Journal articles: 'Injection moulding tool'

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Kashouty, Rennie, and Ghazy. "Tool Life Performance of Injection Mould Tooling Fabricated by Selective Laser Melting for High-Volume Production." Materials 12, no. 23 (November 26, 2019): 3910. http://dx.doi.org/10.3390/ma12233910.

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Rapid Tooling processes are developing and proving to be a reliable method to compete with subtractive techniques for tool making. This paper investigates large volume production of components produced from Selective Laser Melting (SLM) fabricated injection moulding tool inserts. To date, other researchers have focused primarily on investigating the use of additive manufacturing technology for injection moulding for low-volume component production rather than high volume production. In this study, SLM technology has been used to fabricate four Stainless Steel 316L tool inserts of a similar geometry for an after-market automotive spare part. The SLM tool inserts have been evaluated to analyse the maximum number of successful injections and quality of performance. Microstructure inspection and chemical composition analysis have been investigated. Performance tests were conducted for the four tool inserts before and after injection moulding in the context of hardness testing and dimensional accuracy. For the first reported time, 150,000 injected products were successfully produced from the four SLM tool inserts. Tool inserts performance was monitored under actual operating conditions considering high-level demands. In the scope of this research, SLM proved to be a dependable manufacturing technique for most part geometries and an effective alternative to subtractive manufacturing for high-volume injection moulding tools for the aftermarket automotive sector.

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Glozer, G. R., and J. R. Brevick. "Laminate Tooling for Injection Moulding." Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture 207, no. 1 (February 1993): 9–14. http://dx.doi.org/10.1243/pime_proc_1993_207_056_02.

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The main goal of this research was to develop a method of prototyping injection moulded parts which produces a representation of the production part, including not only the part shape and functionality but the process as well. A prototyping method that meets all of these requirements could greatly aid in reducing the time required to bring a new product to the market by using the information gained from this prototype to manufacture a production tool that will be right the first time. Tooling constructed of laminations is appealing for prototyping or production because of the flexibility it affords in terms of rapidly altering mould geometry, gating or cooling passage design. This report summarizes a ‘proof of concept’ project which took a selected part geometry through the entire laminate tool manufacturing process. This report is divided into five sections: (1) introduction to the prototyping process, (2) background of current prototyping processes and description of the laminate tooling method, (3) description of the geometry selected for this work and the manufacturing details, (4) evaluation of the performance of the laminate injection mould and (5) conclusions.

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Harris, R. A., H. A. Newlyn, and P. M. Dickens. "Selection of mould design variables in direct stereolithography injection mould tooling." Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture 216, no. 4 (April 1, 2002): 499–505. http://dx.doi.org/10.1243/0954405021520193.

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Stereolithography (SL) can be used rapidly to produce injection moulding tools. The disadvantage of the technique is that it is capable of producing only a small number of parts before failure. Stereolithography tools may break under the force exerted by part ejection when the friction between a moulding and a feature of the tool is greater than the tensile strength of the tool, resulting in tensile failure. Very few justified recommendations exist concerning the choice of mould design variables that can lower the part ejection force experienced and reduce the risk of SL tool failure. This research investigates the ejection forces resulting from the injection moulding of polypropylene (PP), acrylonitrile-butadiene-styrene (ABS) and polyamide 66 (PA66) parts from SL tools that are identical in all respects except for their build layer thickness (a process variable when generating the SL tooling cavities) and incorporated draft angles (a tooling design variable). This work attempts to identify appropriate evidence for recommendations with respect to these variables and SL injection moulding. The results show that linear adjustment of draft angle results in a fairly minor linear change in part ejection force according to the moulding material. A linear adjustment of the build layer thickness results in a greater change in part ejection force as a more non-linear relationship. In both cases the greatest ejection forces were experienced by PA66, then ABS and then the PP parts. The results also show that the surface roughness of all tools remains unchanged after moulding a number of parts in all polymers. A mathematical model was used in an attempt to predict ejection forces according to the moulding material used. This model did reflect the experimental results in terms of relative values but not in absolute values, which may be due to the limitations imposed by the development of the expressions and uncertainty about some specific values.

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Kiatmanaroj, S., V. Goodship, and G. F. Smith. "Sandwich Injection Moulding of Thermosetting Materials Part II: Effects of Moulding Parameters." Progress in Rubber, Plastics and Recycling Technology 21, no. 1 (February 2005): 27–38. http://dx.doi.org/10.1177/147776060502100102.

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This paper describes experiments on the sandwich injection moulding of two thermosetting polyesters, a powder coating and a bulk moulding compound. The flow of the powder coating in the injection moulding machine at various tool temperatures was investigated in order to find the optimum conditions. The formation of the skin and core layers in the moulding component at various injection times is described and discussed.

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Llewelyn, Gethin, Andrew Rees, Christian A. Griffiths, and Steffen G. Scholz. "Advances in microcellular injection moulding." Journal of Cellular Plastics 56, no. 6 (March 17, 2020): 646–74. http://dx.doi.org/10.1177/0021955x20912207.

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Injection moulding is a well-established replication process for the cost-effective manufacture of polymer-based components. The process has different applications in fields such as medical, automotive and aerospace. To expand the use of polymers to meet growing consumer demands for increased functionality, advanced injection moulding processes have been developed that modifies the polymer to create microcellular structures. Through the creation of microcellular materials, additional functionality can be gained through polymer component weight and processing energy reduction. Microcellular injection moulding shows high potential in creating innovation green manufacturing platforms. This review article aims to present the significant developments that have been achieved in different aspects of microcellular injection moulding. Aspects covered include core-back, gas counter pressure, variable thermal tool moulding and other advanced technologies. The resulting characteristics of creating microcellular injection moulding components through both plasticising agents and nucleating agents are presented. In addition, the article highlights potential areas for research exploitation. In particular, acoustic and thermal applications, nano-cellular injection moulding parts and developments of more accurate simulations.

