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Journal articles on the topic 'Mould core-cavity'
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Nitish, Kumar Mishra, and Vaibhav Bankar Prof. "Design and Analysis of Ceiling Cable Holder Base." International Journal of Trend in Scientific Research and Development 3, no. 4 (2019): 564–67. https://doi.org/10.31142/ijtsrd23840.
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Injection moulds are classified into two types based on runner design i.e. Cold runner moulds and Runner less moulds i.e. hot runner moulds. In cold runner moulds, for multi cavity and multi point injection moulds, there is wreckage of material in runner area. Also wastage of material is more than component weight. To overcome the above problem, the technique used is hot Runner moulds. Hot runner mould is one of the improved manufacturing techniques for multi cavity type moulds. These types of moulds are commonly used for large production rate. While producing plastic components using normal standard multi cavity mould, we are facing the problems like partial filling, cavities in components, less product quality, injection pressure and temperature reduction and war page etc. Thus we are redesigning the holder base by doing some modification in and this will be beneficial for our using purpose. We are making design of the component, mould flow analysis using software Solid works. Nitish Kumar Mishra | Prof. Vaibhav Bankar "Design and Analysis of Ceiling Cable Holder Base" Published in International Journal of Trend in Scientific Research and Development (ijtsrd), ISSN: 2456-6470, Volume-3 | Issue-4 , June 2019, URL: https://www.ijtsrd.com/papers/ijtsrd23840.pdf
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Md Yusof, Mursyidah, and Mohd Salman Abu Mansor. "Core and Cavity Generation Using Slicing and Boolean-Based Algorithm." Applied Mechanics and Materials 761 (May 2015): 175–79. http://dx.doi.org/10.4028/www.scientific.net/amm.761.175.
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In the fast moving technological world, few researchers are trying to formulate systems with automatic mould design processes in order to reduce mould design and development time and produce a consistent mould's quality. Currently, no commercial software are able to generate core and cavity without user intervention during the process. Thus, an algorithm is proposed in this research to automatically generate core and cavity of moulds by using slicing and Boolean-based approach. A 3D moulded part in a standard CAD file format is used as an input for the algorithm and the output is presented as a set of core and cavity in 3D model. Two criteria to define the best generated core and cavity are considered at this stage which is undercut and floating lump.
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Ambhore, Sudhakar S., Alisha Gadhave, Hansel Lewis, Kenneth Lobo, and Ritwik Wani. "Effect of Core Geometry, Orientation and Support on the Core Shift in Mould." International Journal for Research in Applied Science and Engineering Technology 10, no. 5 (2022): 586–92. http://dx.doi.org/10.22214/ijraset.2022.42228.
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Abstract: This paper focuses on how to improve the effect of core geometry and its orientation when core shift occurs in the mould. Core shift is the change in position of the core from its original position in the mould before the molten fluid is passed into the cavity. Core shift occurs due to the temperature difference in the mould box and the pressure induced on the side walls of the mould box. Thus, the final product will have unexpected and uncountable variations and defects which will have a huge impact on the mechanical properties which in turn will affect the performance when running an operation. Also, the design and analysis of the final product will give an estimation on the various stresses acting on the core and how it will eventually affect both the mould and the core during the casting process. The problem of core shift has been resolved and the results obtained from the correction, have made an impact on the small foundries which usually do not operate in a systematic way. Thus, the goal of minimal to absolutely zero core shift can be achieved and the new final product will have more advantages compared to the old product with defects. Keywords: Core shift, Cavity, Knuckle joint, Fork end, Sand casting, Core, Mould.
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Mohit, Milind Sardare, and Bankar Vaibhav. "Design of Family Mould Tool for Plastic Box." International Journal of Trend in Scientific Research and Development 2, no. 4 (2018): 1209–12. https://doi.org/10.31142/ijtsrd14245.
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Injection molding is a cyclic process of forming plastic into a desired shape by forcing the material under pressure into a cavity. The shaping is achieved by cooling thermoplastics or by a chemical reaction thermosets . It is one of the most common and versatile operations for mass production of complex plastics parts with excellent dimensional tolerance. Injection molding is preferred where high tolerance, good quality and high rate productions are required. The aim of this paper is to model, extract core-cavity and develop injection molding tool for manufacturing a plastic box and also to reduce its warpage Core-Cavity design the mould flow analysis of the component is done using SOLIDWORK software. The tool will design to produce a good quality component considering the ease of manufacturability, assembly and positive ejection of the component. The tool design should match the machine specification and should be same for successful life of a component or product. Mohit Milind Sardare | Vaibhav Bankar "Design of Family Mould Tool for Plastic Box" Published in International Journal of Trend in Scientific Research and Development (ijtsrd), ISSN: 2456-6470, Volume-2 | Issue-4 , June 2018, URL: https://www.ijtsrd.com/papers/ijtsrd14245.pdf
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Fu, M. W., J. Y. H. Fuh, and A. Y. C. Nee. "Core and cavity generation method in injection mould design." International Journal of Production Research 39, no. 1 (2001): 121–38. http://dx.doi.org/10.1080/00207540010002379.
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Zhou, Lin Zhen, and Jie Tao. "NX-Based Cell Phone Injection Mould Design." Advanced Materials Research 459 (January 2012): 402–5. http://dx.doi.org/10.4028/www.scientific.net/amr.459.402.
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In cell phone injection mould design process, abundant knowledge is reused. To improve product design efficiency, a NX-based cell phone injection mould was proposed in this paper. The key techniques such as product initialization, setting mould coordinate system, defining blank of mould core, and layout of multi-cavity mould are described in detail. As choosing suitable parting surface is very important for injection mould design, the paper explained the choosing method and process of parting surface very clearly, which effectively cut short the period of product design
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Pastirčák, R., D. Urgela, and E. Krivoš. "Production of Castings by Patternless Process." Archives of Foundry Engineering 12, no. 1 (2012): 87–92. http://dx.doi.org/10.2478/v10266-012-0017-x.
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Production of Castings by Patternless ProcessThis paper deals with production of safety inlay for steam locomotive valve by the Patternless Process method. For the moulds creation was used moulding mixtures of II. generation, whereas binder was used a water glass. CNC miller was used for creation of mould cavity. Core was created also by milling into block made of moulding compound. In this article will be presented also making of 3D model, setting of milling tool paths and parameters for milling.
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Chiu, C. H., J. R. Lu, W. Y. Su, and C. C. Chen. "Micro-injection molding applied to production of optical products-example of lens." Journal of Physics: Conference Series 2878, no. 1 (2024): 012017. http://dx.doi.org/10.1088/1742-6596/2878/1/012017.
