scholarly journals Mold Design For Injection Molding: A Successful Industry University Partnership Case Study

2020 ◽  
Author(s):  
Masud Salimian
Keyword(s):  
Injection Molding ◽  
Mold Design ◽  
University Partnership

Conformal Cooling Versus Conventional Cooling: An Injection Molding Case Study With P-20 and 3DP™-Processed Tooling

2000 ◽  
Vol 625 ◽  
Author(s):  
Wayde R. Schmidt ◽  
Ronald D. White ◽  
Connie E. Bird ◽  
Joseph V. Bak
Keyword(s):  
Injection Molding ◽  
Design Approach ◽  
Mold Design ◽  
Simulation Tool ◽  
Conformal Cooling ◽  
Designed Experiments ◽  
Tool Fabrication ◽  
Conventional Cooling

AbstractA series of designed experiments was performed in an attempt to evaluate and quantify the historically “anecdotal” benefits of conformal cooling for injection molding tooling. The study considered different generic part geometries, gating schemes, mold materials, plastic resins and cooling approaches. This paper provides an overview of the mold design approach, cooling simulation, tool fabrication via the 3DP™ process, as well as part molding and inspection results.

Energy and GHG Emissions Assessment in a Plastic Injection Process at Machine Component Level: A Case Study of ABS Plastic Part Produced in a Hybrid Injection Molding Machine

2017 ◽  
Author(s):  
Javier Ávila ◽  
Vicente Borja ◽  
Marcelo López-Parra ◽  
Alejandro C. Ramírez-Reivich
Keyword(s):  
Injection Molding ◽  
Ghg Emissions ◽  
Energy Usage ◽  
Molding Machine ◽  
Injection Molding Machine ◽  
Energy Assessment ◽  
Injection Process ◽  
Hybrid Injection ◽  
Plastic Injection

In this article a GHG and energy analysis for the plastic injection process of an ABS medium sized injected part carried out in a hybrid injection molding machine is reported. A power consumption process pattern for an ABS medium-size part is defined as well as the energy usage of components, the energy used for the injection process is calculated for the injection cycle and for the process setup. The reported study includes a hybrid machine analysis working under an electric network that relies mainly on thermoelectric energy generation. The GHG emissions assessment was estimated using the 2015 emission factor applied for Mexico. The results provide new experimental data for ABS plastic injected parts in hybrid injection machines. This paper describes the outcomes of a GHG emissions and energy assessment for an ABS medium-sized injected part carried out in a HIMM at UNAM. The approach followed by the authors in this assessment was aimed at providing information about the energy usage and GHG emissions for the process and the part. The main contribution of this paper is the insight related to energy usage indicators in the process, the energy usage and the GHG emissions within components. The product used as a case study and the results of its GHG emissions and energy assessment are presented.

Optimal Layout and Sizing of Ejector Pins for Injection Mold Design

1998 ◽  
Author(s):  
Seongjoon Kwak ◽  
Kunwoo Lee
Keyword(s):  
Wavelet Transform ◽  
Injection Molding ◽  
Mold Design ◽  
Injection Mold ◽  
Optimal Layout ◽  
Rule Based ◽  
Rule Based System ◽  
Molded Part ◽  
Injection Mold Design ◽  
Local Stresses

Abstract Injection molding is the most prevalent technology used for processing thermoplastic polymers. At the end of the injection molding cycle, the plastic molded part should be ejected when the injection mold opens. Complex moldings with bosses, ribs, or other features are generally ejected by ejector pins because they are economical and easy to be installed. However, the ejector pins can cause high local stresses and strains in the molding at the stage of ejection leading to the part deformation and damage. This paper proposes a method to determine the layout and size of the ejector pins required to eject thermoplastic moldings with minimizing the part deformation and damage. The proposed method calculates the distribution of the necessary ejecting forces to overcome the friction between the part and its mold. Then, it transforms the ejecting forces into a certain number of representative forces by the wavelet transform. Finally, we can get the location and size of the ejector pins corresponding to the discrete ejecting forces with the help of a rule-based system. The proposed method helps an injection mold designer to systematically obtain an optimum ejector design.

scholarly journals Measurement of Overall Performance Effectiveness in Setup Improvement

2014 ◽  
Vol 2014 ◽  
pp. 1-7 ◽  
Author(s):  
Shye-Nee Low ◽  
Siu-Hou Chong ◽  
Hui-Yee Sim ◽  
Solehhudin Razalli ◽  
Shahrul Kamaruddin
Keyword(s):  
Injection Molding ◽  
Setup Time ◽  
Process Performance ◽  
Performance Effectiveness ◽  
Significant Time ◽  
Before And After ◽  
Overall Performance ◽  
Time Savings

This study aimed to improve the setup process of injection molding machines by using the developed setup improvement methodology. Overall performance effectiveness (OPE) was used to evaluate the setup improvement. A case study was tested on the application of the developed setup improvement methodology. A 50.1% reduction in setup time was attained by the developed methodology, and significant time savings were achieved with minimum investment. Comparisons between before and after improvement implementation were conducted through OPE to verify the improvement. In terms of OPE, the setup performance in the case study considered an acceptable value of 60.45%. The setup process performance of the developed setup improvement methodology was judged in terms of effectiveness. Results therefore indicate that OPE measurement is an effective way to analyze the efficiency of a single setup process.

