
independent of the injection pressure.
– It opens under injection pressure at the beginning of injection
– It does not depend on the injection pressure for removal of the frozen plastic from
gate.
– Gates can be opened and closed independently, mechanically using a pin or
thermally using a special heater.
– Mechanically controlled gates: single or double acting operators
• Single acting: Gates are opened by the plastic pressure acting on a step in the
valve pin. They may be closed by
– A spring which acts as soon as the pressure drops enough.
» For low injection pressure, the spring must be weak.
» For high pressure it must be stronger. Springs can anneal.
– An in-line air cylinder or a wedge acting anytime after pressure drops
• Double acting: Gates are opened and closed by in-line air cylinders
– Opened usually at the start of the injection cycle. No step in valve pin
Hot Runner Gate Types and Configurations
• Valved Gates
– Basic valve gate (Fig 10.26)
• Early design of gate- cylindrical pin enters a cylindrical gate
– Problems include poor alignment, deflection of pin, wear of plate, nd valve pin
breakage.
– Stoke, S, of pin must be sufficient to clear the gate and to ensure that the end of the
pin which was cooled while inside the gate is heated again while immersed in hot
plastic
• Improved design included a tapered point of the valve gate pin, with a matching
seat as gate (Fig 10.27) avoids some of the problems of alignment
– But creates the problem of the closing forces acting on the gate. The gate must be
strong enough to resist this force.
• Some designs of valve actuator (Pneumatic piston), the length of thevalve pin is
calculated so that with
– Best conditions: The pin will just touch the seat without pressing down on gate
– Worst conditions: There will be a slight gap at the seat
– A stop inside the valve bushing should limit the valve pin stroke to prevent excessive
loading at the gate and limits the pin travel when gate is not tapered.
– Additional length of valve pin is important in gate design.
Hot Runner Gate Types and Configurations
• Factors Affecting Gate Size and Shape
– Definitions and terms
• Rheology: Science of deformation of plastics in response to an applied
pressure or stress. OR... Rheology is the the Science of Plastic Flow
• Melt Index (MI): Indication of the viscosity of the plastic material.
– It is defined as the amount of plastic that flows out of a cylinder in 10 minutes
– The cylinder has a weight pushing a rod through the plastic and is at a specified
temperature.
– Higher Melt index = lower viscosity
• Plastics are Non-Newtonian fluids. The viscosity is NOT constant. Water is a
Newtonian fluid and has one constant viscosity
– Plastics are shear thinning and thin out with increased shear rate
– Plastics thin out with increased temperature
• Viscosity is the materials resistance to flow.
– Low viscosity fluids, like water with a viscosity of 1 centipoise, flow easily and do
not have much pressure drop. Units are cenitpoise or Pa-sec
– High viscosity fluids, like sludge, tar, or melted plastics, flow with a lot of
resistance and require a large pressure drop to flow.
Hot Runner Gate Types and
• Factors Affecting Gate Size and Shape
Configurations
– Definitions and terms
• Shear rate: The rate of change of velocity of a moving plastic divided by the
distance from the center of the channel or tube.
– Shear rate:maximum at the mold wall and minimum at the center of flow channel.
– The higher the shear rate = the lower viscosity.
– Shear rate = volumetric flow rate (cm3/sec) divided by volume of part (cm3)
» Q = volumetric flow rate (cm3/sec) = shot volume/shot time
» r = radius of runner or tube
» L, W, t are Length, Width, and thickness of part 4Q 4Q
3 ;
– Example, r LWt
» Product has a mass of 106 g PS, which corresponds to a volume of 100cm3.
(Note: density of PS = 1.06 g/cc)
» The part is injected in 1 sec, so Q = 100 cm3/sec.
» The gate size has a cross section of 1 mm3,corresponding to a diameter (2r) of
1.27mm = 0.127 cm, therefore r = 0.0635 cm
» The speed of injection is 100,000 mm3 / 1 mm2 = 100,000 mm/sec or 100 m/sec.
» Shear rate = 100 cm3 /sec / (3.14)(0.0635) 3 =527,000 sec-1. Very high
•Hot Runner Gate Types and Configurations
Factors Affecting Gate Size and Shape
– Definitions and terms
• Shear stress- unit pressure on the fluid that is subjected to shearing action
• Shear sensitivity: Various plastics respond differently to the amount of
shearing in the mold. Some plastics degrade if shear too much (PVC)
• Shear insensitive materials: Some plastics are insensitive to the amount of
shearing (PP, ABS)
• Factors Affecting Gate and Land Size in Open Gates
• Part weight and size: Longer flow length and the larger the cavity surface, the
larger gate is required to reduce fill pressure
• Product wall thickness: Large wall thickness requires large gate to provide
material during packing phase.