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Abstract Injection moulding is essential for the mass production of plastic products. This study focuses on the application of micro-injection moulding to produce optical products using self-designed moulds and core structure processing techniques. The chosen material for injection is acrylic PMMA, renowned for its excellent finish, weather resistance, heat resistance, transparency, and gloss. Post-injection, the products were evaluated for their optical properties. The TRIZ analysis provided insights into problem-solving directions and cost reduction strategies. The implementation of a one-mould, four-cavity design enabled mass production, significantly enhancing production efficiency.
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Ali, M. A. M., N. Idayu, Z. Abdullah, et al. "Interchangeable core and cavity plates for two-plate family injection mould." JOURNAL OF MECHANICAL ENGINEERING AND SCIENCES 11, no. 3 (2017): 2815–24. http://dx.doi.org/10.15282/jmes.11.3.2017.4.0255.
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Dai, Ming He, and Zhi Dong Yun. "Application of CAD/CAE/CAM Technology in Plastics Injection Mould Design and Manufacture." Advanced Materials Research 399-401 (November 2011): 2271–75. http://dx.doi.org/10.4028/www.scientific.net/amr.399-401.2271.
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The process of injection mould design and manufacture was introduced by taking the cover as an example. Firstly, the 3D model of the part and the injection mould structure were designed based on SolidWorks software. Secondly, the injection molding progress was analyzed and simulated based on Moldflow software. Finally, the toolpaths of cavity and core were designed based on MasterCAM software, and its manufacture process and numerical control programming was simulated. The period of product development was shortened effectively and the quality of design and manufacture was improved by CAD/CAE/CAM integrated technology.
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Zhang, Heli, Qiang Fei, and Biao Jin. "Design of Injection Mould for Lithium Battery Heat Dissipation Device Connector Bottom Cover." Journal of Physics: Conference Series 2549, no. 1 (2023): 012002. http://dx.doi.org/10.1088/1742-6596/2549/1/012002.
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Abstract The design process of the injection mould for the Lithium battery heat dissipation device connector bottom cover is described in detail. In the design process, the UG software is used to establish the three-dimensional model of the plastic part, and the mould flow analysis is carried out with the help of the moldflow software to determine the optimal gate position of the plastic part. By determining the injection process parameters of Lithium battery heat dissipation device connector bottom cover material, the design of the cavity layout of the plastic part is completed, and the basic size and mould structure of the mould base are determined. Then, the UG injection mould design guide module was used to carry out the parting design, and the structural design of the mould’s gating system, molding parts, lateral parting mechanism, core-pulling mechanism, ejection mechanism, exhaust system and cooling system was completed in turn. The whole design process improved the efficiency of mould design and saved a lot of time and cost.
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Esteves, Fantina R., António Sergio Pouzada, and Carla I. Martins. "Characterization of Polypropylene Structural Foams for Large Part Applications." Materials Science Forum 730-732 (November 2012): 981–87. http://dx.doi.org/10.4028/www.scientific.net/msf.730-732.981.
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Structural foams (SF) consist of a sandwich-like material composed by a cellular core and a solid skin. It is the ideal material solution for injection moulding of short production series of large size parts. The injection moulding of SF is a low pressure process, thus it is a viable alternative for light moulding tools. The right formulation of structural foams and the use of adequate processing conditions are important to optimize the performance of the plastics part. In this study the processing conditions (injection speeds and percentages of mould filling) and the amount of chemical blowing agent (CBA) added to polypropylene were assessed on injection moulding circular discs. A hybrid mould with epoxy/aluminium composite cavity was used to produce the parts. The structural foam performance was evaluated by rheological, morphological and mechanical tests.
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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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Suresh, Sangeeth, Aung Lwin Moe, Noorshahfinas Binti Ahmad, and Suaidatunnajwa Binti Sulaiman. "Experimental Study on the Determinants of Surface Finish in Automated Polishing of Moulds." Applied Mechanics and Materials 664 (October 2014): 122–27. http://dx.doi.org/10.4028/www.scientific.net/amm.664.122.
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Polishing of core and cavity surfaces after machining is a vital operation in the processing of plastic and metal cast products. It is carried out in order to achieve a certain degreeof surfacefinish-roughness or smoothness-on the machined surface, depending on its application as an end product and also for release from the cavities during ejection of the parts after moulding. Polishing is a high skilled manual time-consuming process in the overall cycle time of mould manufacturing. In this study, a CNC toolpath is generated in order to polish the core and cavity on the same machine where it is machined initially. The machine parameters for the polishing of the surfaces are optimized through a DOE set up. The surface finish achieved through machine polishing is inspected and recorded using a surface roughness tester and toolmaker’s microscope. It is observed, through the study that a combination of higher interference values between the tool face and the surface being polished along with higher feed rates proved to be determining factors in providing better surface finishes as high as 0.5μ Ra in machine polishing.
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Sun, Y. F., K. S. Lee, and A. Y. C. Nee. "The application of U-shape milled grooves for cooling of injection moulds." Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture 216, no. 12 (2002): 1561–73. http://dx.doi.org/10.1243/095440502321016314.
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In the injection moulding process, productivity and part quality depend largely on the cooling system of the injection mould. Several cooling methods are being adopted by the mould industry, with the straight-drilled cooling channels method being the most popular. Many reported research activities have been based on this method, but the method has several limitations that prevent it from achieving efficient and uniform cooling. In the present work, a U-shape milled groove method was proposed for large and complicated parts, especially for parts with large free-formed surfaces. Simulations were made to compare the cooling effect of U-shape milled grooves with that of straight cooling channels using COSMOS/DESIGNSTAR, an analysis software based on the finite element method (FEM). The heat flux was calculated on a cycle-averaged basis and the natural convection between ambient air and the exterior mould surface was ignored. A mouse cover was used as a case study. The U-shape milled grooves were found to have better temperature control than straight cooling channels. The temperature distributions of the core and cavity with U-shape milled grooves were more uniform than with straight cooling channels. Moreover, the U-shape milled grooves removed the heat efficiently; the mould temperature was lower than that with straight cooling channels. The U-shape milled grooves method has demonstrated its advantages in mould cooling. Although U-shape milled grooves need to be machined using computer numerical control (CNC) machines and more machining time is required, making them more expensive than straight cooling channels, their potential benefits will be explored for practical applications.
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Li, Hua, Jia Ping Liu, Qian Tian, and Fei Guo. "Effect of Expansive Agent on Concrete Filled Steel Tube." Advanced Materials Research 1145 (March 2018): 95–99. http://dx.doi.org/10.4028/www.scientific.net/amr.1145.95.