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Yanev, A. S., Gustavo R. Dias, and António M. Cunha. "Visualization of Injection Moulding Process." Materials Science Forum 587-588 (June 2008): 716–20. http://dx.doi.org/10.4028/www.scientific.net/msf.587-588.716.

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A special tool-transparent mould designed to visualize the melt flow inside the cavity is used in this research. The aim of the work is to assess the polymer melt behavior under different processing conditions-close to industrial, in conventional and two materials non-conventional injection moulding techniques. The mould is designed with two injection locations and has possibility to change the geometry of the cavity in order to investigate the melt behavior in differently shaped cavities. Visual access in the mould is allowed by the sapphire windows, surrounding the cavity. For image acquisition a high speed video camera NAC 1000 is used. Materials used in the research are three polypropylenes with different flow index. Results are obtained for conventional injection moulding, two material monosandwich and two material biinjection moulding. Apart from visualization, instrumentation of the mould allows to be obtained PT data for each processing condition. Results from conventional injection moulding are compared with MPI5.0 simulations.

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Hernández, P., S. Taboada, L. Suárez, M. D. Marrero, F. Ortega, and A. Benítez. "Interactive Learning Tool in Product Development for Injection Moulding." Procedia Engineering 132 (2015): 197–204. http://dx.doi.org/10.1016/j.proeng.2015.12.470.

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Ramos, Carina, Pedro Carreira, Paulo J. Bártolo, and Nuno Alves. "OPTIMALMOULD | Cooling System Influence in Injection Moulding Cycle Time Optimization." Advanced Materials Research 683 (April 2013): 544–47. http://dx.doi.org/10.4028/www.scientific.net/amr.683.544.

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Most works undertaken on injection moulding cooling time optimization aimed at reducing the time required to produce plastic parts, this way minimizing industrial costs. An optimal cooling system is proposed to improve the injection moulding design. A multi-objective genetic algorithm called NSGA-II is used, to obtain the optimal parameters in the optimal-mould design. This new design method is an efficient tool to get optimal parameters for injection moulding design. A real case study was carried out to test the optimization platform.

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Hric, Slavomir, Dominika Lehocka, Jan Carach, Filip Murgas, and Peter Pastucha. "The Simulation as a Tool for Technical Devices Design and Optimization." Applied Mechanics and Materials 718 (December 2014): 122–27. http://dx.doi.org/10.4028/www.scientific.net/amm.718.122.

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The article deals with the research of the pressures originated inside the cooling system and also in the mould cavity during the injection moulding process. The simulations were realized for three designed types of running system and for four versions of cooling system. 3D model of the mould was created in Autodesk Inventor Proffesional software and then solidification of material was simulated in Autodesk Moldflow Insight software. The results were compared and the best version from the view of pressure was manufactured and placed into the injection moulding machine Arburg Allrounder 320 C.

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Turng, L.-S., and M. Peić. "Computer aided process and design optimization for injection moulding." Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture 216, no. 12 (December 1, 2002): 1523–32. http://dx.doi.org/10.1243/095440502321016288.

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Sophisticated computer aided engineering (CAE) simulation tools for injection moulding have been available and are now widely used in industrial practices. As a result, the design and manufacturing of injection-moulded parts have been literally transformed from a ‘black art’ to an engineering discipline based on scientific principles. It is well recognized that computer simulation tools help engineers to gain process insight and to pinpoint blind spots and problems that are overlooked. Nevertheless, there remains a missing link in CAE, which lies in the ability to identify effectively the optimal design and process variables, as it is hampered by the sheer amount of computer-generated data and complex non-linear interactions among those input variables. This paper presents the system implementation and experimental verifications of an integrated CAE optimization tool that couples a process simulation program with optimization algorithms to determine intelligently and automatically the optimal design and process variables for injection moulding. In addition, this study enables evaluation and comparison of various local and global optimization algorithms in terms of computational efficiency and effectiveness for injection moulding, as presented in this paper.

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Krüger, Kilian, Martin Kain, Yang Zhang, David Bue Pedersen, Matteo Calaon, Guido Tosello, and Hans Nørgaard Hansen. "Enabling Micro Injection Moulding Using a Soft Tooling Process Chain with Inserts Made of Mortar Material." Micromachines 12, no. 8 (July 22, 2021): 857. http://dx.doi.org/10.3390/mi12080857.

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The manufacturing of inserts for micro injection moulding made of mortar material is presented in this work. The fabrication of the mortar insert described in this publication relied on a versatile and relatively fast rapid prototyping process based on soft tooling. The mortar insert has a QR code with micro features on its surface, which was replicated in acrylonitrile butadiene styrene (ABS) polymer by the micro injection moulding process. With this approach, it is possible to fabricate hard inserts for micro injection moulding purposes that are able to compete with conventional-made inserts made of tool steel.

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Godec, Damir, Vladimir Brnadić, and Tomislav Breški. "Optimisation of Mould Design for Injection Moulding – Numerical Approach." Tehnički glasnik 15, no. 2 (June 9, 2021): 258–66. http://dx.doi.org/10.31803/tg-20210531204548.

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Computer simulation of injection moulding process is a powerful tool for optimisation of moulded part geometry, mould design and processing parameters. One of the most frequent faults of the injection moulded parts is their warpage, which is a result of uneven cooling conditions in the mould cavity as well as after part ejection from the mould and cooling down to the environmental temperature. With computer simulation of the injection moulding process it is possible to predict potential areas of moulded part warpage and to apply the remedies to compensate/minimize the value of the moulded part warpage. The paper presents application of simulation software Moldex 3D in the process of optimising mould design for injection moulding of thermoplastic casing.

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Griffiths, C. A., S. S. Dimov, E. B. Brousseau, and R. T. Hoyle. "The effects of tool surface quality in micro-injection moulding." Journal of Materials Processing Technology 189, no. 1-3 (July 2007): 418–27. http://dx.doi.org/10.1016/j.jmatprotec.2007.02.022.

