Design and Manufacturing of the Injection Mold for Metal-Inserted Rubber Parts Using CAD/CAM/CAE Technologies: A Case Study of the Engine Mounting

2008 ◽  
Author(s):  
Supasit Rodkwan ◽  
Wacharapong Chookaew ◽  
Rungtham Panyawipart ◽  
Chana Raksiri
Keyword(s):  
Flow Characteristics ◽  
Injection Pressure ◽  
Injection Mold ◽  
Butadiene Rubber ◽  
Molding Process ◽  
Engine Mounts ◽  
System A ◽  
Design And Manufacturing ◽  
Cad Cam ◽  
Trial And Error Method

In general, rubber parts used in automotive applications are designed and manufactured without any inserts; it is significant, however, that for certain parts, such as an engine mounting that, the metal core must be used to increase the compressive strength of products. With the lack of numerical tools used to predict the rubber flow characteristics and the interaction between rubber and metal insert during the molding process, mold designers must rely on their experience and the trial-and-error method to design molds. Therefore, in this research, an application of CAD/CAM/CAE on the design and manufacturing of an injection mold for the engine mounting rubber made of a blend of Natural Rubber (NR) and AcryloNitrile-Butadiene Rubber (NBR) is performed. A CAD model of the part is constructed and then a two-cavity mold as well as various runner patterns and gate positions are designed and further analyzed using CAE. Subsequently, with use of the CAM system, a metal-inserted mold and related components are manufactured and used to produce the rubber engine mounts on the vertical rubber injection machine. The empirical and numerical resulting parameters, including part geometry, injection pressure, and part temperature at various injection stages, correlate well. This information provides mold designers and manufacturers a better understanding of the rubber behavior during curing in the metal-inserted rubber molding process so that various mold components can properly designed and effectively used. Consequently, better mold and product quality with less defects as well as reduced production time can be obtained.

scholarly journals Study on Stability of a Novel Binder System Based on Palm Stearin in Metal Injection Moulding Application

2007 ◽  
Vol 4 (2) ◽  
pp. 1
Author(s):  
Muhammad Hussain Ismail ◽  
Norhamidi Muhamad ◽  
Aidah Jumahat ◽  
Istikamah Subuki ◽  
Mohd Afian Omar
Keyword(s):  
Injection Molding ◽  
Flow Characteristics ◽  
Injection Pressure ◽  
Palm Stearin ◽  
Steel Powder ◽  
Metal Injection Molding ◽  
Injection Molding Process ◽  
Binder System ◽  
Molding Process ◽  
Flow Activation Energy

Metal Injection Molding (MIM) is a wellestablished technology for manufacturing a variety of complex and small precision parts. In this paper, fundamental rheological characteristics of MIM feedstock using palm stearin are theoretically analyzed and presented. The feedstock consisted of gas atomized 316L stainless steel powder at three different particle size distributions and the binder system of palm stearin (PS) and polyethylene (PE). The powder loading used was 60vol % for all samples (monosize 16 µm, monosize 45 µm, and bimodal 16 µm + 45 µm) and the binder system of 40vol %(PS/PE = 40/60). The viscosity of MIM feedstock at different temperatures and shear rates was measured and evaluated. Results showed that, the feedstock containing palm stearin exhibited suitable rheological properties by increasing the fluidity of feedstock in MIM process. The rheological results also showed a pseudoplastic flow characteristics, which poses higher value of shear sensitivity (n) and lower value of flow activation energy (E), that are both favourable for injection molding process. The green parts were successfully injected and exhibited adequate strength for handling by optimizing the injection pressure and temperature.

Design and NC Manufacturing of Plastic Injection Mold Based on UG Software

2012 ◽  
Vol 630 ◽  
pp. 163-166
Author(s):  
Shan Li ◽  
Liang Xu ◽  
Yu Qi Wang
Keyword(s):  
Traditional Method ◽  
Injection Mold ◽  
Practical Application ◽  
Manufacturing Method ◽  
Whole Process ◽  
Traditional Design ◽  
Design And Manufacturing ◽  
Cad Cam ◽  
Plastic Injection

On the platform of the UG Software’s CAD/MoldWizard/CAM components, the whole process of design and NC manufacturing of the plastic injection mold of a hair dryer’s shell was completed. The CAD/CAM process of the plastic injection mold was introduced by the practical application. The large advantage of the UG platform over the traditional method in the field of plastic injection molds’ design and manufacturing was reflected. The plastic injection molds’ design and manufacturing is a great challenge to the traditional design and manufacturing method, and the UG solutions can promote mold manufacturers’ ability of design and manufacturing remarkably.