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The shrinkage of concrete is one of the main causes of cavity in concrete filled steel tube (CFST). In this paper, the effect of a kind of lab-made expansive agent on the deformation of CFST is studied. The laser displacement sensor combined with the round straight steel tube mould was adopted to test the deformation of concrete from the initial setting to 1 day after pouring, and the mechanical micrometer method was used to test deformation after 1 day in the laboratory. The full-scale model test was carried out to monitor the effect of expansive agent in CFST at the project site. The results show that, the addition of expansive agent produced significant expansion in the first 3 days, with the expansion basically compensating the autogenous shrinkage of the concrete; influenced by thermal deformation, the constraint action of steel tube to the core concrete in temperature rise stage was far greater than that in cooling stage. Compared with expansion produced in temperature rise stage, it is more important to produce expansion in cooling stage to solve the cavity problem of CFST.
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Majerník, Ján, Monika Karková, and Ján Kmec. "Assessment of Suitability of the Design of Gating System with the Use of Simulation Software." Key Engineering Materials 756 (September 2017): 136–41. http://dx.doi.org/10.4028/www.scientific.net/kem.756.136.
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The quality of thin wall castings produced by metal die-casting depends on the coherence and consistency of various aspects influencing the process of casting cycle. The qualitative properties of castings should already be considered in the design phase of construction of the gating system. The simulation software is an effective facility for the initial revealing of defects of the design phase. The assessment of casting cycle by the means of simulation predicts an incidence of defects of the casting core in the design phase and therefore reduces both the incidence of defects in the production and the costs while the production efficiency is increased. The article deals with the assessment of the design of the gating system for a particular casting type. The filling of mould cavity, casting solidification and time course of temperature changes occurring in the selected locations of gating system were defined as parameters indicating the assumptions of design accuracy. Simulation tests were carried out in the NovaFlow&Solid program. The tests resulted in a conclusion evaluating and describing the adequacy of structural design of the gating system.
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Chung, K., K. Lee, and T. Kim. "Recognition of pass features for automatic parting surface generation in injection moulds." Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture 216, no. 5 (2002): 783–96. http://dx.doi.org/10.1243/0954405021520292.
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This paper proposes a topology-based algorithm for recognizing passage features using the concept of a multiface hole loop. The multiface hole loop is a conceptual hole loop that is formed over several connected faces and serves as an entrance or an exit of a passage. A passage feature is thus recognized by identifying two multiface hole loops corresponding to its entrance and exit. To generate the core and the cavity of an injection mould for a part with passage features, either the entrance or the exit of each passage must be covered by a surface, and this surface constitutes the parting surfaces. The algorithm proposed in this paper checks the connectivity of the two multiface hole loops to recognize passage features. The total number of passage features in a part is calculated from the Euler equation, and the identification procedure continues until the number of identified passage features equals this number. To find all of the multiface hole loops in a part, the proposed approach considers all of the combinations of connected faces. The edge convexity is used to judge the validity of multiface hole loops. By using the algorithm proposed in this paper, the passage features could be recognized effectively. The approach proposed is illustrated with several example cases.
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Mohd Khushairi, Mohd Tanwyn, Safian Sharif, and Jaafar Sidek Mohd Ani. "Parameter Design for Hardness of Metal Filled Epoxy Matrix." Advanced Materials Research 1125 (October 2015): 152–56. http://dx.doi.org/10.4028/www.scientific.net/amr.1125.152.
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Epoxy is blended with metal fillers to enhance its performance and application for tooling. Material used contains aluminium particles (Rencast CW47), blended with brass separately. Brass is added into the matrix based on 10%, 20% and 30% of the epoxy mix weight ratio. Using Taguchi method, controls factor such as pre-curing temperature (A), filler percentage (B), degassing time (C), curing time (D) and post curing temperature (E) are selected parameters in order to determine optimum conditions. Noise strategy is adopted for material cooling via ambient (N1) and oven temperatures (N2), which gave different hardness values of the epoxy composite. Optimum parameters were decided based on the prediction of S/N ratio, where A = Room temperature, B = 20%, C = 60 minutes, D = 14 hours and E = 1800C. The most significant control factor is de-gassing time for both fillers, and percentage of filler to weight ratio of epoxy mixture is optimum at 20%. It was found that brass gave higher mean hardness values, (Hv = 24.1) compared to copper (Hv = 22.7) and aluminium filled epoxy (Hv = 22.3) based on the prediction run, and suitable as additional filler to improve the surface toughness of epoxy matrix as inserts. Confirmation run was conducted according to the optimum parameters and validated the gain values for brass at 7.98. Fillers enhance the mechanical properties of epoxy matrix by increasing hardness of mould cavity and core. This work helped to design the best control factors to produce optimum hardness conditions for filled epoxy matrix.
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Li, Si Nian, Yuan Chen, Jia Wang Ye, et al. "Research on the Shrinkage Cavity and Broken Graphite Mold Core of Copper Alloy in Horizontal Continuous Casting." Advanced Materials Research 415-417 (December 2011): 1171–75. http://dx.doi.org/10.4028/www.scientific.net/amr.415-417.1171.
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Copper tube produced by FA6502 copper alloy in a company of Wuhan appears shrinkage cavity in horizontal continuous casting, the graphite mold core which exerts stretching effects is easy to be snapped in production process. The reason why shrinkage cavity appears is found through large number of experiments and analysis. Then we adjust the component of FA6502 copper alloy, the quality of new copper alloy FA6506 is improved significantly. Furthermore, we find the reason why the graphite mold core is snapped in production process, FA6502 copper alloy’s shrinkage rate is too large in solidification. The compact power of the graphite mold core is too large to bear, too much resistance in pulling process is exerted so that the graphite mold core is snapped.
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Zhou, Jian, Li Jun Li, Yi Hua Hu, and Ming Chao Wang. "Television Part of Plastic Mold Design Based on CAE." Materials Science Forum 694 (July 2011): 750–53. http://dx.doi.org/10.4028/www.scientific.net/msf.694.750.
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The article points out the television plastic part size,giving the general design route,then describing the general design process of television back shell by Pro/E.The mold design also is introduced,including mold cavity distrubition, size determining of cavity mold and punch mold, selection of mold frame, set of pushing rod and stripping, sizes of part and mold, side core-drawing mechanism, cooling system design, mold’s assembly,through simulation,the mold’s design can be determined whether good or bad.
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Media, Riona Ihsan, Ismet P. Ilyas, and Mohammad Qomarudin. "Analisis Parameter Proses Injeksi 3D Printed VeroWhite Plus Rapid Tooling Dengan Metode Design of Experiments." Jurnal Rekayasa Mesin 12, no. 3 (2021): 543–59. http://dx.doi.org/10.21776/ub.jrm.2021.012.03.5.