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Bodaghi, Masoud, Pavel Simacek, Suresh G. Advani, and Nuno C. Correia. "A model for fibre washout during high injection pressure resin transfer moulding." Journal of Reinforced Plastics and Composites 37, no. 13 (March 29, 2018): 865–76. http://dx.doi.org/10.1177/0731684418765968.

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High injection pressure resin transfer moulding is a variant of resin transfer moulding in which the preform is compressed in a tool and resin is injected into the mould under very high pressure. The high injection pressure (>20 bar) introduces possible fibre washout that translates into manufacturing defects or causes inconsistencies in processing and leads to scatter in mechanical properties of composite parts. A model is presented which quantifies and provides insight into the influence of process variables such as clamping force and injection pressure on fibre washout distance (the one-dimensional model assumes a rigid preform). A generalised one-dimensional stress model for fibre washout is presented for regions that are impregnated with the resin and the regions that are dry. The model shows fibre washout to be significant at the beginning of the injection process. The model allows one to further refine the injection strategy by adjusting injection pressure to account for washout in high injection pressure resin transfer moulding.

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Košík, Miroslav, Jozef Bílik, and Daynier Rolando Delgado Sobrino. "Reduction of Injection Moulded Plastic Part Warpage Using Advanced Gas Assisted Injection Moulding." Materials Science Forum 862 (August 2016): 200–209. http://dx.doi.org/10.4028/www.scientific.net/msf.862.200.

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Dimensional and shape accuracy are the basic quality criteria of almost every injection moulded plastic part, manufactured in the engineering industry. They are dependent on many production conditions as part and moulding tool design, material structure properties and injection parameters. Generally, it is very difficult to achieve high geometrical accuracy during injection moulding, therefore, dimensional tolerances for plastic parts are usually many times larger than in the case of metals. However, according to requirements of the engineering industry, demands for the plastic parts dimensional accuracy keep growing permanently, what also extends to the growing shape complexity of the produced parts. Due to this tendency, engineers must look for more and more advanced solutions to meet market requirements and keep the competitiveness of their product. In consonance with all this, this paper presents a case study where the progressive gas assisted injection moulding is used as a solution for the plastic part warpage reduction while any other conventional methods failed. The study is performed making use of part from the automotive industry, initially produced with unacceptable deformations. In the first step, the real manufacturing state was studied to determine the warp behaviour. Subsequently, the process parameters and cooling conditions were unsuccessfully modified while trying to reduce deformations. Nevertheless, these were effectively eliminated by the only application of internal gas support to the melt injection phase. A numerical modelling based on Finite Volume and Finite Element Method was also used in the case study in order to mathematically represent the fluid, thermal and mechanical processes during the process of injection moulding.

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Albert, André, Welf Guntram Drossel, Wolfgang Zorn, Wolfgang Nendel, and Dirk Raithel. "Process Combination of Hydroforming and Injection Moulding for the In Situ Manufacturing of Metal and Plastic Composite Structures." Materials Science Forum 825-826 (July 2015): 522–29. http://dx.doi.org/10.4028/www.scientific.net/msf.825-826.522.

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The use of lightweight structures is a major trend in the reduction of fuel consumption and CO2 emissions, especially in transport. Metal plastic hybrid structures are an efficient solution to use the best material at every point in the design space. In the state of the art production technologies, the metal parts are produced separately from the plastic parts. The injection moulding process is only used for forming the plastic parts and for joining. These process chains are very extensive. The article shows the development of new process combinations. The aim is a combination of metal forming and injection moulding in one die and one process. One part should be produced with every single stroke of the press.In the first step, deep drawing, injection molding and media based forming with the plastic melt were successfully merged in one tool and one process. It was possible to integrate the injection moulding process into a deep drawing machine. In the next step, it was possible to successfully combine hydroforming and injection molding. For this process combination the hydroforming process is integrated into an injection moulding press. Different surface structures of the metal tubes, such as sandblasting, knurling and laser structuring, were systematically tested regarding to their properties as an adhesion promoter. The target is to establish a purely mechanical connection between the hydroformed metal component and the injection moulded component from glass fibre reinforced plastic instead of the chemical bonding agents often used previously, such as Vestamelt®.

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Godinho, J. S., A. Cunha, and R. J. Crawford. "Prediction of the mechanical properties of polyethylene parts produced by different moulding methods." Proceedings of the Institution of Mechanical Engineers, Part L: Journal of Materials: Design and Applications 216, no. 3 (July 1, 2002): 179–91. http://dx.doi.org/10.1177/146442070221600303.

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The properties of moulded plastic products are dependent on the processing technology used in their manufacture and in particular on the structural morphology resulting from the thermomechanical environment experienced by the melt. This paper presents a unified approach to predict the mechanical properties of moulded parts. A linear medium-density polyethylene (LMDPE) was processed using injection moulding, rotational moulding and compression moulding in order to induce different thermomechanical conditions (i.e. shear rates and cooling rates). Two models were then developed to predict the mechanical properties of the parts produced by the quite different moulding methods. One model is based on laminate theory, in which the mechanical properties of the individual layers through the wall thickness are used to predict the tensile and flexural properties of the full-thickness moulding. The other approach is more generic in that it predicts the properties as a function of two thermomechanical indices. A good agreement is achieved between the experimental data and the values predicted by the models. It is also shown that the combined use of the thermomechanical indices concept and the laminate analysis permits good predictions to be made for the mechanical properties of plastic mouldings with complex microstructures. It is proposed that this approach could provide a very valuable addition to existing melt flow simulation packages. This would provide a valuable tool for designers in that not only would it be possible to optimize processing conditions but also the properties of the end product could be predicted.

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Bulla, Benjamin, Fritz Klocke, Olaf Dambon, and Martin Hünten. "Influence of Different Steel Alloys on the Machining Results in Ultrasonic Assisted Diamond Turning." Key Engineering Materials 523-524 (November 2012): 203–8. http://dx.doi.org/10.4028/www.scientific.net/kem.523-524.203.

