Week 5 - Complex gating system and occurrence number.

PART – 1

Objective

Complex gating system to accommodate 8 molds using only one sprue.

Procedure

Following is the process to perform complex gating system:

• Create a ruler of dimension (40x10) mm and perform dual domain mesh by taking value of 1 mm as global edge length as shown below

• Add cold gate to the centre of ruler width.

Cold gate values are:

1. Cross-section = rectangle
2. Shape = tapered (by end dimension)
3. Number of beams = 5
4. Cross-sectional dimensions are:
   • Start width = 1mm
   • End width = 0.6mm
   • Start height = 1mm
   • End height = 3mm.

• Add cold secondary runner to the end of cold gate.

Secondary cold runner values are:

1. Number of beams = 8
2. Cross-section = circular
3. Shape = non-tapered
4. Cross-sectional dimensions are:
   • Diameter = 1mm

• Duplicate the part by using reflect feature into 8 numbers as shown below:

• Add primary cold runner to the ends of secondary cold runners of 8 different molds.

Primary cold runner values are:

1. Number of beams = 50
2. Cross-section = circular
3. Shape = non tapered
4. Cross-sectional dimensions are:
   • Diameter = 3mm

• Add cold sprue to the centre of primary cold runner

Cold sprue dimensions are:

1. Number of beams = 5
2. Shape = tapered (by end dimensions)
3. Cross-sectional dimensions:
   • Start diameter = 1mm
   • End diameter = 3mm

• Now set injection location to the start of sprue as shown

PART – 2

Objective

Complex gating system to accommodate 8 molds using only one sprue.

Procedure

Following is the process to perform complex gating system:

• Create a ruler of dimension (40x10) mm and perform dual domain mesh by taking value of 1 mm as global edge length as shown below

• Add cold gate to the centre of ruler width.

Cold gate values are:

1. Cross-section = rectangle
2. Shape = tapered (by end dimension)
3. Number of beams = 5
4. Cross-sectional dimensions are:
   • Start width = 1mm
   • End width = 0.6mm
   • Start height = 1mm
   • End height = 3mm.

• Add cold secondary runner to the end of cold gate.

Secondary cold runner values are:

1. Number of beams = 8
2. Cross-section = circular
3. Shape = non-tapered
4. Cross-sectional dimensions are:
   • Diameter = 1mm

• Add sprue to the end of primary cold runner and set injection location at its top.

Cold sprue dimensions:

1. Shape = tapered by end dimensions
2. Start diameter = 0.5mm
3. End diameter = 1mm
4. Number of beams = 10

• Change the occurrence numbers to 8 for the ruler, sprue and gate.

Learning outcomes

Following things that I have learned in this week challenge are:

• Came to know about gate, runner, sprue and mold.
• Gate provides molten metal inlet into mold.
• Runner connects gate and sprue.
• Sprue provides entry to the molten material.
• Mold is the cavity which holds molten material and gives desired shapes.
• With the help of reflect feature we can duplicate the model in many numbers.
• Setting of injection location.
• Occurrence number helps to run the analysis faster as compare with multi cavity gating system.

Conclusion

Week 5 challenge helps me to understand the gating system and design of it with the help of software. I would like to thanks support engineer ‘David sir’ for helping me in clearing the doubts and also thanks to lecturer for his good explanation. I would like to thank Skill-Lync for helping me to enhance the skill.