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The insert cavity and core produced by the previous research were made using the polymer rapid tools (PRT) technique and will be used for the experimental production process. PRT is a technique for making tools with polymer materials using Additive Manufacturing (AM) technology. In this research, the polymer material used is VeroWhite Plus. The insert cavity and core will be tested to produce ± 100 key chain products. The adjustment of the injection process parameters is sought through the simulation process to obtain low insert cavity and core temperature values so that the mold is not damaged at the beginning of the injection process. There are 5 parameters of the injection process that affect the optimal mold durability, namely: mold temperature, injection speed, injection pressure, hold pressure and cooling time. The analysis was carried out using the design of experiments (DOE) method to obtain the optimal combination of injection process parameters. Analysis of the DOE method based on software simulation obtained the optimal combination of injection process parameters with details (injection speed: 5 mm / s, injection pressure: 15 Mpa, holding pressure: 10 Mpa and cooling time: 100 seconds). The durability of the insert cavity and core produced by PRT is able to produce products as desired by 100 products or even more.
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Kuang, Wei Hua, Biao Biao Chen, and Yu Cheng Lin. "Complicated Model Establishment and Second Development for Enterprises by MoldWizard." Advanced Materials Research 97-101 (March 2010): 3451–54. http://dx.doi.org/10.4028/www.scientific.net/amr.97-101.3451.
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Injection molding is among the most widely used techniques for thermoplastics, and many complicated models are used in the mold enterprises. In the paper, the mold design flow by UG MoldWizard was analyzed. A mold for hair drier cover was successfully developed. How to search parting lines, create/edit parting surfaces, extract regions and create cavity and core were researched deeply. Best gate location analysis was studied by MoldFlow software, and a multi-cavity mold was designed. Angled-lift splits were developed to form the concave grooves. Lastly, the gating system and the cooling system were designed. It proved that MoldWizard can obviously improve the drafting efficiency and quality.
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Chen, Yong, and David W. Rosen. "A Reverse Glue Approach to Automated Construction of Multi-Piece Molds." Journal of Computing and Information Science in Engineering 3, no. 3 (2003): 219–30. http://dx.doi.org/10.1115/1.1603308.
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Mold design can be a difficult, time-consuming process. Determining how to split a mold cavity into multiple mold pieces (e.g., core, cavity) manually can be a tedious process. This paper focuses on the mold construction step of the automated mold design process. By investigating glue operations and its relations with parting faces, an approach based on a new reverse glue operation is presented. The key to the reverse glue operation is to generate parting faces. A problem definition of parting face generation for a region is provided. Correspondingly, three face generating criteria are identified. Based on the parting lines of a region, our algorithms to generate the parting faces are presented. Our mold construction algorithms for two-piece molds and multi-piece molds are also presented with brief discussions. Some industrial examples are provided which illustrate the efficiency and effectiveness of our approach. We tested our mold designs by fabricating stereolithography mold inserts (a rapid tooling method) and molding parts.
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Iwami, Hiroyuki. "Advanced Cavity-Core System Mold for Ultra Low Pressure Injection Molding." Seikei-Kakou 9, no. 2 (1997): 123–27. http://dx.doi.org/10.4325/seikeikakou.9.123.
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Khanh Linh, La Do, and Tran Thi Thu Hang. "DESIGN OF CORE AND CAVITY INSERT OF PILL BLISTER INJECTION MOLD." International Journal of Current Research and Applied Studies 3, no. 6 (2024): 23–33. https://doi.org/10.61646/ijcras.vol.3.issue6.96.
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Ye, X. G., J. Y. H. Fuh, and K. S. Lee. "Automatic Undercut Feature Recognition for Side Core Design of Injection Molds." Journal of Mechanical Design 126, no. 3 (2003): 519–26. http://dx.doi.org/10.1115/1.1737379.
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For any undercut region of a plastic molded part, a side core has to be designed to form the complex geometry while avoiding the interference between the injection mold and the plastic molded part (molding). Viewing undercuts as features in the context of injection mold design, this paper presents a new method to recognize both isolated and interacting undercut features extracted from a mold cavity or core. With the introduction of the face property and the EAFEG representation scheme, an undercut feature can be precisely defined by an undercut subgraph. Unlike conventional graph-based methods, which recognize features by graph matching, the proposed algorithm recognizes undercut features by searching the cut-sets of subgraphs. After recognizing undercut features, a Boolean operation is used to generate a side core for each undercut. Rules to eliminate the side core intersection are also presented for implementation.
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Alim, M. S. A. M., F. Mustapha, M. N. Abdullah, M. T. H. Sultan, and M. K. H. Muda. "Fabrication technique using a core and cavity mold of a hybrid composite ballistic helmet." Journal of Computational Methods in Sciences and Engineering 21, no. 3 (2021): 623–29. http://dx.doi.org/10.3233/jcm-200047.
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Material used for helmet technology has transformed moderately little since the introduction of aramids, which ballistic helmets still uses woven aramids with a thermoset resin system. Most widely used strengthening material for ballistic helmet is Kevlar fibers which comprise outstanding impact resistance and high strength to weight ratio. For Kevlar reinforcement and resin shaping process, composite materials uses molding process in the fabrication methods. The most vital fabrication method is the hand lay-up process. Hand lay-up process normally consists of laying a dry fabric layer by hand onto a mold to shape into desirable design and shape. After the lay-up process is done, resin is then applied to the dry plies. There are several accessible curing methods and the most commonly used method is to let the product to cure at room temperature. This paper presents the fabrication process of ballistic helmet using a hand lay-up fabrication process with a core and cavity mold. This paper also describes the helmet mold design, materials and processing methods.
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Yan, C., M. Nakao, T. Go, K. Matsumoto, and Y. Hatamura. "Injection molding for microstructures controlling mold-core extrusion and cavity heat-flux." Microsystem Technologies 9, no. 3 (2003): 188–91. http://dx.doi.org/10.1007/s00542-002-0262-y.
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Wu, Bo, Likuan Zhu, Zhiwen Zhou, Cheng Guo, Tao Cheng, and Xiaoyu Wu. "An Efficient Method to Fabricate the Mold Cavity for a Helical Cylindrical Pinion." Processes 11, no. 7 (2023): 2033. http://dx.doi.org/10.3390/pr11072033.
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An efficient method was proposed to fabricate the mold cavity for a helical cylindrical pinion based on a plastic torsion forming concept. The structure of the spur gear cavity with the same profile as the end face of the target helical gear cavity was first fabricated by low-speed wire electrical discharge machining (LS-WEDM). Then, the structure of the helical gear cavity could be obtained by twisting the spur gear cavity plastically around the central axis. In this way, the fabrication process of a helical cylindrical gear cavity could be greatly simplified, compared to the fabrication of a multi-stage helical gear core electrode and the highly difficult and complex spiral EDM process in the current gear manufacturing method. Moreover, several experiments were conducted to verify this novel processing concept, and a theoretical model was established to show the relationship between the machine torsion angle and the helical angle of a helical gear. Based on this theoretical model, the experimental results showed that it is feasible to precisely control the shape accuracy of a helical cylindrical pinion mold cavity by adjusting the machine torsion angle.
