IJSTE–International Journal of Science Technology & Engineering| Vol. 1, Issue 6, December 2014| ISSN(online): 2349-784X All rights reserved by www.ijste.org 16 A Review of Design And Development of Plastic Injection Molding Machine To Enhance The Efficiency Anand S. Dangi Rakesh Prajapati PG Student Assistant Professor ME- Machine design Mechanical Engineering Department Sal Collage of Engineering, Ahmedabad, India. Sal Collage of Engineering, Ahmedabad, India. Parth Gajjar Dipen Modi Assistant Professor Assistant Professor Mechanical Engineering Department Mechanical Engineering Department Sal Collage of Engineering, Ahmedabad, India. Sal Collage of Engineering, Ahmedabad, India. Abstract Injection molding has been a challenging process for many manufacturers and researchers to produce products meeting requirement at the lowest cost. The quality of molded part can be classified into four categories: part design, mold design, machine performance and process conditions. The development of unique technologies for high accuracy, high speed injection molding machine including a high rigidity, high speed driving mechanism and high dispersion, high speed plasticization mechanism through the structure analysis technology, flow analysis technology and control simulation technology. The each process variable can be categorized into one of five main types such as speed, pressure, time, Temperature and stroke. The cooling time period is depended on the general shape of the component, the wall thickness of the component, and type of material being processed. The cooling time can represent more than 70% of injection cycle.The cycle time can be reduced by reducing the cooling time. We also perform multiple optimization simultaneously minimizing cycle time, wasted materials, and pressure drop. Keywords: Injection Molding, Injection Mold Design, Baffle Cooling, Mold Flow, Cooling Time, Finite Element Analysis (FEM), Cycle Time. _________________________________________________________________________________________________________ I. INTRODUCTION Injection molding has been the most popular method for making plastic product due to high efficiency and manufacturability. The injection molding machine includes main for stage for production of plastic parts: filling and packing Stage, cooling stage and ejection stage. Among these stage cooling stage is a very important one because it mainly the productivity, quality and total efficiency of the machine. The cooling stage taken 70% time of cycle time [7]. The appropriate design of cooling channel reduces cooling time, increase the productivity and minimizes undesired defect such as sink marks, differential shrinkage, thermal residual stress and warpage. The cooling phase, heat transfer between the molten materials inside the cavity and the cooling fluid flow in the cooling channel inside the mold. The rate of heat exchange is very important and directly related to the time taken by the cooling phase. So it is important to understand and optimize the cooling channel design to optimize the rate of heat transfer in an injection molding process. The optimizing convectional cooling channels (straight-drilled cooling lines) and finding architecture for injection mold cooling channel (conformal cooling channel). The optimize the configuration of the cooling system in the terms of shape, size and location of cooling line. The cooling layout conformal cooling channel the conform to the mold cavity surface and examines the effectiveness of the cooling system. Solid free- form fabrication (SFF) or rapid prototype (RP) techniques have been proposed build this complex cooling system. The cooling quality is better than that conventional cooling channel. Along with SFF technique, milled groove conformal cooling channel. The conformal cooling channel in the plastic injection mold by using an array of baffles. The combination of analytical method, design of experiment(DOE), finite element method, boundary element method (BEM) and CAE tool, especially the mold flow software were used to derive approximate equations showing the relation among cooling channel design variables, mold material process parameter for a given polymer [5] [7]. The design of injection mold is highly interactive and manual process involving substantial knowledge of multiple areas, such as mold design features, mold making processes, molding equipment and part design, all of which are highly coupled to each other. The main challenge is to design and produce a mold that is straightforward to manufacture, while providing uniform filling and cooling of plastic parts. At the same time the tool has to be strong enough to withstand millions of cyclic internal loads from injection pressures and external clamp pressures, in order to assure the target part‟s reproducibility.