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This publication focuses on the ultra precision manufacturing of hardened steel parts with single crystal diamond tools for optical applications such as injection moulding. Nowadays optical steel moulds are nickel plated, in order to be able to machine the surface with single crystalline diamond tools. One technology that has proven its potential for replacing this procedure is the ultrasonic assisted diamond turning technique. This process allows direct machining of hardened steel with single crystal diamond tools, which is conventionally not possible due to the high tool wear. The ultrasonic assisted diamond turning process is applied in order to machine different steel alloys that are conventionally used for mould manufacturing in injection moulding. The goal is to analyze the influence of the steel alloy and the material microstructure on the machining results. The presented analysis show the capabilities of this new technology and opens the door for it to compete with established manufacturing processes, such as the manufacturing of nickel plated mold inserts.

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Au, Kin Man, and Kai Ming Yu. "Variable Radius Conformal Cooling Channel for Rapid Tool." Materials Science Forum 532-533 (December 2006): 520–23. http://dx.doi.org/10.4028/www.scientific.net/msf.532-533.520.

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The cooling system of a plastic injection mould is important as it affects the quality and productivity of the polymeric components or assemblies. Contemporary cooling channel design is confined to simple configurations of straight-drilled coolant passageway around the mould insert. Undesirable defects resulted during injection moulding, such as warpage, are inevitable. The application of rapid tool (RT) based on solid freeform fabrication (SFF) technologies with conformal cooling channel (CCC) design has provided a profound opportunity in quality improvement of polymeric components. In this study, a novel design of variable radius conformal cooling channel (VRCCC) is proposed to achieve better uniform cooling performance. Thermal-FEA and melt flow analysis are used to validate the method.

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Sateesh, N., S. Devakar Reddy, Ram Subbiah, D. Siva Nagaraju, and BCh Nookaraju. "Processing parameters Optimization of Injection Moulding in DN20 Vent of Water Meter Manufacturing." E3S Web of Conferences 184 (2020): 01008. http://dx.doi.org/10.1051/e3sconf/202018401008.

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The conventional optimization process in Injection Moulding includes actual shop floor trials in which melt temperature, mould temperature, injection time, injection pressure, pattern, feeder size, shape and location cores, mould layout, gating etc. are changed in each iteration which involves high machining cost, tooling cost, modification cost, melting cost, and transportation cost as well as, materials, energy, time are wasted in each trial until and unless the required results are obtained. Water meter component (DN20 Vent) is designed in CREO 5.0, and then components are 3D printed to cross check the dimensions and also to confirm whether all the other components can be accommodated or not. Then the mould flow analysis will be performed on a water meter components using different materials and changing the processing parameters. The input processing parameters considered are melt temperature, mould temperature and injection time, whereas the responses are warpage, volumetric shrinkage, cycle time and quality prediction. Grey relational analysis is carried out to determine the optimum injection moulding processing parameters.. The effort has been made to minimize the warpage, volumetric shrinkage, cycle time and maximize the quality prediction mould cavity and core for the components are designed in CREO 5.0 and manufactured using P20 tool steel. Then the water meter components are manufactured by inputting the optimal processing parameters in injection moulding machine to achieve high productivity and quality.

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Zhang, Yang, Hans Nørgaard Hansen, and Søren Sørensen. "Replication of micro-pillars by PEEK injection moulding with CrN-coated Ni tool." International Journal of Advanced Manufacturing Technology 80, no. 1-4 (March 25, 2015): 383–88. http://dx.doi.org/10.1007/s00170-015-6991-8.

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Othman, Mohd Hilmi, Sulaiman Hasan, and Muhammad Farid Shaari. "Development and Structural Analysis of Injection Moulding-Hydraulics Clamping Unit Testing System." Applied Mechanics and Materials 315 (April 2013): 156–60. http://dx.doi.org/10.4028/www.scientific.net/amm.315.156.

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This project is focusing on the development of a test unit for the hydraulically driven clamping system, typically used in injection moulding. The objectives of this project are to fabricate the model of clamping unit and to perform structural analysis based on the model design through simulation and by performing actual experiment on the real fabricated model. This actual test was conducted by compressing the load cell in between the two moulds halves in order to get the clamping force value through the data logger. The results obtained from simulation shows that the maximum stress of clamping unit with tie bar can achieve up to 11.2 MPa, with the safety value of 2.5. In the other hand, for the actual test experiment, the result the maximum clamping force produce is 3160N at 52bar of pressure. These values are important to be used as guidance in selecting the suitable injector part. As a conclusion, this clamping system has work properly and efficiently to be used for further research and a tool to understand more about the mechanism and the effects of clamping units in injection moulding process.

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Bagalkot, Anurag, Dirk Pons, Digby Symons, and Don Clucas. "Analysis of Raised Feature Failures on 3D Printed Injection Moulds." Polymers 13, no. 10 (May 11, 2021): 1541. http://dx.doi.org/10.3390/polym13101541.

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Background: Polymer-based 3D Printed Injection Mould (3DIM) inserts are used as a cost-effective method for low volume injection moulding (50–500 parts). However, abrupt failure leading to a short tool life is a common shortcoming of 3DIM. Need: The underlying causes of raised feature failures on 3DIM are not well known. Failure is commonly attributed to bending or shearing of raised features on the tool. Understanding the causes may help in delaying the failure and increasing tool life. Approach: Tool failure was analysed from a first-principles perspective, using pressure and temperature fields as determined by mould flow simulation. Experimental results were also obtained for two types of tool material (Visijet M3-X and Digital ABS) with polycarbonate (Lexan 943A) as the part material. Findings: Results find against the idea that pin failure in 3DIM tools is caused by bending and shear failures induced by injection pressures. We also conclude that failure of raised features is not necessarily an abrupt failure as mentioned in the literature. Originality: The generally accepted explanation for the failure of raised features in 3DIM tooling is that injection pressures cause bending and shear failure. This paper disconfirms this notion on theoretical and experimental grounds.