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Hao, Mingliang, and Haimei Li. "Optimization and application of temperature field in rapid heat cycling molding." Thermal Science, no. 00 (2021): 291. http://dx.doi.org/10.2298/tsci210606291h.
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The rapid thermal cycle molding (RHCM) belongs to the injection mold temperature control system which is helpful to improve mold ability and enhance part quality. Despite many available literatures, RHCM does not represent a well-developed area of practice. The challenge is the uneven distribution of temperature in the cavity after heating, which mostly leads to defects on the surface of the products. In order to obtain uniform cavity surface temperature distribution of RHCM, the power of heating rods of the electric-heating system in an injection mold was optimized by the response surface method(RSM) in this work. The proposed optimization result was applied to design a complex RHCM injection mold with side core-pulling, holes and different thickness of an automotive part to verify its effectiveness by injection molding. Compared with initial design, the mold temperature uniformity was remarkably improvedby79%. Based on the optimization and injection molding numerical simulation results, the workable molding process to weaken the weld-lines effects on the quality was suggested and the practical injection molded parts were well produced.
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Kuang, Wei Hua, and Fa Piao Li. "Rapid Establishment of 3D Intricate Design Platform Based on Modular Technology by UG." Key Engineering Materials 460-461 (January 2011): 36–39. http://dx.doi.org/10.4028/www.scientific.net/kem.460-461.36.
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In order to solve the problem of 3D intricate product design and mold development, an approach based on UG NX was proposed. The design platform and modular technology of UG MoldWizard were introduced. How to add and edit attributes of the standard part library was explained by using sankyo lifter as example. As an application, a lamp set and its injection mold were rapidly designed by UG MoldWizard. How to patch surfaces, define parting lines and how to extract mold core and mold cavity were illustrated step by step. It proved that UG MoldWizard efficiently promoted work and integrated complex elements of design technology into automated sequences.
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Zhao, Meiyun, and Zhengcheng Tang. "Finite Element Simulation of Injection Mold Design Integrating Different Structures of Conformal Cooling Channels." Processes 13, no. 1 (2025): 234. https://doi.org/10.3390/pr13010234.
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Injection molding (IM) is a process in which completely melted plastic material is injected into the mold cavity under high pressure at a specific temperature, and the molded product is obtained after pressure holding, cooling, and demolding. During the mold cooling process, the conformal cooling channel system can improve the uniformity of mold temperature, reduce warping deformation, and significantly improve product accuracy. However, the cost consumption of conformal cooling channels for the cavity and core of injection molds is significant, which is a distinct disadvantage. This paper proposes an innovative conformal cooling channel. Compared with conventional cooling channels, the warpage of plastic parts has been reduced by 0.3401 mm. Moreover, the cooling time difference between C2 and C4 is relatively small, about 7.9 s. Among them, C4 takes the shortest time, C1 takes the longest, and C4 is 4.371 s shorter than C1. Compared with C1, the cooling efficiency of C4 has increased by 35.48%. In addition, from a commercial value perspective, many mold manufacturing companies’ real production applications are better suited for using conformal cooling channels alone on the injection mold core. This paper establishes injection molding models under different working conditions, simulates the cooling of dynamic mold temperature molds, and analyzes the effects of fluid media and various fluid rates on mold temperature changes. The results indicate that the cooling effect of cooling water is significantly better than that of cooling oil at the same fluid rate. When the fluid rate increases from 0.75 L/min to 6 L/min, the effect of cooling oil on the temperature change in the mold is significantly higher than that of cooling water. The influence of mold temperature on the cooling medium’s fluid rate tends to stabilize once the cooling medium’s flow rate reaches a specific value.
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Irawan, Surya, and Bambang Hermanto. "ANALISA KEGAGALAN INTI CETAKAN JENIS SKD 61 PADA PROSES PELEBURUAN DENGAN CARA DIECASTING." JURNAL ILMIAH TEKNIK SIPIL 11, no. 2 (2023): 174. http://dx.doi.org/10.46930/tekniksipil.v11i2.3720.
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Damage to the surface of the mold core by loss of the nitride layer from the surface hardening process, namely the name of the surface hardening process for the mold core, namely Nitriding on the surface of the metal core type skd61 series in die casting molds. In the die casting process is a process in which a process by melting molten aluminum metal at a pouring temperature of 720 0 C , then the liquid is taken with a ladle inserted into the sleeve cylinder and then pressed by the piston to fill the iron casting cavity so that it forms a casting object called a brake drum. The service life is only 80,000 shoots while the standard uses 160,000 shoots in the sub-section of the steel mold of the casting brake drum product. And to find out the low life time, the cause of the wear is sought, tests are carried out including: analysis of chemical composition, visual, microstructure and hardness
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Irawan, Surya, and Bambang Hermanto. "ANALISA KEGAGALAN INTI CETAKAN JENIS SKD 61 PADA PROSES PELEBURUAN DENGAN CARA DIECASTING." JURNAL ILMIAH TEKNIK SIPIL 12, no. 1 (2023): 150. http://dx.doi.org/10.46930/tekniksipil.v12i1.3720.
Full textAbstract:
Damage to the surface of the mold core by loss of the nitride layer from the surface hardening process, namely the name of the surface hardening process for the mold core, namely Nitriding on the surface of the metal core type skd61 series in die casting molds. In the die casting process is a process in which a process by melting molten aluminum metal at a pouring temperature of 720 0 C , then the liquid is taken with a ladle inserted into the sleeve cylinder and then pressed by the piston to fill the iron casting cavity so that it forms a casting object called a brake drum. The service life is only 80,000 shoots while the standard uses 160,000 shoots in the sub-section of the steel mold of the casting brake drum product. And to find out the low life time, the cause of the wear is sought, tests are carried out including: analysis of chemical composition, visual, microstructure and hardness
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Ramadhan, Rizki, and Haris Abizar. "PEMBUATAN PROGRAM CORE PADA CETAKAN PIRING PLASTIK MENGGUNAKAN SOFTWARE MASTERCAM X5." Steam Engineering 4, no. 1 (2022): 33–43. http://dx.doi.org/10.37304/jptm.v4i1.5273.
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The mold generally consists of two parts, namely the cavity and the core. CAD and CAM are solutions that can meet the needs of cavity and core fabrication. The CAM process is displayed to get a program in the form of a code file which will later be entered into the CNC machine. This study aims to be able to design and plan the process of making cores on plastic plate molds and being able to program core plate molds with software. This research was conducted to determine the process of making core plate molds. To determine the spindle speed and feed speed for each tool, see the cutting speed reference. From all stages of core plate manufacture with MasterCAM software, several machining processes are produced, namely drill, tap, boring, surface roughing, surface semi-finishing, and surface finishing. The total time required to complete all processes is 42 hours 48 minutes 11 seconds.