Establishing a rapid cooling complex mold design for the quality improvement of microcellular injection molding

2020 ◽  
Vol 60 (12) ◽  
pp. 3072-3085 ◽  
Author(s):  
Yung‐Hsiang Chang ◽  
Min‐Chi Chiu ◽  
Shia‐Chung Chen ◽  
Che‐Wei Chang ◽  
Chia‐Yen Tseng
Keyword(s):  
Quality Improvement ◽  
Injection Molding ◽  
Mold Design ◽  
Rapid Cooling ◽  
Microcellular Injection Molding

Finite Element Design and Numerical Simulation on Non-Pneumatic Beehive Damping Tire

2011 ◽  
Vol 291-294 ◽  
pp. 418-422
Author(s):  
Ge Gang Zhu ◽  
Chen Xu ◽  
Long Yi ◽  
Ning Li
Keyword(s):  
Numerical Simulation ◽  
Finite Element ◽  
Injection Molding ◽  
Simulation Analysis ◽  
Mold Design ◽  
Molding Process ◽  
Improvement Measures ◽  
Quality Issues

The design and numerical simulation and analysis on non-pneumatic beehive damping tire were discussed in this paper by finite element techniques. And use the molding software filling its experimental to analyze the process of injection molding qualities for the reasonable mold design. And the corresponding improvement measures, the rationality of mold design and molding process were arised for quality issues according to the simulation analysis.

Polyurethane Reaction Injection Molding: Process, Materials, and Properties

1980 ◽  
Vol 53 (3) ◽  
pp. 542-599 ◽  
Author(s):  
L. J. Lee
Keyword(s):  
Injection Molding ◽  
Flow Rate ◽  
Weight Reduction ◽  
Flexural Modulus ◽  
Impact Resistance ◽  
Mold Filling ◽  
Injection Molding Process ◽  
Mold Design ◽  
Thermal Coefficient ◽  
Reaction Injection Molding

Abstract Reaction injection molding includes aspects of polymerization reactor analysis as well as melt injection molding. Processing can be broken down into several unit operations: metering and machine performance, impingement mixing, mold filling, curing and mold design. Commercial RIM machines have been used successfully for non-filler systems. The results are generally satisfactory. Reactants are usually allowed to circulate through the mixhead, or even through impingement nozzles, such that uniform temperature control and appropriate agitation of reactants can be obtained. Most heads can switch from the recycle to injection mode under high pressure operation, to minimize the lead/lag problem. The mixing chamber is self-cleaned at the end of each shot by a hydraulically driven piston which pushes out all the residue mixture from the mixhead after mold filling. Flow rate/flow area can be adjusted externally by the nozzle size adjuster. Flow rate also can be controlled by the pressure setting. Two or four streams impingement mixing is the common mixing technology used in the present RIM machines. Static or impingement type after-mixers have been used extensively to improve the mixing. Mold filling seems not to be a problem for conventional RIM operation if mold design is appropriate. The typical pressure inside the mold cavity during filling is less than 350 kPa. With the help of slight foaming during curing, RIM polyurethanes usually have excellent, depression-free surfaces. A number of qualitative descriptions of automotive type RIM have appeared, and some basic studies of the process are being carried out. However, as yet there does not appear to be a complete understanding of how the process influences the structure and properties of the polymer formed. The majority of RIM parts have been made in the 140–300 MPa flexural modulus range for fascia applications, where appearance, weight-reduction, and impact resistance are the most important criteria. A representative formulation used to produce automotive fascia by reaction injection molding consists of a polyether/polyester polyol with molecular weight in the range of 1000–3000, a short chain extender like ethylene glycol, 1,4-butane diol or a diamine and a modified derivative of 1,4-diphenylmethane diisocyanate, MDI. The need for further weight reduction to meet government mileage requirements, and for improved corrosion and impact resistance, makes the extension of RIM materials to other external automotive body components increasingly attractive. For these applications, there will be several new requirements: flexural moduli in the 700–4000 MPa range to provide dimensional stability, but still with the desirable impact strength; a low thermal coefficient of linear expansion to allow satisfactory mating with sheet metal surfaces. An increased thermal stability would also be required for parts that would be painted and baked on the car, or for applications such as hoods with higher in-use thermal exposure.

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