Design optimization of plastic injection runner for coconut punch holder product

Abstract

This study optimizes the runner system design for a plastic coconut punch holder component using Computer-Aided Engineering (CAE) through Autodesk Moldflow Insight software. The simulation process is evaluated across three distinct gate models, namely the fan gate, the half-circular gate, and the cashew gate, with variations in sprue height at 52 mm, 57 mm, and 67 mm. These configurations are systematically analyzed to identify the most efficient design layout based on key performance indicators, including flow distribution, volumetric fill time, injection pressure at V/P switchover, and wall shear stress. The simulation results demonstrate that the 57 mm cashew gate operates as the most optimal layout by successfully minimizing the fill time to 0.4156 seconds and reducing the wall shear stress to 0.2367 MPa, thereby protecting the Polypropylene material from localized thermo-mechanical degradation. Alternatively, the 52 mm half-circular gate serves as a robust secondary choice due to its capability to yield the lowest fluid flow resistance with an injection pressure of 15.51 MPa while offering a simpler profile for CNC machining. Ultimately, these optimized runner designs provide plastic injection industries with actionable engineering data to maximize manufacturing production efficiency and enhance local part quality.