Technology and equipment of vertical‑stack molding for the production of castings without pattern drafts

The article reports on the new technology and equipment of vertical‑stack molding (VSM), created by OJSC “BELNIILIT” for the manufacture of vertical‑stack molds. The development is intended for the production of molds and cast blanks of oil, which are later used for the manufacture of piston rings of internal combustion engines.The difference between the above‑mentioned technology and traditional methods of VSM is the use of models without drafts. The development is export‑oriented and has a great economic effect for ring manufacturers due to the absence of drafts on castings, since part of the mechanical operations for their processing is excluded, the metal consumption of blanks is reduced, the production spaces required in this regard are reduced, the necessary labor supply is reduced, etc.OJSC “BELNIILIT” has successfully carried out experimental design and technological work on the new scientific and technical products creation, which are of great interest to the world manufacturers of piston rings. An industrial sample of a molding machine and a mold manipulator were manufactured.

PLANNING AND SCHEDULE OF MAINTENANCE WORKS FOR INJECTION MACHINES

Keeping the equipment and machinery in working order is a very important activity in the field of industrial production, being specific to the maintenance department within an enterprise. Ensuring an optimal in operation of the manufacturing systems is closely related to the prevention of defects, an action that must be found in a planning and scheduling of preventive-planned maintenance works. In the paper, in addition to the introductory part on the main objectives and implementation of the maintenance system and maintenance-specific operations, a case study is conducted for the planning and organization of maintenance in a company equipped with plastic injection machines. The main stages developed consisted in elaborating the maintenance plan, establishing the optimal moment for replacing the machine tools, choosing the optimal type of machine tool and establishing the elements of random wear of the machine tools. It is concluded that the optimal type of injection molding machine that will be chosen to replace the T10 injection molding machine is T14, because it has a minimum average cost of acquisition, maintenance and repair, respectively 42.286 UV.

Education in plastics manufacturing: Aluminum mold making and injection molding

Plastics are ubiquitous in the modern world with both positive and negative consequences. Students will benefit from understanding how plastics are manufactured. They will be more aware of the material and have a better appreciation for the need to recycle. Injection molding is one of the primary plastics manufacturing methods and hobby scale injection molding machines can be used to educate students about plastics and polymers. Furthermore, it is possible to create custom injection molds from aluminum using similar hobby scale tools. In this article, experiences introducing injection molding in the classroom and experiences with mold making as a senior design project are presented. Suggestions and procedures for using the injection molding machine and for creating custom aluminum molds are covered.

DESIGN AND PRODUCTION OPTIMIZATION OF PP 20% TALC ADDITIVE FILTER WITH PLASTIC INJECTION MOLDING MACHINE

In the paper, the design optimization of the food-contact water tank filter used in industrial kitchen products was made and produced in plastic injection molding machine with different parameters. The effects of production parameters on product weight, fabric filter strength (tearing), production time and surface quality (burrs and gas gap) were investigated experimentally and statistically. The design of the experiments was prepared with the Taguchi L[Formula: see text] orthogonal array. Experiment parameters are determined as injection speed (A), holding press (B), holding speed (C), mold temperature (D), melting temperature (E) and compression waiting time (F). As a result, 154% improvement was achieved in the fabric strength as a result of design optimization. As a result of the optimization of the injection parameters of the product, when the response tables were examined, it is determined that the greatest value of filter fabric strength is 298[Formula: see text]N in A2B2C2D1E1F3 parameters. When ANOVA results are analyzed, the most effective parameter for fabric strength and surface quality was determined as mold temperature with 36.38% and compression waiting time with the lowest effective parameter as 0.08%.

Online Semisupervised Learning Approach for Quality Monitoring of Complex Manufacturing Process

Data-driven quality monitoring is highly demanded in practice since it enables relieving manual quality inspection of the product quality. Conventional data-driven quality monitoring is constrained by its offline characteristic thus being unable to handle streaming nature of sensory data and nonstationary environments of machine operations. Recently, there have been pioneering works of online quality monitoring taking advantage of online learning concepts in the literature, but it is still far from realization of minimum operator intervention in the quality monitoring because it calls for full supervision in labelling data samples. This paper proposes Parsimonious Network++ (ParsNet++) as an online semisupervised learning approach being able to handle extreme label scarcity in the quality monitoring task. That is, it is capable of coping with varieties of semisupervised learning conditions including random access of ground truth and infinitely delayed access of ground truth. ParsNet++ features the one-pass learning approach to deal with streaming data while characterizing elastic structure to overcome rapidly changing data distributions. That is, it is capable of initiating its learning structure from scratch with the absence of a predefined network structure where its hidden nodes can be added and discarded on the fly in respect to drifting data distributions. Furthermore, it is equipped by a feature extraction layer in terms of 1D convolutional layer extracting natural features of multivariate time-series data samples of sensors and coping well with the many-to-one label relationship, a common problem of practical quality monitoring. Rigorous numerical evaluation has been carried out using the injection molding machine and the industrial transfer molding machine from our own projects. ParsNet++ delivers highly competitive performance even compared to fully supervised competitors.

Designing the Ergonomic Press and Molding Machine of Cassava Chips for Sustainable Development in SMEs

The sustainability of the SMEs depends on how the SMEs could compete with their competitor. Utilizing technology is a way that can be used to survive in those competitions. Unfortunately, some of the SMEs in Indonesia could not afford to utilize the technology due to financial problems. Therefore, the aim of this research is to create an ergonomic working environment by utilizing the technology through the design of the press and molding machine. In its application, the concepts of Rapid Entire Body Assessment (REBA) and Rapid Upper Limb Assessment (RULA) were used to assess the working posture. The results of this assessment show that the working environment of this SME, especially in the pressing and molding process was not ergonomic and need to be improved. The given improvement is in the form of press and molding machine design and its prototype. The designing process was done using the concept of Quality Function Deployment (QFD). On the other side, to assess the level of success for the given design and machine, the REBA and RULA assessment was carried out. The results of the REBA and RULA assessment for the new machine showed that it could decrease the previous score of both REBA and RULA. The results of this research are expecting to increase the production capacity, minimizing the occurrence of MSDs, and improving the quality of the chips. In the long-term, it will be able to increase the competitiveness of this SME.

The Low Breaking Fiber Mechanism and Its Effect on the Behavior of the Melt Flow of Injection Molded Ultra-Long Glass Fiber Reinforced Polypropylene Composites

In this study, fiber breaking behavior, fiber orientation, length variation, and changes in melt flow ability of long glass fiber reinforced polypropylene (L-FRP) composites under different mold cavity geometry, melt fill path, and plasticization parameters were investigated. The matrix material used was polypropylene and the reinforcement fibers were 25 mm long. An ultra-long-fiber composite injection molding machine (with a three-stage plunger and injection mechanism design) was used with different mold cavity geometry and plasticization parameters. Different screw speeds were used to explore the changes in fiber length and to provide a reference for setting fiber length and parameter combinations. Flow-length specimen molds with different specimen thickness, melt fill path, and gate design were used to observe the effect of plasticizing properties on the flow ability of the L-FRP composite materials. The experimental results showed that the use of an injection molding machine with a mechanism that reduced the amount of fiber breakage was advantageous. It was also found that an increase in screw speed increased fiber breakage, and 25 mm long fibers were shortened by an average of 50% (to 10 mm). Long fibers were more resistant to melt filling than short fibers. In addition, the thickness of the specimen and the gate design were also found to affect the filling process. The rounded angle gate and thick wall product decreased the flow resistance and assisted the flow ability and fiber distribution of the L-FRP injection molding.