scholarly journals Gate Location and Injection Analysis of a Spur Gear

2018 ◽  
Vol 225 ◽  
pp. 06012
Author(s):  
Wafiuddin Md Ghazali ◽  
Daing Mohamad Nafiz Daing Idris ◽  
Azizul Helmi Sofian ◽  
Januar Parlaungan Siregar ◽  
Mohamad Firdaus Basrawi
Keyword(s):  
Injection Moulding ◽  
Process Analysis ◽  
Spur Gear ◽  
Moulding Process ◽  
Gate Location ◽  
Injection Process ◽  
Injection Moulding Process ◽  
The Common ◽  
Plastic Parts ◽  
Sink Mark

Injection moulding process is one of the common processes to produce plastic parts from simple to complicated parts. This paper focuses on the injection process analysis of a 25 tooth spur gear. Three runner system are proposed for the gear and each system will be analysed using Autodesk Simulation Moldflow Advisor. The most suitable design will then be chosen based on the results obtained from the simulation. The design undergoes cooling quality, sink mark, fill + pack, and warp analysis. Based on these analyses, Design 1 gave the better results compared to Design 2 and 3. From there, Design 1 runner system is chosen for the injection moulding mould which will be fabricated later in the research.

Investigating the Effects of Injection Moulding Process Parameters on Multiple Tensile Characteristics of Plastic Spur Gear via Experimental Approach

2013 ◽  
Vol 748 ◽  
pp. 544-548 ◽  
Author(s):  
Nik Mizamzul Mehat ◽  
Shahrul Kamaruddin ◽  
Abdul Rahim Othman
Keyword(s):  
Process Parameters ◽  
Injection Moulding ◽  
Experimental Approach ◽  
Low Cost ◽  
Spur Gear ◽  
Melt Temperature ◽  
Moulding Process ◽  
Packing Pressure ◽  
Injection Moulding Process ◽  
State Of Tension

This paper presents the original development of an experimental approach in studying the multiple tensile characterizations as key quality characteristics for several different plastic gear materials related to various parameters in injection moulding process. In this study, emphases are given on a new low-cost mechanism for the testing of the injection moulded plastic spur gear specimens with various teeth module. The testing fixture are developed and validated to provide uniform state of tension with series of plastic gear specimens produced in accordance with the systematically designed of experiment. The effects of changes in the process parameters including melt temperature, packing pressure, packing time and cooling time at three different levels on the elongation at break and ultimate strength of plastic gear is evaluated and studied through the proposed experimental approach.

scholarly journals Computer-Aided Reengineering towards Plastic Part Failure Minimization

Materials ◽  
2021 ◽  
Vol 14 (21) ◽  
pp. 6303
Author(s):  
Tiago Pinho ◽  
Tatiana Zhiltsova ◽  
Mónica Oliveira ◽  
Andreia Costa
Keyword(s):  
Injection Moulding ◽  
Original Design ◽  
Plastic Part ◽  
Load Bearing Capacity ◽  
X Ray ◽  
Moulding Process ◽  
The Core ◽  
Injection Moulding Process ◽  
History Of ◽  
Plastic Parts

The work reported here intends to identify and mitigate the causes for failure in a plastic faucet holder, a part of an integral float faucet with a well-documented history of fracture occurrence. A methodology for the identification of hidden internal defects in plastic parts and the elaboration of the required corrective actions towards quality improvement is, therefore, presented. Firstly, part defects were identified via injection moulding process numerical simulation. The latter has enabled the prediction of an excessive volumetric shrinkage at the core of the faucet holder, highlighting the presence of internal voids and, hence, the possible deterioration of the load-bearing capacity. The supposition was later confirmed by X-ray topography scans. Part reengineering, consisting of localized thickness reduction, was the option chosen for decreasing the high shrinkage at the core. For validation purposes, structural analyses were carried out, with and without accounting for the injection moulding processing history. The results obtained during part structural analysis have enabled us to conclude that, when taking into account the residual stresses generated during injection moulding, the analysis more closely reflects the experimental data and allows us to implicitly envisage the propensity to fracture. Moreover, the part modifications, undertaken during the faucet holder reengineering, led to the reduction of the cumulative (processing and imposed by load) stresses by 50%, when compared to the original design analysed.

The Effect of TiH2 Particle on Rheological Behaviour of NiTi for Metal Injection Moulding

2017 ◽  
Vol 882 ◽  
pp. 23-27
Author(s):  
Ros Atikah Abdul Kadir ◽  
Nor Hafiez Mohamad Nor ◽  
Istikamah Subuki ◽  
Muhammad Hussain Ismail
Keyword(s):  
Shear Rate ◽  
Titanium Hydride ◽  
Injection Moulding ◽  
Rheological Behaviour ◽  
Nickel Titanium ◽  
Elastic Behaviour ◽  
Capillary Rheometer ◽  
Moulding Process ◽  
Injection Process ◽  
Injection Moulding Process

This paper highlights the influence of titanium hydride particle on the rheological behaviour of nickel-titanium feedstock used in the metal injection process. The ratio of 50at% nickel and 50at% titanium hydride with 2 different powder loadings (65.5vol% and 67.5vol%) were investigated. A Rosand RH2000 capillary rheometer was used to determine the flow behaviour of feedstocks. The feedstocks were characterized at different temperature ranging from 150°C and 170°C and shear rate ranging from 50/s and 4442.63/s. The results showed on pseudo-elastic behaviour flow of NiTi feedstock which is suitable for injection moulding process.

