The aim of the project work is to specify optimum design of runner and gate systems to enhance the production rate for plastic part manufacturing. Literature survey will be done on runner and gate system to understand simulation or analysis approach. Data collection will be done to brief about runner and gate system importance, design method and variations. Plastic flow analysis will be done on digital prototype of a specimen by various runner and gate profiles and also done by changing materials. The optimum profiles for the runner and gate system will be suggested by comparing flow results with specific materials and profiles.

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International Journal of Research and Innovation on Science, Engineering and Technology (IJRISET)
International Journal of Research and Innovation in
Mechanical Engineering (IJRIME)
PREDICTIVE ANALYSIS OF GATE AND RUNNER SYSTEM
FOR PLASTIC INJECTION MOULD
Botla Sudheer Kumar1
, N.Rajesh2
.
1 Research Scholar, Department of Mechanical Engineering, Sri Venkateswara College of Engineering Technology, Andhra Pradesh,
India.
2 Assistant professor, Department of Mechanical Engineering, Sri Venkateswara College of Engineering Technology, Andhra Pradesh,
India.
*Corresponding Author:
Botla Sudheer Kumar,
Research Scholar, Department of Mechanical Engineering,
Sri Venkateswara College of Engineering Technology, Andhra
Pradesh, India.
Email: darajojappa@gmail.com
Year of publication: 2016
Review Type: peer reviewed
Volume: III, Issue : I
Citation: Botla Sudheer Kumar, Research Scholar, "Predictive
Analysis of Gate And Runner System For Plastic Injection Mould"
International Journal of Research and Innovation on Science,
Engineering and Technology (IJRISET) (2016) 199-206
Literature survey
[1 ]Mr. Tangqing Kuang Wenjuan Gu from School of Me-
chanical and Electrical Engineering, East China Jiaotong
University, Nanchang 330013, China has done the re-
search work on “Optimum Design of Runner System for
Router Cover Based on Mold Flow Analysis Technology” in
that publication they have done comparison and worked
on selection of different gate settings by using mold flow
analysis. Finally they got the best gate location and gate
panel number for the router, the length and cross section
size can be determined by the following choice of mold
plate and the mold specifically designs. The runner sec-
tion size can be optimized by runner balance analysis.
And the gate section size can be optimized to ensure the
full compensation by packing analysis and cooling analy-
sis. The resulting optimum runner system can be used to
improve product quality.
From this example, we know that the successful applica-
tion of mold flow analysis for injection mold design pro-
vides the scientific basis and reference for mold design-
ers and aids designers to optimize the design programs,
reduce testing time, and improve qualities of mold and
products.
[2] Mr.Chandan Deep Singh fromUniversity College of
Engineering, Punjabi University has done the reasearch
work on “Feature Library of Gating System for a Die-Cast-
ing Die” and he has given the conclusions as “The system
has inbuilt feature library for gate, runnerand overflow
designs. The system helps a die-castingengineer in re-
ducing time and efforts as there is noneed to design the
gating system for a part fromscratch. The system would
go a long way in bridging the gap between designing and
manufacturing of diecasting.The present work has over-
come the shortcomings of the previous.”
INTRODUCTION
RUNNERS
Distribution system for the resin from the sprue to the
cavities Flow characteristics (viscosity), temperature and
other factors are important in determining the runner di-
ameter and length If the diameter of the runner is too
small or the length is too long, the resin can freeze in the
runner before the mold is completely full If the runner
system is too large, excess material would be ejected and
too much regrind created If the resins have a high viscos-
ity, larger runners are needed compared to low viscosity
resin.
The optimum flow of the resin through the runner system
depends on the shape and diameter of the channel Round
channel give the best flow characteristics but difficult to
machine Machining cost can be reduce by machining one
side of the mold plates Better shape where the depth of
the channel is at least two-thirds the size of the width and
the sides are tapered between 2 to 5º.
Abstract
The aim of the project work is to specify optimum design of runner and gate systems to enhance the production rate for
plastic part manufacturing.
Literature survey will be done on runner and gate system to understand simulation or analysis approach.
Data collection will be done to brief about runner and gate system importance, design method and variations.
Plastic flow analysis will be done on digital prototype of a specimen by various runner and gate profiles and also done
by changing materials.
The optimum profiles for the runner and gate system will be suggested by comparing flow results with specific materials
and profiles.