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Jia, Heng Qiong, Tao Wang, and Zhao Wei. "Research on Performance of CRTS I Cement-Emulsified Asphalt Mortar on Site." Advanced Materials Research 1142 (January 2017): 334–39. http://dx.doi.org/10.4028/www.scientific.net/amr.1142.334.
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For construction method of infusion bag, expansion of CRTSⅠCA mortar on site by core drilling, water absorption, chloride ion permeability and frost resistance and other properties were studied in comparison with performance of mortar in laboratory under standard curing. The results showed that expansion of the mortar on site was 2%, water absorption was 0.5%, charge amount was 210C, quality loss after 300 freeze-thaw cycles was -1.1%, the performance was much better than molded mortar in laboratory. Pore structure analysis showed that the internal pore diameter of the mortar on site was about 150μm, pore content was 9% to 12%; the internal pore diameter of the mortar in laboratory was also about 150μm, pore content was 10% to 15%. China railway track system（CRTSⅠ）slab ballastless track is one of the main structure forms of the modern high-speed railway and mainly composed of concrete basement, the Cement-emulsified Asphalt Mortar layer and concrete slab, featured by its rapid construction, convenient maintenance, and so on, has been widely applied in high-speed railway construction in our country. The cement-emulsified asphalt（CA） Mortar is one of the key materials and structures in slab ballastless track, providing the appropriate stiffness and elasticity which is usually composed of cement, emulsified asphalt, grit, water and many types of additives, containing a variety of inorganic/organic compositions and many types of surfactants, through the special bag, filling inside the flat cavity by its own weight between track slab and concrete basement with a thickness of 50mm (length×width 4962 mm×2400 mm). The construction method of CA mortar is grouting the non-woven fabrics bag after setting the bag under the track slab fixed by fine adjustment claw, which is convenient and has no requirement of mould removal. The bag is fixed before the perfusion process and does not produce wrinkles. The method greatly enhances the construction efficiency and has been widely utilized in high-speed railway. To full perfusion and tightness with track board, CA mortar contains gas former and expands after the end of infusion in a restricted state. Non-woven fabrics bag itself with breathable permeable, a small amount of water seeps around infusion bags in a period of time after the end of the infusion. Theoretically free water seepage of mortar on the one hand increases the compactness and durability of the mortar, but on the other hand will reduce the mortar expansion; the quality of filling layer mortar can meet the acceptance requirements in the engineering practice. In the same raw materials and mortar mixing, the performance of fresh mortar can require CRTSⅠ type of slab track emulsified asphalt cement mortar in high-speed railway Q / CR 469-2015. After water seepage performance of hardening mortar on site is different from laboratory mortar, because the surface of laboratory mortar is without compression and free deformation. In this paper, contrast mortar on site and molded mortar in laboratory, the performance of hardened mortar on site were studied.
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Łucarz, Mariusz, Dariusz Drożyński, Karolina Kaczmarska, Alena Pribulová, and Peter Futáš. "Influence of the Applied Protective Coating on the Technological Parameters of the Moulding or Core Sand Surface." Materials 17, no. 23 (2024): 5737. http://dx.doi.org/10.3390/ma17235737.
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An important issue in obtaining a good casting surface without defects in contact with the liquid metal is the use of protective coatings on the surface of the moulding sand forming the mould cavity. Protective coatings are based on highly refractory materials that are finely ground and protect the moulding sand from thermal stresses from the molten metal. An important aspect of obtaining the appropriate properties of the protective coatings used is the method of application. This article presents the results of a quality study of the protective coatings obtained, which were applied by dip and painting with a brush. Four different coatings were applied to mould sand samples prepared on grain matrices with different average grain sizes. During the tests, the viscosity of the protective coatings, their gas-forming capacity, sieve analyses of the grain matrix used, the permeability of the moulding sand with the protective coating and the abrasiveness and adhesion of the protective coatings were determined. The quality of the coating obtained was found to depend on its type, the size of the grain matrix used in the moulding sand and the method of application. The experiments carried out indicate that a comparative study of the available protective coatings can indicate the best solution, taking into account the grain matrix used and the method of application adopted.
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Al Masta, Muslimin, Maulidya Rahman, Dhiya Luqyana, and Azam Milah Muhamad. "Heat distribution analysis of cartridge heater in core and cavity of compression mold for bio-composite roof tile fabrication." Jurnal Polimesin 22, no. 6 (2024): 662. https://doi.org/10.30811/jpl.v22i6.5721.
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Bio-composite roof tiles use polypropylene matrix material and rice straw fiber as reinforcement processed by compression molding to create innovative and sustainable building products. This research aims to analyze heat distribution from the cartridge heater in the mold core during the compression molding process for fabricating bio-composite roof tiles. The research employs Finite Element Analysis (FEA), and laboratory experiments to measure temperature distribution and heating efficiency. The results showed that even heat distribution on the mold core is crucial to ensure optimal final product quality. Manual calculation estimated a heating time of 170.78 seconds to reach the desired temperature. Simulations conducted using Ansys R19.2 software shows that the temperature variation on the surface of the mold core can be minimized with the optimal placement of the heater cartridge. The simulation results obtained a time of 10 seconds to reach a temperature of 200℃ gradually. Laboratory experiments support the simulation results by showing that good heat distribution improves bio-composite tile materials' mechanical strength and homogeneity. This research significantly contributes to the design and optimization of mold cores for bio-composite applications. It offers practical guidance to the industry in improving the efficiency of the production process.
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Sun, Xiao. "Mold Material Selection and Development Trends." Advanced Materials Research 490-495 (March 2012): 3878–82. http://dx.doi.org/10.4028/www.scientific.net/amr.490-495.3878.
Full textAbstract:
With wide use of mold in modern industry, to extend its service life has become urgent problem to solve. Based on its usage, components of mold can be divided into 2 parts. One is structural parts which consist of guide, set (dynamic) template, ejecting machine, supporting member, etc. These are usually made of low carbon structural steel, alloy structural steel, or carbon tool steel. the other is molding parts which include cavity, type core, forming insert, etc. these are key parts for direct molding. Because they must bear temperature, pressure, erosion, wear and tear when used, the service life depends on material of them. Appropriate material is the main way to extend its service life.
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Zhang, Wei, Li Zheng Jiang, Rui Quan Wang, and Bo Lin. "Research of Microstructure and Property of Laser Alloying on the Surface of P20 Steel Compared with Nitriding." Advanced Materials Research 217-218 (March 2011): 1629–32. http://dx.doi.org/10.4028/www.scientific.net/amr.217-218.1629.