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Razak, Zakaria, Abu Bakar Sulong, Norhamidi Muhamad, Mohd Khairul Fadzly Md Radzi, Nur Farhani Ismail, Dulina Tholibon, and Izdihar Tharazi. "Numerical Simulation Analysis of Wood/PP Composites for Injection-Moulded Car Battery Trays." International Journal of Engineering & Technology 7, no. 3.17 (August 1, 2018): 15. http://dx.doi.org/10.14419/ijet.v7i3.17.16613.

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This research focused on the simulation analysis of wood polymer composites (WPCs) based on polypropylene (PP) for the injection moulding of automotive parts, namely car battery trays (CBTs). A plastic CBT, which is commonly used to support the battery in a car engine, is manufactured completely through the injection moulding process. The conventional design method is clearly unable to satisfy production requirements; however, with the application of the Moldflow software rational production process parameters, the filling time, injection pressure, clamping force, and others, can be formulated. A moulded CBT was designed using a computer-aided design tool, namely CatiaV5R20, before being imported to the finite element analysis tool, Moldflow. The use of the Moldflow software enabled a full analysis to be conducted of the material flow inside the mould cavity for the moulded CBT. Two types of gates, namely, the sprue and pinpoint gates, were used, through which the analyses were carried out by the Moldflow software to check the filling time, injection pressure, clamping force and warpage, by simulation in the sequential trials. The data on the wood fibre/PP composite, where 40 wt% of wood fibre loading was used. Finally, the use of the Moldflow simulation software was presented.

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Gornik, Christian, and Jochen Perko. "Comprehensive Wear Study on Powder Metallurgical Steels for the Plastics Industry, Especially Injection Moulding Machines." Materials Science Forum 534-536 (January 2007): 657–60. http://dx.doi.org/10.4028/www.scientific.net/msf.534-536.657.

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M390 microclean® of Böhler Edelstahl is a powder metallurgical plastic mould steel with a high level of corrosion and wear resistance and therefore often used in the plastics processing industry. But as a consequence of rapidly advancing developments in the plastics processing industry the required level of wear resistance of tool steels in this field is constantly rising. For that reason a new PM tool steel with higher hardness values and an increased amount of primary carbides has been developed to improve the resistance against abrasive and adhesive wear. The wear resistance of both steels against adhesive situations for components of the plastification unit of injection moulding machines has been tested with a novel method. In case of processing polyolefins with an injection moulding machine it was found that there is adhesive wear between the check-ring and the flights of the screw tip of the non-return valve under certain circumstances. The temperature in that region was measured with an infrared temperature sensor. The existence of significant peaks of that signal was used as an indicator for an adhesive wear situation.

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Calaon, Matteo, Federico Baruffi, Gualtiero Fantoni, Ilenia Cirri, Marco Santochi, Hans Nørgaard Hansen, and Guido Tosello. "Functional Analysis Validation of Micro and Conventional Injection Molding Machines Performances Based on Process Precision and Accuracy for Micro Manufacturing." Micromachines 11, no. 12 (December 16, 2020): 1115. http://dx.doi.org/10.3390/mi11121115.

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Micro polymer parts can be usually manufactured either by conventional injection moulding (IM) or by micro-injection moulding (µIM). In this paper, functional analysis was used as a tool to investigate the performances of IM and µIM used to manufacture the selected industrial component. The methodology decomposed the production cycle phases of the two processes and attributed functions to parts features of the two investigated machines. The output of the analysis was aimed to determine casual chains leading to the final outcome of the process. Experimental validation of the functional analysis was carried out moulding the same micro medical part in thermoplastic elastomer (TPE) material using the two processes by means of multi-cavity moulds. The produced batches were assessed using a precision scale and a high accuracy optical instrument. The measurement results were compared using capability indexes. The data-driven comparison identified and quantified the correlations between machine design and part quality, demonstrating that the µIM machine technology better meets the accuracy and precision requirements typical of micro manufacturing productions.

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Hopkinson, N., and P. M. Dickens. "Using stereolithography tools for injection moulding: Research into tensile tool failure and unexpected benefits of the process." Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture 214, no. 10 (October 2000): 891–99. http://dx.doi.org/10.1243/0954405001517973.

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Bagalkot, Anurag, Dirk Pons, Don Clucas, and Digby Symons. "A methodology for setting the injection moulding process parameters for polymer rapid tooling inserts." Rapid Prototyping Journal 25, no. 9 (October 14, 2019): 1493–505. http://dx.doi.org/10.1108/rpj-10-2017-0217.

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Purpose Polymer rapid tooling (PRT) inserts can be used as injection moulding (IM) cavities for prototyping and low volume production but lack the robustness of metal inserts. Metal inserts can withstand high injection pressure and temperature required, whereas PRT inserts may fail under similar parameters. The current method of parameter setting starts with using the highest pressure setting on the machine and then fine-tuning to optimize the process parameters. This method needs modification, as high injection pressures and temperatures can damage the PRT inserts. There is a need for a methodical process to determine the upper limits of moulding parameters that can be used without damaging the PRT inserts. Design/methodology/approach A case study analysis was performed to investigate the causes of failure in a PRT insert. From this, a candidate set-up process was developed to avoid start-up failure and possibly prolong tool life. This was then tested on a second mould, which successfully avoided start-up failure and moulded 54 parts before becoming unusable due to safety issues. Findings Process parameters that are critical for tool life are identified as mould temperature, injection pressure, injection speed, hold pressure and cooling time. Originality/value This paper presents a novel method for setting IM process parameters for PRT inserts. This has the potential to prevent failure at start up when using PRT inserts and possibly extend the operating life of the PRT inserts.

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Kampker, Achim, Johannes Triebs, Sebastian Kawollek, Peter Ayvaz, and Tom Beyer. "Direct polymer additive tooling – effect of additive manufactured polymer tools on part material properties for injection moulding." Rapid Prototyping Journal 25, no. 10 (November 11, 2019): 1575–84. http://dx.doi.org/10.1108/rpj-07-2018-0161.