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International Journal of Research and Innovation on Science, Engineering and Technology (IJRISET)
Secondary Runners
• Secondary runner channel are used for multi cavity
molds
• The flow into the secondary channel should be stream-
lined (angle in flow direction)
• The streamlined minimizes shear on the resin
Runners are the major part of feed system of moulding
process it has to design very carefully most commonly
USED CROSS-SECTIONS AS BELOW.
New
Gate type
As important as selecting the optimal gate size and loca-
tion is the choice of the type of gate.
Gate types can be divided between manually and auto-
matically trimmed gates.
Manually trimmed gates Manually trimmed gates are
those that require an operator to separate parts from run-
ners during a secondary operation. The reasons for using
manually trimmed gates are:
• The gate is too bulky to be sheared from the part as the
tool is opened.
• Some shear-sensitive materials (e.g., PVC) should not be
exposed to the high shear rates inherent to the design of
automatically trimmed gates.
• Simultaneous flow distribution across a wide front to
achieve specific orientation of fibers of molecules often
precludes automatic gate trimming.
Gate types trimmed from the cavity manually include:
• Sprue gate
• Edge gate
• Tab gate
• Overlap gate
• Fan gate
• Film gate
• Diaphragm gate
• External ring
• Spoke or multipoint gate
MODEL OF SPECIMAN WITH RUNNERS
The above image shows semicircular runner
The above image shows square runner
The above image shows trapezoid

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International Journal of Research and Innovation on Science, Engineering and Technology (IJRISET)
The above image shows modified trapezoid
MOULD FLOW ANALYSIS
Mould flow, 3D solids-based plastics flow simulation that
allows plastics part designers to determine the manu-
facturability of their parts during the preliminary design
stages and avoid potential downstream problems, which
can lead to delays and cost overruns. Following are the
benefits:
• Optimize the part wall thickness to achieve uniform fill-
ing patterns, minimum cycle time and lowest part cost
Identify and eliminate cosmetic issues such as sink
marks, weld lines and air traps.
• Determine the best injection locations for a given part
design
Mould flow analysis gives you the ability to maintain the
integrity of your product designs. It provides you the tools
to quickly optimize part designs and check the impact
of critical design decisions on the manufacturability and
quality of the product early in the design process.
MATERIALS
Polypropylene (pp)
Acrylonitrile Butadiene Styrene (ABS)
High Density Polyethylene (HDPE)
Polyvinyl Chloride (PVC)
PLASTIC FLOW ANALYSIS OF SPECIMEN USING SEMI
CIRCULAR RUNNER
MATERIAL: PP
The above image shows fill time
The above image shows injection pressure
The above image shows surface temp variance
PLASTIC FLOW ANALYSIS OF SPECIMEN USING
SQUARE RUNNER
MATERIAL: PP
The above image shows fill time
The above image shows Injection Pressure

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International Journal of Research and Innovation on Science, Engineering and Technology (IJRISET)
PLASTIC FLOW ANALYSIS OF SPECIMEN USING
TRAPEZOID RUNNER
MATERIAL: PP
The above image shows fill time
The above image shows injection pressure
PLASTIC FLOW ANALYSIS OF SPECIMEN USING MOD-
IFIED TRAPEZOID RUNNER MATERIAL: PP
The above image shows fill time
The above image shows injection pressure
Plastic Flow analysis of Specimen using Semi - Circu-
lar Gate MATERIAL: PP
The above image shows fill time
The above image shows injection pressure
PLASTIC FLOW ANALYSIS OF SPECIMEN USING
SQUARE GATE MATERIAL: PP
The above image shows fill time
The above image shows injection pressure

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International Journal of Research and Innovation on Science, Engineering and Technology (IJRISET)
PLASTIC FLOW ANALYSIS OF SPECIMEN USING TRAP-
EZOID GATE
The above image shows fill time
The above image shows injection pressure
PLASTIC FLOW OF SPECIMEN USING MODIFIED
TRAPEZOID GATE MATERIAL: PP
The above image shows fill time
The above image shows injection pressure
Plastic Flow analysis of Specimen using modified
trapezoid runner with over Lap Gate
MATERIAL: PP
The above image shows fill time
The above image shows injection pressure
Plastic Flow analysis of Specimen using modified
trapezoid runner with Bottom Gate
MATERIAL: PP
The above image shows fill time
The above image shows injection pressure

