scholarly journals Design of Large Injection Mould for Car Dashboard

2020 ◽  
Vol 2 (2) ◽  
Author(s):  
Weihe ZHANG
Keyword(s):  
Injection Moulding ◽  
Advanced Technology ◽  
Injection Mould ◽  
Body Model ◽  
Engineering Plastics ◽  
Large Injection

The dashboard is the most important part of the large inner decoration of cars; it should not only have enough strength and rigidity, but also have a harmonious body model which can unify the theme. Besides, it needs to reach the goal of lightweight. In order to achieve these three goals, the car dashboard is made by engineering-plastics and adopts the technology of injection moulding. This paper introduces the keys of design and the advanced technology of large injection moulding for car dashboard.

scholarly journals Selective laser melting for improving quality characteristics of a prism shaped topology injection mould tool insert for the automotive industry

2021 ◽  
pp. 095440622198938
Author(s):  
Mennatallah F El Kashouty ◽  
Allan EW Rennie ◽  
Mootaz Ghazy ◽  
Ahmed Abd El Aziz
Keyword(s):  
Surface Roughness ◽  
Selective Laser Melting ◽  
Automotive Industry ◽  
Injection Moulding ◽  
Dimensional Accuracy ◽  
Quality Characteristics ◽  
Surface Topology ◽  
Laser Melting ◽  
Injection Mould ◽  
Tool Insert

Manufacturing process constraints and design complexities are the main challenges that face the aftermarket automotive industry. For that reason, recently, selective laser melting (SLM) is being recognised as a viable approach in the fabrication of injection moulding tool inserts. Due to its versatility, SLM technology is capable of producing freeform designs. For the first reported time, in this study SLM is recognized for its novel application in overcoming fabrication complexities for prism shaped topology of a vehicle headlamp’s reflector injection moulding tool insert. Henceforth, performance measures of the SLM-fabricated injection mould tool insert is assessed in comparison to a CNC-milled counterpart to improve quality characteristics. Tests executed and detailed in this paper are divided into two stages; the first stage assesses both fabricated tool inserts in terms of manufacturability; the second stage assesses the functionality of the end-products by measuring the surface roughness, dimensional accuracy and light reflectivity from the vehicle reflectors. The results obtained show that employing SLM technology can offer an effective and efficient alternative to subtractive manufacturing, successfully producing tool inserts with complex surface topology. Significant benefits in terms of surface roughness, dimensional accuracy and product functionality were achieved through the use of SLM technology. it was concluded that the SLM-fabricated inserts products proved to have relatively lower values of surface roughness in comparison to their CNC counterparts.

Integration of CAD CAM Techniques in the Development of an Injection Mould for Automotive Parts

2014 ◽  
Vol 216 ◽  
pp. 322-325 ◽  
Author(s):  
Andrei Adam ◽  
Cristian Cosma ◽  
Adrian Ilie Dume ◽  
Sorin Jadaneantu
Keyword(s):  
Injection Moulding ◽  
Unit Cost ◽  
Value Added ◽  
Injection Mould ◽  
Moulding Process ◽  
Global Competitiveness ◽  
Plastic Materials ◽  
Injection Moulding Process ◽  
Cad Cam ◽  
Automotive 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 design process using CAD-CAM software applied to an injection mould for manufacturing a plastic component that is used in the automotive industry. The component was analyzed, measured and subjected to simulations that will certify the quality of the final product.

scholarly journals Investigation of an inverse thermal injection mould design methodology in dependence of the part geometry

2021 ◽  
Author(s):  
C. Hopmann ◽  
J. Gerads ◽  
T. Hohlweck
Keyword(s):  
Wall Thickness ◽  
Injection Moulding ◽  
Thermal Design ◽  
Internal Stresses ◽  
Cooling Channel ◽  
Injection Mould ◽  
Compression Moulding ◽  
Compression Pressure ◽  
Injection Moulding Process ◽  
Thin Walled