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Purpose This study aims to investigate the influence of additive manufactured polymer injection moulds on the mechanical properties of moulded parts. Therefore, polymer moulds are used to inject standard specimens to compare material properties to specimens produced using a conventional aluminium tool. Design/methodology/approach PolyJet technology is used to three-dimensional (3D)-print a mould insert in Digital ABS and selective laser sintering (SLS) technology is used to 3D-print a mould insert in polyamide (PA) 3200 GF. A conventionally aluminium milled tool serves as reference. Standard specimens are produced to compare resulting mechanical properties, shrinkage behaviour and morphology. Findings The determined material characteristics of the manufactured prototypes from the additive manufactured tools show differences in terms of mechanical behaviour to those from the aluminium reference tool. The most significant differences are an up to 25 per cent lower tensile elongation and an up to 63 per cent lower elongation at break resulting in an embrittlement of the specimens produced. These differences seem to be mainly due to the different morphological structure caused by the lower thermal conductivity and greater surface roughness of the polymer tools. Research limitations/implications The determined differences in mechanical behaviour can partly be assigned to differences in surface roughness and morphological structure of the resulting parts. The exact extend of either cause, however, cannot be clearly determined. Originality/value This study provides a comparison between the part material properties from conventionally milled aluminium tools and polymer inserts manufactured via additive tooling.

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Mansour, S., and R. Hague. "Impact of rapid manufacturing on design for manufacture for injection moulding." Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture 217, no. 4 (April 1, 2003): 453–61. http://dx.doi.org/10.1243/095440503321628134.

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Rapid manufacturing (RM) employs similar technologies and processes to rapid prototyping (RP), hence resulting in a tool-less manufacturing process. This is achieved by assuming that RP machines have been converted to proper manufacturing machines. The current approaches to the design process, product development cycle and manufacturing considerations at the design stage within a concurrent engineering environment are closely examined. An attempt is then made to investigate the effect of the RM processes on the design process and product development cycle. This is further expanded to consider the impact of RM on rules and guidelines that have been established for design for manufacturing (DFM). This paper is limited to a comparison of RM with regards to injection moulding as RM is most likely to compete with this process in the first instance. This is the first research work to investigate the impact of RM on the design process.

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Brinksmeier, Ekkard, Ralf Gläbe, and Jen Osmer. "Diamond Cutting of FeN-Layers on Steel Substrates for Optical Mould Making." Key Engineering Materials 438 (May 2010): 31–34. http://dx.doi.org/10.4028/www.scientific.net/kem.438.31.

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The mass production of glass or plastic components by replication techniques, like hot pressing or injection moulding, requires inserts made of temperature resistant and hard materials. Generating an optical surface finish in these materials is time consuming and difficult. By using thermo-chemically treated steels as mould materials diamond cutting processes generating high form accuracies and low surface roughness can be applied without significant tool wear.

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Goodship, V., N. Cook, I. Dargue, C. Lobjoit, K. Makenji, and G. F. Smith. "In mould painting using thermoset powder coating and thermoplastic substrate in closed tool injection moulding." Plastics, Rubber and Composites 36, no. 1 (February 2007): 34–41. http://dx.doi.org/10.1179/174328907x171217.

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Ogur, E. O., M. C. Davis, V. Goodship, and G. F. Smith. "Effect of Magnetic Field on the Distribution and Orientation of Magnetic Particles in Co-injection Moulding." Progress in Rubber, Plastics and Recycling Technology 24, no. 4 (November 2008): 227–37. http://dx.doi.org/10.1177/147776060802400401.

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This paper presents a study of the effect of an external magnetic field on the distribution and orientation of magnetic particles in co-injection moulding. The orientation of the magnetic particles was determined using optical microscopy and image analysis techniques. The external magnetic field was placed in the tool cavity and used to magnetize the particles and to generate the necessary magnetic field gradient to manipulate them. The ferromagnetic nickel particles remained magnetic enough to overcome the strong drag forces imposed on them by the polymeric fluid matrix and to be orientated by the permanent magnet in the tool.

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Shari, Naain, B. T. Hang Tuah bin Baharudin, Norsilawati Ngah, and M. F. C. Ibrahim. "Machining of Injection Mould Materials for Different Cutting Flute in Low-Speed End Milling." Applied Mechanics and Materials 564 (June 2014): 538–42. http://dx.doi.org/10.4028/www.scientific.net/amm.564.538.

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The complexity of mould shapes and the hardness of the mould material contribute to difficulties in machining. Examination of the capability of atypeof cutting tool (Tungsten Carbide Ball Nose) towards machining mould material that is usually used in Injection Moulding Industries. Following this, an experimental work was detailed relating to the use of ball nose end mill to machine hardened injection mould materials (up to 62 HRC).Surface roughness, surface topography and tool wear data were presented. The relationships of all these three properties respect to each other were also investigated. By machining these materials (Stavax, Stainless Steel, DF3 and XW5), a major wear occur on cutting tool which is called flank wear. Theflank wear is increased by increasing the hardness of the material used. This fact was supported by the result obtained, in which the surface roughness increases when the material hardness increased. Surface topography isdescribed through wavy marks and surface tearing. For 2 and 4-flute cutting tools, the waviness phenomenal ondecreases when material hardness was increased. Meanwhile, for surface tearing, the rate of occurrence is proportional to the increment of the material hardness.

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Kuschan, Jan, Vinzenz Müller, Stephan Monchinger, Oliver Heimann, Carsten Niebuhr, and Oday Kabha. "Production environment of tomorrow (ProMo): Partially automated repair process of small tool moulds, forming tools, injection moulding tools and sand casting tools." IOP Conference Series: Materials Science and Engineering 1140, no. 1 (May 1, 2021): 012036. http://dx.doi.org/10.1088/1757-899x/1140/1/012036.