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The experiment of laser alloying on the surface of P20 steel was made. Tungsten carbide (WC) powder was used as alloying material. The microstructure and property of laser alloying layer and nitriding layer are studied. The research showed that laser alloying layer had better properties such as minute crystals, deeper layer, higher hardness and good metallurgical bonding with base metal. The average hardness of alloying zone was 600HV0.2. The average hardness of phase-change hard zone was 450HV0.2. P20 steel was widely used in the field of plastic mold manufacture, especially mold core and cavity. Abrasion, corrosion and pressure resulted in change of mold size and shape which could greatly affect molding precision. Using laser alloying, the good wear layer would be made on the surface of p20 steel and would greatly increase the mold useful life.
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Kuang, Wei Hua, and Ju Liang Liu. "Forming Process and Technology Research of Mobile Telephone Frame." Applied Mechanics and Materials 20-23 (January 2010): 1401–4. http://dx.doi.org/10.4028/www.scientific.net/amm.20-23.1401.
Full textAbstract:
Injection molding is widely used to produce a variety of parts, from the smallest component to entire body panels of cars. It has some advantages, including high production rates, repeatable high tolerances, ability to use a wide range of materials, low labour cost and minimal scrap loss. As a case, the paper introduced the application of MoldFlow software in injection molding development of the mobile telephone frame. Best gate location was obtained. The numerical simulation provided scientific and valuable injection process information. At last, a multi-cavity injection mold for mobile telephone frame was designed, and the NC machining of the mold core was programmed by UG NX software.
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Leushin, I. O., A. N. Grachev, L. I. Leushina, and A. I. Markov. "TO THE QUESTION ABOUT THE ROLE OF WATER IN THE PRODUCTION OF CASTING FORMS AND RING ONE-TIME APPLICATION." IZVESTIA VOLGOGRAD STATE TECHNICAL UNIVERSITY, no. 7(242) (July 29, 2020): 10–14. http://dx.doi.org/10.35211/1990-5297-2020-7-242-10-14.
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The production of single casting molds and cores is still relevant and will not lose its practical significance in the foreseeable future. In the vast majority of cases, the technology for the production of single molds and cores involves working with mixtures containing water. In this regard, the role of moisture in the composition of molding and core mixtures is difficult to overestimate. Among its main functions is to impart plasticity, fluidity, formability, and survivability to the material when it is loaded into the working cavity of the technological tooling. Water takes part in almost all processes of a physical and chemical nature occurring in foundry molds and cores, both at the stages of their manufacture and during application. However, to ensure the necessary characteristics of the casting mold or core and further casting quality, the water content in the composition of the mold or core should change at various stages of the manufacturing process. For this reason, manufacturers are faced with a number of issues related not so much to determining the optimal quantitative range of water content in the material of the mold or core, but to retention mechanisms and methods for removing water and the choice of methods for their practical implementation to increase the controllability of the process. This problem is the focus of attention in this article.
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Wei, Xiaoyu, Yi Wan, and Xichang Liang. "Effect of hollow core on cooling temperature in 3D printing." Journal of Physics: Conference Series 2396, no. 1 (2022): 012037. http://dx.doi.org/10.1088/1742-6596/2396/1/012037.
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Abstract 3D printing is a very promising method for sand mold manufacturing with a shorter design time and simpler manufacturing process compared with conventional technology in the casting industry. The heat preservation and feeding effect of the riser can effectively reduce the occurrence of shrinkage cavity and porosity in the casting. Therefore, the insulation effect of the riser is an important index to evaluate sand mold design. In this study, a hollow sand core was designed and used for casting a cylindrical thin-walled part by the binder jetting 3D printing method. The temperature change curve of the hollow core during the No. 35 steel pouring process and the riser site during the A356 aluminum alloy solidification process in this sand mold was tested to explore the effect of the hollow core on the cooling process. The A356 pouring results showed that the concretion time of the riser with a hollow core was prolonged by over 20%; the cooling rate of casting was accelerated by over 20% by applying this hollow core before sand shakeout. The No. 35 steel pouring facts reflected that the temperature rise rate of the solid core was more visible than that of the hollow core in the early process of casting solidification. The work in this paper indicated that a sand core with a hollow structure could not only accelerate casting cooling but also draw out the concretion duration of the riser to improve its supplying function and can reduce the thermal expansion of the sand core. This study provides a new and effective design idea for 3D printed sand core, which can be used as a reference for the design of 3D sand core molds and the research of casting solidification and cooling.
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Hakim, Rahman, Vicqi Pratama Putra, Abulija Maskarai, and Hasan Priyanto. "DESAIN CETAKAN PLASTIK MULTI CAVITY DENGAN SISTEM INTERCANGEABLE MOLD INSERT." Simetris: Jurnal Teknik Mesin, Elektro dan Ilmu Komputer 11, no. 1 (2020): 23–30. http://dx.doi.org/10.24176/simet.v11i1.3425.
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Berdasarkan data dari Survey Industri BP Batam tahun 2017, peningkatan kapasitas produksi produk plastik semakin signifikan. Hal ini ditunjukkan dengan banyaknya perusahaan dari China yang datang ke Batam untuk mengembangkan usaha plastik mereka. PT. Schneider Electric Batam, salah satunya yang mengalami peningkatan kapasitas produksi. Return pin merupakan salah satu produk yang akan dikembangkan, melalui penambahan jumlah core dan cavity nya. Jenis bahan baku plastik yang digunakan, yaitu POM (Polyoxymethylene), serta Stavax ESR sebagai bahan baku mold insert yang digunakan. Penelitian ini bertujuan untuk peningkatan kapasitas produksi cetakan plastik, dengan usulan perancangan baru untuk merubah mold insert dan tetap mempertahankan mold based yang telah ada. Perancangan dilakukan dengan metode VDI (Verein Deutsche Inginieuer) 2222 yang merupakan standar perancangan dalam membuat desain Mold. Software CAD yang digunakan adalah Siemens NX 9.0 dan Software CAE yang digunakan adalah Moldex 3D Flow Mold. Dari perancangan ini, didapatkan hasil cycle-time sebesar 11.5 detik dengan penghematan anggaran sebesar 46.7%.
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Latief, Alfan Ekajati, M. Pramuda Nugraha S., Adimas Prasetyo S., Ramdan Prianto, Sarmada Sarmada, and Laode Mochamad Irfan. "Designing CVT Slide Piece Molds for Cavity 24 Pieces on Injection Molding Machine." METAL: Jurnal Sistem Mekanik dan Termal 8, no. 2 (2024): 56–62. https://doi.org/10.25077/metal.8.2.56-62.2024.