AbstractThe production of injection moulded components with low shrinkage and warpage is a constant challenge for manufacturers. The thermal design of the injection mould plays an important role for the achievable quality, especially the placement of the cooling channels. This design is usually based on empirical knowledge of the mould designers. The construction is supported iteratively by injection moulding simulations. In the case of thick-walled plastic optics with big wall thickness jumps, the shrinkage is compensated by injection compression moulding. In this process, the thin-walled areas freeze earlier and the necessary compression pressure introduces stresses into these areas which reduces the optical performance. An adapted cooling channel design can reduce these problems. At the IKV, Institute for Plastics Processing in Industry and Crafts at the RWTH Aachen University, a methodology was developed which inversely calculates the cooling requirement of the moulded part A demand-oriented cooling channel system is derived based on the computed results. The aim of the research projects is to minimise displacement and internal stresses by temperature control of the moulded parts according to the demand. In this paper, the methodology is applied to three different geometries, representing three classical parts for the injection moulding process. Three different quality areas in the mould for the inverse optimisation are defined and investigated. For each geometry the cooling channel designs are then validated in injection moulding simulations based on the results from the thermal optimisation. It can be shown that for different component geometries and thicknesses, different quality areas are advantageous and decrease the maximum warpage of the parts. For thin-walled ribbed components, a 2D approach leads to a 15% smaller displacement, for components with wall thickness jumps, all investigated quality ranges show no differences in displacement, but a surface in the middle of the part is preferred due to a 3 °C lower standard deviation of the temperature distribution.

Polymer Based Injection Mould Cavity Inserts: An Influence on Crystallization and Thermo-Mechanical Properties of Injection Moulded Parts

2020 ◽  
Vol 994 ◽  
pp. 143-151
Author(s):  
Martina Češková ◽  
Petr Lenfeld
Keyword(s):  
Mechanical Properties ◽  
Product Development ◽  
Injection Moulding ◽  
Development Process ◽  
Product Development Process ◽  
Injection Mould ◽  
Polymer Injection ◽  
Mould Cavity ◽  
Manufacturing Technologies ◽  
The Impact

Injection moulding is a major used technology in mass production of high-quality plastic and composite parts. Once the initial costs have been paid the price per produced part is extremely low and part is then created up to million times. On the other hand, the product development process is time-consuming and costly due to preparation time. Therefore, the efficiency and similarity to real production are essential. Injection moulding into polymer injection mould cavity inserts appears to be an appropriate step in the product development process in particular concerning quickly developing additive manufacturing technologies. Though polymers are thermal insulators, therefore, cooling time is longer compared to injection into fully metal moulds. The impact of different cooling conditions is a change in the crystallization of injected material causing different mechanical properties of products. Removable injection mould cavity inserts were made from PET (Polyethylene terephthalate), PEEK (Polyether ether ketone), PSU (Polysulfone) and PTFE (Polytetrafluoroethylene). The main goal was to compare crystallization and thermo‑mechanical properties of injected PP (Polypropylen) parts into polymer cavity inserts to those injected into a steel mould.

Analysis of the Pressure and Shrinkage in the Mould for PLA and PLLA

2018 ◽  
Vol 919 ◽  
pp. 128-135
Author(s):  
Monika Kučerová ◽  
Petr Lenfeld
Keyword(s):  
Taguchi Method ◽  
Injection Moulding ◽  
Injection Pressure ◽  
Biodegradable Materials ◽  
Technological Parameters ◽  
Injection Mould

Paper is focused on analysis of a local shrinkage and injection pressure of the biodegradable materials PLLA and PLA. Analysed products were prepared with thickness of 4 mm in the patent injection mould. The technological parameters of the injection moulding were established by the Taguchi method. In this article, the influence of these main technological parameters on the local shrinkage and injection pressure is evaluated.