Theoretical Contributions to the Accuracy of Parts by Moulding and Injection Moulding

2014 ◽  
Vol 656 ◽  
pp. 270-279
Author(s):  
Ionela Iordan ◽  
Constantin Dogariu ◽  
Cristina Mohora
Keyword(s):  
Optimal Design ◽  
Numerical Methods ◽  
Theoretical Analysis ◽  
Injection Moulding ◽  
Process Analysis ◽  
Injection Process ◽  
Plastic Parts

The purpose of this study is to analyse, by simulation, the injection of ABS plastic parts and track results on piece deformations after the latter was removed from the mould. Injection Process. Analysis was performed using the Autodesk Moldflow professional package. The results of the theoretical analysis by numerical methods are used for optimal design of the die to reduce and eliminate the strains and defect parts.

Ultrasonic Activated Injection Used on Manufacturing Thin Wall Plastic Parts

2014 ◽  
Vol 555 ◽  
pp. 524-529 ◽  
Author(s):  
Andrei Adam ◽  
Cristian Cosma ◽  
Andrei Pop
Keyword(s):  
Injection Moulding ◽  
Influence Factor ◽  
Unit Cost ◽  
Injection Pressure ◽  
Value Added ◽  
Thin Wall ◽  
Moulding Process ◽  
Global Competitiveness ◽  
Injection Moulding Process ◽  
Plastic Parts

Processing by injection is the technological process by that the thermoplastics material is injected, under pressure, in the cavity of a mould, where it cools down and solidifies. This process is the most common method for obtaining plastic materials. Injection moulding of thermoplastics has emerged as the premier vehicle for delivering high quality, value added commercial products. Continued global competitiveness has increased standards for product capability and quality while requiring reduced product development time and unit cost. Despite advanced design methods and new process technologies, it is becoming apparent that the injection moulding process is neither flexible nor robust. This paper presents a set of experiments that focused on particular processing conditions of injection through narrow section, thin-wall injection and microinjection. In these cases, the ultrasonic activation does not play an important role as single influence factor but could amplify or strengthen the influence of classical setting parameters of the process: mould temperature, injection pressure and temperature

scholarly journals Use of a Holistic Design and Manufacturing Approach to Implement Optimized Additively Manufactured Mould Inserts for the Production of Injection-Moulded Thermoplastics

2020 ◽  
Vol 4 (4) ◽  
pp. 100
Author(s):  
Loucas Papadakis ◽  
Stelios Avraam ◽  
Demetris Photiou ◽  
Simona Masurtschak ◽  
Juan Carlos Pereira Falcón
Keyword(s):  
Cycle Time ◽  
Injection Moulding ◽  
Mould Insert ◽  
Conformal Cooling ◽  
Moulding Process ◽  
Cooling Channels ◽  
Injection Process ◽  
Conformal Cooling Channels ◽  
Injection Moulding Process ◽  
Design And Manufacture

Injection moulding is one the most familiar processes for manufacturing of plastic parts by injecting molten thermoplastic polymers into a metallic mould. The cycle time of this process consists of the phases of injection, packing, cooling, and ejection of the final product. Shortening of cycle time is a key consideration to increase productivity. Therefore, in this manuscript the adoption of additively manufactured mould inserts with conformal cooling channels by means of selective laser melting (SLM) with the aim to reduce process cycles is presented. The design and manufacture of a mould insert with conformal cooling channels for producing pressure fitting thermoplastic parts is described. Numerical analysis of the injection process and simulation of shape distortions after SLM were conducted providing useful results for the design and manufacture of the mould insert. The results of the numerical analyses are compared with experimental 3D geometrical data of the additively manufactured mould insert. Temperature measurements during the real injection moulding process demonstrating promising findings. The adoption of the introduced method for the series production of injection moulded thermoplastics proves a shortening of cycle times of up to 32% and a final product shape quality improvement of up to 77% when using mould inserts with conformal cooling channels over the conventional mould inserts.

scholarly journals Analysing Powder Injection Moulding of a Helix Geometry Using Soft Tooling

Polymers ◽  
2021 ◽  
Vol 13 (23) ◽  
pp. 4183
Author(s):  
Alberto Basso ◽  
Yang Zhang ◽  
Jacob Kjeldahl Pløger ◽  
Jon Spangenberg ◽  
Hans Nørgaard Hansen
Keyword(s):  
Injection Moulding ◽  
Steel Powder ◽  
Powder Injection ◽  
Moulding Process ◽  
Injection Process ◽  
Geometrical Complexity ◽  
Powder Injection Moulding ◽  
Injection Moulding Process ◽  
3D Printed ◽  
Powder Suspension

Freeform injection moulding is a novel technology for powder injection moulding where a sacrificial 3D printed mould (i.e., a soft tooling) is used as an insert in the injection process. The use of 3D printed moulds enable a higher geometrical design flexibility as compared to the conventional injection moulding process. However, there is still very limited knowledge on how the sacrificial soft tooling material and powder suspension handles the increased geometrical complexity during the process. In this study, a stainless steel powder suspension is injected into a geometrically challenging sacrificial mould (viz. a helix structure) that is produced by vat photopolymerization additive manufacturing. Computed tomography is used to quantify the geometrical precision of the mould both before and after injection. In addition, a new numerical model that considers the suspension feedstock is developed to investigate the powder injection moulding process. The numerical results are found to be in qualitative good agreement with the experimental findings in terms of pinpointing critical areas of the structure, thereby highlighting a new pathway for evaluating sacrificial inserts for powder injection moulding with a high geometrical complexity.

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