• Resin: Viscous resins require larger gates and shorter lands to reduce
restriction at gate.
• Location of cooling lines for mold: Too close to gate will cause premature
gate freeze-off. Too far from gate, will cause drooling.
• Injection time: Very fast injection requires a larger gate to reduce local
pressure drop and prevent excessive shearing
Hot Runner Gate Types and Configurations
• Factors Affecting Gate and Land Size in Open Gates
• Melt temperature: Gate can be reduced to increase shear rate and heat the
plastic more and fill the part easier.
• Entrance effects: Sharp corners or restrictions impede the flow of resin and
can cause shear-induced degradation. Use a generous radius on the cavity
side of the gate to help provide smooth laminar flow and prevent jetting.
• Nozzle tip position: If tip is too close to the gate, the gate is less likely to
freeze off prematurely, and as a result, a smaller gate can be used.
• Dimple: If dimple is too large, the cycle will slow down.
• Requirements for a Correctly Designed Gate
• Permit unrestricted flow- to the greatest possible extent- to prevent
degradation of the plastic.
• Prevent drooling or stringing
• Provide correct shearing to condition the resin and to reduce its viscosity to
achieve the greatest flow length possible.
• Hide or disperse the cold slug without impeding flow. This also is helped by a
dimple.
Hot Runner Gate Types and Configurations
• Consequences of improperly Designed Gate
– Jetting (visible flow lines away from the gate)
– Blushing (a concentric, cloud-like blemish around the gate)
– Stringing (threads of resin sticking to the product)
– Warping (deformation of the product)
– Degradation of the resin
– Improper filling (short shots)
– Premature freeze-off of gates, and
– Bad vestiges (gate marks)
Hot Runner Gate Types and Configurations
• Gate Shape and Size
– Land Length (Gate height)
• Land should be short as possible to achieve lower pressure for filling and to
improve degating by reducing the height of vestige.Lengths= 0.13 to 0.25mm
– Gate diameter
• Too small a gate can be recognized by blemishes at the gate and surface
imperfections.
• Too high an injection pressure and short shots
• Premature gate freeze-off
– Role of Shearing in Gate Diameter Sizing
• High shear rates can raise local melt temperature of the melt and reducing
viscosity making the plastic flow easier in the cavity
• High shear rates can improve the gloss of the plastic
• If gate is too large, then very little shearing may occur and could cause gate
freeze-off
• Fig 10.29
Hot Runner Gate Types and Configurations
• Gate Shape and Size
– Role of Shearing in Gate Diameter Sizing
• Fig 10.29
– Fig 10.29 creates four times as much shearing as in B and none in C.
– Shear rate in gate should be greater than 1,000 sec-1
– In thin walled molding (<1mm), the shear rate should be between 100,000 and
1,000,000 sec
– All materials have a maximum shear rate at which they will degrade.
– Table 10.1
Material Max Shear Stress Max Shear Rate
PP 250,000 100,000
HDPE 80,000 40,000
LDPE 80,000 40,000
PS 250,000 40,000
HIPS 300,000 40,000
SAN 300,000 40,000
ABS 300,000 50,000
PPS 345,000 50,000
Nylon 500,000 60,000
PET 500,000 6,000
PUR 250,000 40,000
PBT 400,000 50,000
Hot Runner Gate Types and Configurations
• Gate Shape and Size
– Time of Exposure to Shear
• Longest time exposure to shear has an effect on the resin
• Long exposures can degrade some plastics
• Establish a Proper Gate Size
• Use past experience, Use computer analysis, Use empirical approximation
– Computer analysis
• Gate is part of the hot runner and should be designed with the rst of the hot
runner
– Pressure drop: less than 6,000 psi or less than 5,000 psi for General Purpose
– Melt Temp Rise: Less than 15C but less for shear sensitive plastics
– Shear rate: Greater than 1,000 sec -1
– Shear stress Table 10.1
– Empirical Analysis: Use the formula to determine gate diameter d
• A is surface area, N and C are constants d NC 4 A
Hot Runner Gate Types and Configurations
• Establish a Proper Gate Size
– Empirical Analysis: Use the formula to determine gate diameter d
• A is surface area, N and C are constants
– thickness of product: d NC 4 A
• Quantity of plastic
• Color or product
• Method of gating
• Power requirement