Mold Design for Polystyrene Plastic Anchor

MM Science Journal, 2022

The article describes an optimization methods analysis in the technological process of plastic injection using the simulation tool Autodesk Moldflow Adviser. The Polyethylene 120J was the material used in production of the plastic part analyzed. Following the simulations, deficiencies affecting the quality of the final part were identified. Modifications were gradually made both in the cover's design and as changes in the process parameters so as to eliminate the deficiencies identified. In the first step, the value of the injection time was modified based on the results of the analysis of the determination of the ratio of solidified layers at the end of the process of filling the mold cavity. The second type of adjustment required a change in the molding's design. Based on the result of the simulation of forecasting cooling quality, we proposed a change in the wall thickness of selected model elements, specifically the adjustment of the wall thickness of the bolted joint co...

Journal 4 Research - J4R Journal, 2016

Injection moulding calculation is most important for the mould designing, according to the plastic Injection moulding machine specification. It is required to determine number of cavities in mould during Injection mould designing. There are basically three methods we are used to determine the number of cavities. These methods are depending upon Shot Capacity, Clamping Force of machine and plasticising rate of polymer which is used for a product. With the help of these calculations we designed a proper balanced mould and maximum utilize the machine.

The injection molding process itself is a complex mix of time, temperature and pressure variables with a multitude of manufacturing defects that can occur without the right combination of processing parameters and design components. Determining optimal initial process parameter settings critically influences productivity, quality, and costs of production in the plastic injection molding (PIM) industry. Up to now, most production engineers have used trial-and-error method to determine initial settings for a number of parameters, including melt temperature, injection pressure, injection velocity, injection time, packing pressure, packing time, cooling temperature, and cooling time which depend on the engineers’ experience and intuition to determine initial process parameter settings. However, the trial-and-error process is costly and time consuming. The method for finding the optimized solution would involve use of Flow analysis software like Mold-Flow. The use of this software would highlight the recommended values of the parameters for Injection Molding for the specified component design. Defect prevention coupled with minimum cycle time results in optimization of the process. Mold-flow software offers simulation of the melt during passage through the Mold. The design features like the gate, vent holes, draft, etc too can be improved through the interface. A real time analysis of the flow helps to identify the problem areas and depicts the results while the parameters are manipulated for effecting better results. • Set the parameters based on historical data and experience. • Fine tune the process parameters for the component which can be considered for evaluation and observe the trend while setting each process. • Document the data for research and analysis further using DOE (Taguchi Method/Minitab). • Derive a standard based on the material and the configuration. • Optimize the setting time and validate the process Injection Molding Machine Sectional view.

Pertanika Journal of …, 2004

Injection moulding calculation is most important for the mould designing, according to the plastic Injection moulding machine specifications. It is required to determine number of cavities in mould during Injection mould designing. There are basically three methods we are used to determine the number of cavities. These methods are depending upon Shot Capacity, Clamping Force of machine and plasticizing rate of polymer which is used for a product. With the help of these calculations we designed a proper balanced mould and maximum utilize the machine.

Cost estimates during the early stages of product development are crucial. They influence the go or no-go decision concerning a new development. If an estimate is too high it could mean the loss of business to a competitor. If the estimate is too low it could mean the company is unable to produce the product and make a reasonable profit. This ever-increasing competitive market, cost engineering is becoming a necessity for survival. The designer who is able to make these estimations would reduce the overall manufacturing costs of the product. Mold MoldflowXpress gives every SolidWorks plastics part designer an entry-level analysis tool to be used as the first step in determining the manufacturability of plastics injection-molded parts.

Open Engineering

The article presents the methodology of using the results of computer simulation of the injection process to assess the suitability of the material for the injection molding. Computer simulation of the basic phenomena occurring during the filling phase, packing, and cooling phase of the injection molding provides a number of different results, containing typical information both on the suggested technological parameters of the process and on the dimensional accuracy of the molded part, but also allows obtaining data on the production efficiency and energy demand of the processing machine. On the basis of this information, it is possible to assess the suitability of the polymer materials used in the simulation, intended for the production of products from a specific industry, taking into account various criteria, mainly of an economic or qualitative nature.

Periodica Polytechnica, Mechanical Engineering, 2005

Around one third of all plastics are processed by injection molding, therefore its economy and manufacturing technology have fundamental importance. The major issues in the development of injection molding tools include the progress in material technology and the developments in tool design methodology, such as developing rapid tool inserts. It is essential to develop fast methods to manufacture tools for injection-molded-like prototype parts or mass-produced parts. Due to these high requirements, it is more and more significant to use simulation methods to optimize the part before manufacturing. This paper shows the advantages of tool inserts in injection molding. The main difference between the conventional injection molding tools and rapid tool insert is also described in this paper. Beyond all questions, the rapid tool inserts cause different properties such as different warpage of the polymeric part.