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Composite materials are often used in the industrial world, one of which is in the automotive industry. Material composite based on polypropylene high impact (PPHI) and natural fiber can be used to create slide piece components on the CVT of automatic motor vehicles. In this study, we will design molds from injection molding on an industrial scale en masse, producing a slide piece product made from composite materials. This research is a development of the previous injection molding mold. In the study, the solidworks software will compare three types of multi-cavity, namely circular, series, and parallel, to get more efficient and effective molds. This multi-cavity type is designed to print PPHI material and pineapple fiber with a volume fraction of 20% and a mesh of 170. The mold material designed is made of stainless steel 2316 for cavity and core parts with a size of 180mm x180mm. Using simulation plastic on solidworks, the simulation results obtained a type of circular type that can be applied to injection machine molds because it has the most effective pressure value of 4.8 MPa and its geometric shape. Then obtained a fill time of 1,89s and volumetric shrinkage at the end of fill at a max of 17.56%, which is more efficient.
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Harry, Hutchinson. "The Molding Influence." Mechanical Engineering 121, no. 10 (1999): 70–72. http://dx.doi.org/10.1115/1.1999-oct-5.
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This article presents study that shows beta testing shapes software to the users’ hands so the product will fit the marketplace. MoldWizard is intended to reduce the time necessary to design complex mold tooling, such as this mold used to manufacture the plastic housings for high-quality nail guns. Depending on the complexity of a mold and its eventual use, the design process can require as many as 50 different steps, including tasks such as importing and cleaning up the CAD model of the part, adjusting its size for shrinkage, separating the core and cavity, generating mold bases, and adding sliders, inserts, and other standard components. Minco Tool & Mold uses Unigraphics to design molds like the one shown in the article for an automobile hubcap. Minco participated in the MoldWizard beta test program. A news group at the website let the test users communicate directly with each other. When beta testers had questions about how to use the program, they posted them in the news group and other testers would respond.
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Irawan, Benny Haddli, Putri Septaningrum, Ita Wijayanti, Rahman Hakim, and Ihsan Saputra. "PERANCANGAN DAN MODIFIKASI MOLD INSERT UNTUK MENINGKATKAN KAPASITAS PRODUKSI LIGHT GUIDE." Jurnal Rekayasa Mesin 14, no. 3 (2023): 927–38. http://dx.doi.org/10.21776/jrm.v14i3.1457.
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The use of plastic is often found in human life. Therefore, many manufacturing companies are competing to increase the production and quality of their plastic products. One way to increase production is to redesign a Mold base so that the Mold has a larger production capacity than before. The increase in product demand from consumers, which was initially 65,000 pcs/month to 95,000 pcs/month, is also the background for conducting this research. The purpose of this study is to redesign the soft tool using the old Mold base. The design uses Siemens UG NX 5 software. The Mold used is a two-plate Mold. The manufacture of the core cavity uses NAK 80 steel and plastic raw material in the form of Polycarbonate (PC). At the end of the study, a simulation was carried out using the Moldex 3D Flow Mold software to see the cycle time of the old and new Mold injection processes. From the results of this study, production capacity increased from 67,804 pcs/month to 118,536 pcs/month resulting in twice as many products as the old Mold design, with an increase in cycle time of 14.37% longer than the old Mold design also ensuring the quality of the product is maintained.
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Liparoti, Sara, Vito Speranza, Giuseppe Titomanlio, and Roberto Pantani. "Effect of Rapid Mold Heating on the Structure and Performance of Injection-Molded Polypropylene." Polymers 12, no. 2 (2020): 341. http://dx.doi.org/10.3390/polym12020341.
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The tailoring by the process of the properties developed in the plastic objects is the more effective way to improve the sustainability of the plastic objects. The possibility to tailor to the final use the properties developed within the molded object requires further understanding of the relationship between the properties of the plastic objects and the process conduction. One of the main process parameters that allow adjusting the properties of molded objects is the mold temperature. In this work, a thin electrical heater was located below the cavity surface in order to obtain rapid and localized surface heating/cooling cycles during the injection molding process. An isotactic polypropylene was adopted for the molding tests, during which surface temperature was modulated in terms of values and heating times. The modulation of the cavity temperature was found able to control the distribution of relevant morphological characteristics, thus, properties along the sample thickness. In particular, lamellar thickness, crystallinity distribution, and orientation were analyzed by synchrotron X-ray experiments, and the morphology and elastic modulus were characterized by atomic force microscopy acquisitions carried out with a tool for the simultaneous nanomechanical characterization. The crystalline degree slightly increased with the cavity temperature, and this induced an increase in the elastic modulus when high temperatures were adopted for the cavity surface. The cavity temperature strongly influenced the orientation distribution that, on its turn, determined the highest values of the elastic modulus found in the shear layer. Furthermore, although the sample core, not experiencing a strong flow field, was not characterized by high levels of orientation, it might show high values of the elastic modulus if temperature and time during crystallization were sufficient. In particular, if the macromolecules spent adequate time at temperatures close to the crystallization temperature, they could achieve high levels of structuring and, thus, high values of elastic modulus.
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Kuo, Chil-Chyuan, Pin-Han Lin, Jing-Yan Xu, et al. "Development of a Silicone Rubber Mold with an Innovative Waterfall Cooling Channel." Polymers 16, no. 2 (2024): 256. http://dx.doi.org/10.3390/polym16020256.
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A conformal cooling channel (CCC) follows the mold core or cavity profile to carry out uniform cooling in the cooling stage. However, the significant pressure drop along the cooling channels is a distinct disadvantage of the CCC. In this study, an innovative waterfall cooling channel (WCC) was proposed and implemented. The WCC cools the injected products via surface contact, replacing the conventional line contact to cool the injected products. The WCC was optimized using numerical simulation software. Silicone rubber molds with two kinds of cooling channels were designed and implemented. The cooling time of the molded part was evaluated using a low-pressure wax injection molding machine. The experimental results of the cooling time of the molded part were compared with the simulation results from numerical simulation software. The results showed that the optimal mesh element count was about 1,550,000 with a mesh size of 1 mm. The simulation software predicted the filling time of the water cup injection-molded product to be approximately 2.008 s. The cooling efficiency for a silicone rubber mold with a WCC is better than that of the silicone rubber mold with a CCC since the core and cavity cooling efficiency is close to 50%. The pressure drop of the WCC is smaller than that of the CCC, which reduces the pressure drop by about 56%. Taking a water cup with a mouth diameter of 70 mm, a height of 60 mm, and a thickness of 2 mm as an example, the experimental results confirmed that the use of the WCC can save the cooling time of the product by about 265 s compared with the CCC. This shows how a WCC can increase cooling efficiency by approximately 17.47%.