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Jauregui-Becker, Juan M., Guido Tosello, Fred J. A. M. van Houten, and Hans N. Hansen. "Performance Evaluation of a Software Engineering Tool for Automated Design of Cooling Systems in Injection Moulding." Procedia CIRP 7 (2013): 270–75. http://dx.doi.org/10.1016/j.procir.2013.05.046.

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Tosello, Guido, Hans Nørgaard Hansen, Stefania Gasparin, José Antonio Albajez, and José Ignacio Esmoris. "Surface wear of TiN coated nickel tool during the injection moulding of polymer micro Fresnel lenses." CIRP Annals 61, no. 1 (2012): 535–38. http://dx.doi.org/10.1016/j.cirp.2012.03.016.

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Mazur, Maciej, Martin Leary, Matthew McMillan, Joe Elambasseril, and Milan Brandt. "SLM additive manufacture of H13 tool steel with conformal cooling and structural lattices." Rapid Prototyping Journal 22, no. 3 (April 18, 2016): 504–18. http://dx.doi.org/10.1108/rpj-06-2014-0075.

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Purpose Additive manufacture (AM) such as selective laser melting (SLM) provides significant geometric design freedom in comparison with traditional manufacturing methods. Such freedom enables the construction of injection moulding tools with conformal cooling channels that optimize heat transfer while incorporating efficient internal lattice structures that can ground loads and provide thermal insulation. Despite the opportunities enabled by AM, there remain a number of design and processing uncertainties associated with the application of SLM to injection mould tool manufacture, in particular from H13/DIN 1.2344 steel as commonly used in injection moulds. This paper aims to address several associated uncertainties. Design/methodology/approach A number of physical and numerical experimental studies are conducted to quantify SLM-manufactured H13 material properties, part manufacturability and part characteristics. Findings Findings are presented which quantify the effect of SLM processing parameters on the density of H13 steel components; the manufacturability of standard and self-supporting conformal cooling channels, as well as structural lattices in H13; the surface roughness of SLM-manufactured cooling channels; the effect of cooling channel layout on the associated stress concentration factor and cooling uniformity; and the structural and thermal insulating properties of a number of structural lattices. Originality/value The contributions of this work with regards to SLM manufacture of H13 of injection mould tooling can be applied in the design of conformal cooling channels and lattice structures for increased thermal performance.

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Chethan, K. N., V. Sabarinathan, R. Vivek Ram, and G. T. Mahesh. "Numerical Analysis and Fabrication of Battery Holder for Two Wheelers." Journal of Advanced Research in Fluid Mechanics and Thermal Sciences 78, no. 2 (December 10, 2020): 114–31. http://dx.doi.org/10.37934/arfmts.78.2.114131.

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The high-performance plastics usage is increasing in the automobile field because of its advantages over other metals and alloys. Corrosion resistance, light weight, low cost, flexibility in design are the major advantages of plastics above the conventional metallic materials. In this paper a metal version component converted into plastic version in order to increase efficiency, reduce the overall cost of a two-wheeler and to improve the production rate of component. Different types of material such as PP + 15% TALC, PP + 30% GF, PP + 30% TALC, Nylon 6 + 15% GF, Nylon 66 UF, Nylon 6 UF, Nylon 66 + 30% GF, ASA LI941 and ASA LI913 tested for 10,000km road test, vibration test and fitment test. An injection moulding used to produce the component and ‘Mouldx3D’ software was used for mould flow analysis and other simulation. The different parts of injection moulding tool made up of C45, P20 and D2 materials. Among different materials, ASA LI913 was selected since it has better weather resistance than others and the impact strength matched to metal version component. Finally, it was found that the cost of the component made of Plastic considerably less than same component made of metal.

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Nunthavarawong, Peerawatt. "Slurry Erosion Model for Wear Performance Prediction of Tool Steel." Advanced Materials Research 717 (July 2013): 194–99. http://dx.doi.org/10.4028/www.scientific.net/amr.717.194.

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Erosive wear is one of the major failure modes in metal and plastic injection moulding. Certain regions such as gate, runner and some areas on the cavity wall, are particularly susceptible to erosive wear damage, leading to the reduction in the mould lifetime. Several parameters such as pressure, injection velocity, melting temperature, including various contaminants during material processing, have influenced to decrease the surface quality of the mould. Hence, the wear test and prediction are necessary information for the life extension of the mould material, and were carried out in present work. This work therefore aims to determine slurry erosion wear behaviour of the mould material, and presents a new semi-empirical approach to estimate the wear coefficient of material itself as a function of impact angles via an erosion test apparatus. It was found that the maximum wear coefficient of the tool material is around ~ 2.51 x 10-7 at the impact angle of 60o. While that the minimum value was found to be ~ 4.70 x 10-8 at the angle of impingement of 30o. Therefore, the effect of the different angle of impact on the impact energy, can also represent the failure modes in the tool steel material as ductile failures.

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Sonne, M. R., J. Cech, H. Pranov, G. Kofod, J. Garnæs, Y. C. Lam, J. H. Hattel, and R. Taboryski. "Modelling the deformations during the manufacturing of nanostructures on non-planar surfaces for injection moulding tool inserts." Journal of Micromechanics and Microengineering 26, no. 3 (February 8, 2016): 035014. http://dx.doi.org/10.1088/0960-1317/26/3/035014.

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Selvaraj, S., and P. Venkataramaiah. "Design and Fabrication of an Injection Moulding Tool for Cam Bush with Baffle Cooling Channel and Submarine Gate." Procedia Engineering 64 (2013): 1310–19. http://dx.doi.org/10.1016/j.proeng.2013.09.212.

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Moshiri, Mandaná, Dario Loaldi, Filippo Zanini, Damiano Sgaravato, Simone Carmignato, and Guido Tosello. "Analysis of an as-built metal additively manufactured tool cavity insert performance and advantages for plastic injection moulding." Journal of Manufacturing Processes 61 (January 2021): 369–82. http://dx.doi.org/10.1016/j.jmapro.2020.11.035.