Layout and sizing of ejector pins for injection mould desian using the wavelet transform

2003 ◽  
Vol 217 (4) ◽  
pp. 463-473 ◽  
Author(s):  
S Kwak ◽  
T Kim ◽  
S Park ◽  
K Lee
Keyword(s):  
Wavelet Transform ◽  
Injection Moulding ◽  
Injection Mould ◽  
Thermoplastic Polymers ◽  
Local Stresses ◽  
Mould Design

Injection moulding is one of the most prevalent technologies used in processing thermoplastic polymers. At the end of the injection moulding cycle, the plastic moulded part should be ejected when the injection mould opens. To eject complex mouldings with bosses, ribs and other features, ejector pins are generally used because they are economical and easy to install. However, the ejector pins can cause high local stresses and strains in the moulding at the stage of ejection, leading to part deformation and damage. Thus, the proper layout of ejector pins is very important in mould design. A method is proposed for determining the layout and size of the ejector pins required to eject thermoplastic mouldings, minimizing part deformation and damage. The proposed method computes the distribution of the necessary ejecting forces to overcome the friction between the part and its mould. Then, it transforms the ejecting forces into a certain number of representative forces by the wavelet transform. Finally, the location and size of the ejector pins that correspond to the discrete ejecting forces are obtained. The proposed method will help injection mould designers systematically to obtain ejector designs.

Laminate Tooling for Injection Moulding

1993 ◽  
Vol 207 (1) ◽  
pp. 9-14 ◽  
Author(s):  
G R Glozer ◽  
J R Brevick
Keyword(s):  
Manufacturing Process ◽  
Injection Moulding ◽  
New Product ◽  
Proof Of Concept ◽  
Injection Mould ◽  
Part Geometry ◽  
Time Required ◽  
Cooling Passage ◽  
First Time ◽  
Production Part

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

Cooling Analysis of Cylindrical Void Method for an Injection Mould in Injection Moulding Process

2020 ◽  
Vol 45 (7) ◽  
pp. 5285-5294
Author(s):  
Abdellah Abdellah El-Hadj ◽  
Shayfull Zamree Abd Rahim ◽  
Mohd Nasir Mat Saad ◽  
Chye Lih Tan
Keyword(s):  
Injection Moulding ◽  
Injection Mould ◽  
Moulding Process ◽  
Injection Moulding Process

Enhancing Clinical Supervision Using High-Definition Real-Time Digital Recording, Annotation, and Bluetooth Technology

2019 ◽  
Vol 4 (2) ◽  
pp. 356-362
Author(s):  
Jennifer W. Means ◽  
Casey McCaffrey
Keyword(s):  
Graduate Students ◽  
Data Collection ◽  
Real Time ◽  
Clinical Supervision ◽  
Video Recording ◽  
Advanced Technology ◽  
High Definition ◽  
Recording Technology ◽  
Self Confidence ◽  
Additional Data Collection

Purpose The use of real-time recording technology for clinical instruction allows student clinicians to more easily collect data, self-reflect, and move toward independence as supervisors continue to provide continuation of supportive methods. This article discusses how the use of high-definition real-time recording, Bluetooth technology, and embedded annotation may enhance the supervisory process. It also reports results of graduate students' perception of the benefits and satisfaction with the types of technology used. Method Survey data were collected from graduate students about their use and perceived benefits of advanced technology to support supervision during their 1st clinical experience. Results Survey results indicate that students found the use of their video recordings useful for self-evaluation, data collection, and therapy preparation. The students also perceived an increase in self-confidence through the use of the Bluetooth headsets as their supervisors could provide guidance and encouragement without interrupting the flow of their therapy sessions by entering the room to redirect them. Conclusions The use of video recording technology can provide opportunities for students to review: videos of prospective clients they will be treating, their treatment videos for self-assessment purposes, and for additional data collection. Bluetooth technology provides immediate communication between the clinical educator and the student. Students reported that the result of that communication can improve their self-confidence, perceived performance, and subsequent shift toward independence.

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