Design and Simulation of Injection Mold for the Shell of Switch

2010 ◽  
Author(s):  
Chuanyang Wang ◽  
Shuai Hu ◽  
Qiubo Qian ◽  
Xuanxuan Shen
Keyword(s):  
Simulation Analysis ◽  
Cooling System ◽  
Injection Pressure ◽  
3D Models ◽  
Injection Molding Process ◽  
Injection Mold ◽  
Molding Process ◽  
Development Cycle ◽  
Successful Probability ◽  
Filling Time

The 3D models of gating system, ejection mechanisms and cooling system of the swtich shell for injection mold are designed by using Pro/ENGINEER software. MOLDFLOW is utilized for CAE analysis. Three schemes are obtained by changing the gate location during the injection molding process. After comparing the volume shrinkage during injection, shrink marks index, filling time and the injection pressure, the best scheme is obtained. According to the optimal scheme, the injection mold is designed. The results showed that simulation analysis method can not only improve the successful probability of mold trial, but also shorten the production development cycle of developing product.

The Analysis of Core Shift in Injection Mold and its Optimization Based on AMI

2011 ◽  
Vol 189-193 ◽  
pp. 2879-2883 ◽  
Author(s):  
Zhi Zhong Guo ◽  
Yue Li ◽  
Xian Jun Zhao
Keyword(s):  
Economic Benefit ◽  
Injection Pressure ◽  
Structural Performance ◽  
Injection Mold ◽  
Injection Mould ◽  
Molding Process ◽  
The Core ◽  
The Cost ◽  
Core Shift ◽  
Crust Thickness

Core shift is the phenomenon that the core will be shifted under the injection pressure during its molding process. Excessive core shift will bring variation in frozen-crust thickness which will lead to the buckling deformation of products and lower their structural performance. This paper takes the shell of U-disk as an example and analyzes the reasons of core shift in the injection mould designing with AMI, and its analyzed findings can be used for mould designing to shorten the developing period of products and decrease the cost of products and increase their economic benefit.

scholarly journals Study on Stability of a Novel Binder System Based on Palm Stearin in Metal Injection Moulding Application

2007 ◽  
Vol 4 (2) ◽  
pp. 1 ◽  
Author(s):  
Muhammad Hussain Ismail ◽  
Norhamidi Muhamad ◽  
Aidah Jumahat ◽  
Istikamah Subuki ◽  
Mohd Afian Omar
Keyword(s):  
Injection Molding ◽  
Flow Characteristics ◽  
Injection Pressure ◽  
Palm Stearin ◽  
Steel Powder ◽  
Metal Injection Molding ◽  
Injection Molding Process ◽  
Binder System ◽  
Molding Process ◽  
Flow Activation Energy

Metal Injection Molding (MIM) is a wellestablished technology for manufacturing a variety of complex and small precision parts. In this paper, fundamental rheological characteristics of MIM feedstock using palm stearin are theoretically analyzed and presented. The feedstock consisted of gas atomized 316L stainless steel powder at three different particle size distributions and the binder system of palm stearin (PS) and polyethylene (PE). The powder loading used was 60vol % for all samples (monosize 16 µm, monosize 45 µm, and bimodal 16 µm + 45 µm) and the binder system of 40vol %(PS/PE = 40/60). The viscosity of MIM feedstock at different temperatures and shear rates was measured and evaluated. Results showed that, the feedstock containing palm stearin exhibited suitable rheological properties by increasing the fluidity of feedstock in MIM process. The rheological results also showed a pseudoplastic flow characteristics, which poses higher value of shear sensitivity (n) and lower value of flow activation energy (E), that are both favourable for injection molding process. The green parts were successfully injected and exhibited adequate strength for handling by optimizing the injection pressure and temperature.