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Ruh, Andreas, Volker Piotter, Klaus Plewa, Hans-Joachim Ritzhaupt-Kleissl, and Jürgen Haußelt. "Effects of material improvement and injection moulding tool design on the movability of sintered two-component micro parts." Microsystem Technologies 16, no. 11 (August 25, 2010): 1989–94. http://dx.doi.org/10.1007/s00542-010-1128-3.

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Kreisel, C. "ToolRep/Toolrep. Development of a system for the automated laser-based repair of structured mould inserts." wt Werkstattstechnik online 109, no. 11-12 (2019): 852–56. http://dx.doi.org/10.37544/1436-4980-2019-11-12-54.

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Texturierte Spritzgusswerkzeuge sind aus der Kunststoffverarbeitung nicht mehr wegzudenken. Auf die Beschädigung einer Textur folgen Ausfallzeiten, teure Reparaturen bis hin zum Totalausfall des Werkzeugs. Ziel des vom BMBF geförderten Projektes „ToolRep“ war es, die gesamte Reparaturkette in einer prototypischen Anlage abzubilden. Texturfehler werden automatisch erkannt und selektiert, mittels additivem Laserauftrag gefüllt und mittels spezieller Reparaturalgorithmen und Lasergravur wiederhergestellt.   Textured injection moulding tools have become indispensable in plastics processing. Damage to a texture is followed by downtimes, expensive repairs and even total tool failure. The aim of the BMBF-funded „Toolrep“ project was to map the entire repair chain in a single system. Texture errors are automatically detected and selected, filled by means of additive laser application and restored by means of special repair algorithms and laser engraving.

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Uhlmann, E., J. Polte, M. Polte, C. Jahnke, H. M. Wiesner, and C. Hein. "Mikrofräsbearbeitung von MMC-Werkstoffschichten unter Einsatz von binderlosem PKD*/Micro-milling of MMC-materials with binderless PCD as cutting material, Analysis of the influence of process parameters on the micro-milling process." wt Werkstattstechnik online 109, no. 07-08 (2019): 570–74. http://dx.doi.org/10.37544/1436-4980-2019-07-08-60.

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Das Spritzgussverfahren ist für die Herstellung von kostengünstigen Kunststoffbauteilen eine industrielle Schlüsseltechnologie. Die für den Prozess notwendigen Spritzgusswerkzeuge aus gehärtetem Stahl werden unter anderem durch den Prozess Mikrofräsen hergestellt, wobei es bis heute zu hohem Verschleiß an den Mikrofräswerkzeugen kommt. Begegnet werden kann dieser Herausforderung durch Spritzgusswerkzeuge, bestehend aus Nichteisenmetall-Legierungen, die eine endkonturnahe Oberflächenverstärkung durch das Aufbringen einer Wolframkarbid-Partikel-Matrix erfahren. Gegenstand dieses Beitrags ist das Mikrofräsen dieser Metal-Matrix-Composite-Beschichtung. Dabei wurde die Einsetzbarkeit des polykristallinen Diamanten ohne Bindephase als innovativem Schneidstoff untersucht und nachgewiesen.   Micro-injection moulding is a key technology for the cost-effective production of plastic parts. The commonly used moulds are made of hardened steel and machined by micro-milling with coated cemented carbide tools. Today, these tools suffer from random tool breakage and excessive wear. One solution of this problem is to produce injection moulds made of non-ferrous metals and enhance them by applying a tungsten carbide matrix on the surface. Thus, this investigation addresses the micro-milling process of the resulting Metal-Matrix-Composites. Furthermore, the feasibility of binderless polycrystalline diamond as an innovative cutting material could be shown for this purpose.

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Otanocha, Omonigho B., Lin Li, Shan Zhong, and Zhu Liu. "High Power Picosecond Laser Surface Micro-texturing of H13 Tool Steel and Pattern Replication onto ABS Plastics via Injection Moulding." Lasers in Manufacturing and Materials Processing 3, no. 1 (January 4, 2016): 22–49. http://dx.doi.org/10.1007/s40516-015-0021-4.

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Ghita, Oana R., David C. Baker, and Ken E. Evans. "An in-line near-infrared process control tool for monitoring the effects of speed, temperature, and polymer colour in injection moulding." Polymer Testing 27, no. 4 (June 2008): 459–69. http://dx.doi.org/10.1016/j.polymertesting.2008.01.010.

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Davoudinejad, Ali, Mohamad Bayat, David Bue Pedersen, Yang Zhang, Jesper Henri Hattel, and Guido Tosello. "Experimental investigation and thermo-mechanical modelling for tool life evaluation of photopolymer additively manufactured mould inserts in different injection moulding conditions." International Journal of Advanced Manufacturing Technology 102, no. 1-4 (January 3, 2019): 403–20. http://dx.doi.org/10.1007/s00170-018-3163-7.

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Saravanan, V., S. Nallusamy, and K. Balaji. "Lead Time Reduction through Execution of Lean Tool for Productivity Enhancement in Small Scale Industries." International Journal of Engineering Research in Africa 34 (January 2018): 116–27. http://dx.doi.org/10.4028/www.scientific.net/jera.34.116.

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In the current dynamic global market place, especially among small and medium scale manufacturing industries the competition is show rigorous for a profitable survival. To be competent the industries have to necessarily work in an efficient way by updating and implementing new techniques. These day’s manufacturers may have to introduce and prove the success of the products not only faster but also to deliver it to the end users at the right time. The aim of this study has been to present a lean approach in the manufacturing system of injection moulding facility by reducing the change over time. In this research a lean tool of Single Minute Exchange of Die (SMED) has proved to be an effective tool for eliminating waste of time. In SMED the time taken for mould or die exchange should be less than 10 minutes. This improves the productivity by reducing the down time of a machine. The main objective has been to reduce the change over time from the current setup time of 39.94 minutes to less than 10 minutes. After implementing the SMED, the total change over time was reduced by about 67.72% which indirectly reduced production losses and increased the productivity.

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Journal articles on the topic 'Injection moulding tool'

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