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International Journal of Research and Innovation on Science, Engineering and Technology (IJRISET)
Plastic Flow analysis of Specimen using modified
trapezoid runner with Top Gate
MATERIAL: PP
The above image shows fill time
The above image shows injection pressure
Plastic Flow Analysis Using Multi Cavity System Poly-
propylene (PP)
The above image shows fill time
The above image shows confidence of fill
The above image shows injection pressure
Runner system
Semi-
Circular
Square Trapezoid Modified
Trapezoid
Fill Time 6.82 5.12 5.34 5.27
Injection
Pressure
14.45 5.92 7.24 5.90
Pressure
Drop
14.45 5.92 7.24 5.90
Flow Front
Temp
240.10 240.02 240.02 240.01
Surface
Temp
Variance
91.58 89.18 101.80 39.99
Gate geometry
Semi-
Circular
Square Trapezoid Modified
Trapezoid
Fill Time 5.34 5.56 5.77 5.11
Injection
Pressure
6.55 7.82 7.44 6.12
Pressure
Drop
6.55 7.81 7.44 6.04
Flow Front
Temp
240 240.03 240.02 240
Surface
Temp
Variance
1.46 1.67 1.69 1.61
Gate systems
Over
Lap
Bot-
tom
Top Tap Fan Ring
Fill
Time
4.93 5.58 5.21 6.02 5.34 3.37
Injec-
tion
Pres-
sure
4.05 8.11 5.97 10.12 7.34 8.75
Pres-
sure
Drop
4.05 8.11 5.97 10.12 7.34 8.75
Flow
Front
Temp
240 240.01 240 240.02 240.01 240.02
Sur-
face
Temp
Vari-
ance
1.99 1.87 1.60 3.84 1.45 4.68

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International Journal of Research and Innovation on Science, Engineering and Technology (IJRISET)
Multi cavity
PP ABS HDPE PVC
Fill Time 6.03 7.84 6.40 13.82
Injection
Pressure
18.77 28.38 34.87 43.87
Pressure
Drop
18.77 28.38 34.87 43.87
Flow Front
Temp
240.08 230.16 210.46 170.45
Surface
Temp
Variance
11.30 11.30 11.30 11.30
CONCLUSION
This research paper gives the complete orientation on
runner and gate system of plastic product manufacturing
Mould.
Initially literature survey and data collection was done on
gate and runner system to understand the methodology
and selection of geometry.
Mould flow analysis was done using plastic advisor on
various runners and gate profiles, to specify the optimum
model for gate and runner.
In first case:- Semi circular, square, trapezoid and modi-
fied trapezoid models where analyzed using standard
pressure with regular material polypropylene, In this case
modified trapezoid runner system is giving optimum Flow
with low pressure.
In second case:- Various geometric profiles of gate system
are implemented to provide the optimum gate geometry.
In this case modified trapezoid gate geometry with modi-
fied trapezoid runner is having optimum quality.
In third case:-Different methods of gate systems are im-
plemented to fine optimum feed system.
In this case overlap type is showing good charter sticks.
In fourth case:-The mould flow analysis was done using
different materials on multi cavity model. In this case
all the thermo plastics (PP, ABS, HDPE) is showing good
charter sticks, along with trapezoid gate with runner
with overlap system , but when coming to thermo setting
plastic(PVC) is not suitable for multicavity system.
As per the obtaining results of above four different cas-
es this research work concludes that modified trapezoid
runner and gate system with overlap method will perform
better injection moulding process, it uses very low pres-
sure, it losses pressure drop with nominal surface tem-
perature variance.
REFERENCE
1 Tangqing Kuang “Optimum Design of Runner System
for Router Cover Based on Mold Flow Analysis Technol-
ogy” School of Mechanical and Electrical Engineering,
East China Jiaotong University, Nanchang 330013, Chi-
na.2015 .pp1-13
2 Chandan Deep Singh Department of Mechanical Engi-
neering, University College of Engineering, Punjabi Uni-
versity, Patiala, (PB) (India
3 Mohd. RizwanHamsin, AzuddinMamat and AznijarAh-
mad-Yazid Department of Engineering Design and Manu-
facture Faculty of Engineering, University of Malaya,
4 E. Bociąga, T. Jaruga* Institute of Polymer Processing
and Production Management, Al. ArmiiKrajowej 19c 42-
200 Częstochowa, Poland * Corresponding author: E-mail
address: jaruga@kpts.pcz.czest.pl
5 E. Bociąga, T. Jaruga* Institute of Polymer Processing
and Production Management, Czestochowa University of
Technology, Al. ArmiiKrajowej 19c, 42-200 Częstochowa,
Poland * Corresponding author: E-mail address: jaruga@
kpts.pcz.czest.pl
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mechanical engineering R.V. college of Engineering, Ban-
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ShridharBagalkot NTTF, Peenya 2nd stage Bangalore,
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2Asst. Professor, Department of Mechanical Engineering,
R V College of Engineering, Karnataka, India, vikas5440@
gmail.com., chandrakumarr@rvce.edu.in

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International Journal of Research and Innovation on Science, Engineering and Technology (IJRISET)
AUTHORS
Botla Sudheer Kumar,
Research Scholar,
Department of Mechanical Engineering,
Sri Venkateswara College of Engineering Technology,
Andhra Pradesh, India.
N.Rajesh,
Assistant professor,
Department of Mechanical Engineering,
Sri Venkateswara College of Engineering Technology,
Andhra Pradesh, India.