An Application of Computer Aided Engineering in Rubber Injection Mold With a Cold Runner System Design and Manufacturing

2007 ◽  
Author(s):  
Supasit Rodkwan ◽  
Rungtham Panyawipart ◽  
Chana Raksiri ◽  
Kunnayut Eiamsa-ard
Keyword(s):  
Injection Molding ◽  
Raw Material ◽  
Injection Molding Process ◽  
Molding Process ◽  
Actual System ◽  
Part Quality ◽  
Injection Process ◽  
Design And Manufacturing ◽  
Trial And Error Method ◽  
And Behavior

With a recent growth in the demand of the rubber products globally, the latest technology is adopted to improve the design and manufacturing of those rubber products in term of part quality and production lead time and cost. The cold runner system is one of the technologies which can assist in unfilling part problem and raw material saving. Nevertheless, with the lack of numerical tool with an ability to predict the behavior of rubber during the injection molding process, designers still need to use their experience and trial-and-error method to design the mold and the cold runner system. Therefore, in this research, the use of CAE and a cold runner system is applied to the design and manufacturing of rubber injection molding process with a gasket mold made of SBR as a case study. The empirical and simulated results agree well and the use of raw material in the actual system is decreased by 12% shot weight which can lead to the reduced cost of products. Finally, it can be seen that the use of CAE can assist the mold designers and manufacturers to get better understanding of flow pattern and behavior of rubber during the injection process so the better part quality can be obtained.

The Optimal Design of Injection Mold Gate Based on CAE

2013 ◽  
Vol 690-693 ◽  
pp. 2772-2775
Author(s):  
Jian Wen Tang
Keyword(s):  
Optimal Design ◽  
Injection Molding ◽  
Traditional Method ◽  
Injection Molding Process ◽  
Mold Design ◽  
Injection Mold ◽  
Molding Process ◽  
Design And Manufacturing ◽  
The Cost ◽  
Cae Technology

In the injection molding process, CAE technology is used for detailed analysis of the designing of injection mold gate location and number, this method can optimize the pouring system, and change the traditional method which improves the mold structure by mold testing, so the cost of mold design and manufacturing can be reduced.

The Optical Fiber Connector Ceramic Insert Core Injection Mold Design

2014 ◽  
Vol 624 ◽  
pp. 712-714
Author(s):  
Pei Yun Ao
Keyword(s):  
Optical Fiber ◽  
Structural Characteristics ◽  
Flow Characteristics ◽  
Powder Injection ◽  
Mold Design ◽  
Injection Mold ◽  
Additive Formulation ◽  
Injection Mold Design ◽  
Optical Fiber Connector ◽  
Ceramic Insert

According to the structural characteristics of optical fiber connector Ceramic insert core, this article analyzed the structure technology of it. Based on Mold wizard module and Pro/Moldsign module. We conducted injection mold design of optical fiber connector ceramic insert core; Put forward the flow characteristics of zirconia powder injection feeding and binder, lubricants and other additive formulation.

Usability of Web-Based Design and Manufacturing Systems: Case Study of Micro Machining

2005 ◽  
Author(s):  
Hyung-Jung Kim ◽  
Won-Shik Chu ◽  
Hyuk-Jin Kang ◽  
Sung-Hoon Ahn ◽  
Dong-Soo Kim ◽  
...  
Keyword(s):  
Manufacturing Systems ◽  
Processing Time ◽  
Micro Machining ◽  
User Friendliness ◽  
Web Based ◽  
Design And Manufacturing ◽  
Cad Cam ◽  
Machining System ◽  
Web Based System ◽  
The Web

In this paper, web-based design and manufacturing systems are compared with a commercial CAD/CAM system from the point of usability. The web-based systems included in this study were MIcro Machining System (MIMS) and SmartFab. In the MIMS architecture, a 3D model in STL format was read via a web browser, sent to the web server for toolpath planning, and NC codes were generated to be fed back to the designer through the web connection. In the SmartFab system, SolidWorks was used as the design interface with provided modified menus for micro machining. These additional menus were created by SolidWorks API that also provided web-based links to the toolpath planner. In the commercial CAD/CAM case, without using any web connection, SolidWorks or CATIA was used for design, and PowerMill was used as a CAM tool. For each design and manufacturing system, accessibility, user-friendliness, toolpath-reliability, and processing time were compared. Total 91 students tested these systems in undergraduate CAD class, and the feedback showed better performance of the web-based system in accessibility, user-friendliness, and processing time. However, reliability of the web-based system showed necessity of further improvement.

scholarly journals Sample of CAD/CAM/CAE in Injection Mold

2011 ◽  
Vol 77 (7) ◽  
pp. 644-647
Author(s):  
Junichi HASHIGUCHI
Keyword(s):  
Injection Mold ◽  
Cad Cam
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