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ORIGINALARTICLEMODULARDESIGNAPPLIEDTOBEVERAGECONTAINERINJECTIONMOLDSMINGSHYANHUANGMINGKAIHSURECEIVED16MARCH2010/ACCEPTED15JUNE2010/PUBLISHEDONLINE25JUNE2010SPRINGERVERLAGLONDONLIMITED2010ABSTRACTTHISWORKAPPLIESMODULARDESIGNCONCEPTSTODESIGNATINGBEVERAGECONTAINERINJECTIONMOLDSTHISSTUDYAIMSTODEVELOPAMETHODOFCONTROLLINGCOSTSANDTIMEINRELATIONTOMOLDDEVELOPMENT,ANDALSOTOIMPROVEPRODUCTDESIGNTHISINVESTIGATIONCOMPRISESTWOPARTSFUNCTIONALITYCODING,ANDESTABLISHINGASTANDARDOPERATIONPROCEDURE,SPECIFICALLYDESIGNEDFORBEVERAGECONTAINERINJECTIONMOLDDESIGNANDMANUFACTURINGFIRST,THEINJECTIONMOLDISDIVIDEDINTOSEVERALMODULES,EACHWITHASPECIFICFUNCTIONEACHMODULEISFURTHERDIVIDEDINTOSEVERALSTRUCTURALUNITSPOSSESSINGSUBFUNCTIONORSUBSUBFUNCTIONNEXT,DIMENSIONSANDSPECIFICATIONSOFEACHUNITARESTANDARDIZEDANDACOMPATIBLEINTERFACEISCONSTRUCTEDLINKINGRELEVANTUNITSTHISWORKEMPLOYSACUPSHAPEDBEVERAGECONTAINERTOEXPERIMENTALLYASSESSTHEPERFORMANCEOFTHEMODULARDESIGNAPPROACHTHEEXPERIMENTALRESULTSINDICATETHATTHEMODULARDESIGNAPPROACHTOMANUFACTURINGINJECTIONMOLDSSHORTENSDEVELOPMENTTIMEBY36ANDREDUCESCOSTSBY1923COMPAREDWITHTHECONVENTIONALAPPROACHMEANWHILE,THEINFORMATIONONMODULARITYHELPSDESIGNERSINDIVERSEPRODUCTSDESIGNADDITIONALLY,THEFUNCTIONALITYCODEHELPSEFFECTIVELYMANAGEANDMAINTAINPRODUCTSANDMOLDSKEYWORDSBEVERAGECONTAINERINJECTIONMOLDMODULARDESIGNPRODUCTFAMILY1INTRODUCTIONRECENTLY,GROWINGMARKETCOMPETITIONANDINCREASINGLYDIVERSECUSTOMERDEMANDHASFORCEDCOMPETITORSTOINCREASETHESPEEDATWHICHTHEYDELIVERNEWPRODUCTSTOTHEMARKETHOWEVER,DEVELOPINGAMOLDFORMASSPRODUCTIONREQUIRESCONSIDERINGNUMEROUSFACTORS,INCLUDINGPRODUCTGEOMETRY,DIMENSIONS,ANDACCURACY,LEADINGTOLONGPRODUCTDEVELOPMENTTIMEINTRODUCINGMODULARDESIGNCONCEPTSINTOPRODUCTDESIGNAPPEARSAKEYMEANOFFACILITATINGPRODUCTDEVELOPMENT,SINCEITINCREASESDESIGNFLEXIBILITYANDSHORTENSDELIVERYTIME14MEANWHILE,AHIGHLEVELOFPRODUCTMODULARITYENHANCESPRODUCTINNOVATIVENESS,FLEXIBILITY,ANDCUSTOMERSERVICES5MODULARITYISTOSUBDIVIDEACOMPLEXPRODUCTINTOMODULESTHATCANBEINDEPENDENTLYCREATEDANDTHENAREEASILYUSEDINTERCHANGEABLY6,7THEREARETHREEGENERALFIELDSWHEREMODULARITYCOULDBEIMPLEMENTEDINCLUDINGMODULARITYINDESIGNMID,MODULARITYINUSEMIU,ANDMODULARITYINPRODUCTIONMIP8MIDINVOLVESSTANDARDIZINGBASICSTRUCTURALUNITSWHICHPERFORMSPECIFICFUNCTIONS,THUSFACILITATINGFLEXIBLEASSEMBLYOFVARIOUSPRODUCTS9,10MIDCANREVEALPRODUCTSTRUCTURE,NAMELYTHERELATIONSHIPAMONGDIFFERENTPRODUCTSRELATEDPRODUCTSARETERMEDPRODUCTFAMILYANDINCLUDEBOTHBASICANDSPECIFICFUNCTIONSDEVELOPINGPRODUCTFAMILIESOFFERSBENEFITSINTERMSOFMULTIPURPOSEDESIGNANDTHUSREDUCESPRODUCTIONCOSTS11,12MIUISCONSUMERDRIVENDECOMPOSITIONOFAPRODUCTWITHAVIEWTOSATISFYINGTHEEASEOFUSEANDINDIVIDUALLYMIPENABLESTHEFACTORYFLOORTOPRECOMBINEALARGENUMBEROFCOMPONENTSINTOMODULESANDTHESEMODULESTOBEASSEMBLEDOFFLINEANDTHENBROUGHTONTOTHEMAINASSEMBLYLINETOBEINCORPORATEDINTOASMALLANDSIMPLESERIESOFTASKSMSHUANGMKHSUDEPARTMENTOFMECHANICALANDAUTOMATIONENGINEERINGANDGRADUATEINSTITUTEOFINDUSTRIALDESIGN,NATIONALKAOHSIUNGFIRSTUNIVERSITYOFSCIENCEANDTECHNOLOGY,2JHUOYUEROAD,NANZIH,KAOHSIUNGCITY811,TAIWAN,REPUBLICOFCHINAEMAILMSHUANGCCMSNKFUSTEDUTWINTJADVMANUFTECHNOL201153110DOI101007/S001700102796YMIDHASBEENBROADLYAPPLIEDTONUMEROUSAREASANDHASEXERTEDSIGNIFICANTEFFECTSINTERMSOFCOSTREDUCTIONANDDESIGNDIVERSITY13,14HOWEVER,THEREISLIMITEDEMPIRICALRESEARCHTHATHASAPPLIEDMODULARDESIGNTOMOLDS1518THISSTUDYTHUSAIMSTOREDUCEMOLDDEVELOPMENTTIMEBYAPPLYINGMODULARDESIGNANDDEVELOPASTANDARDOPERATIONPROCEDUREFORDESIGNINGBEVERAGECONTAINERINJECTIONMOLDS,WHICHARECHARACTERIZEDBYSCORESOREVENHUNDREDSOFCOMPONENTS2GENERALPROCEDURESOFDESIGNINGINJECTIONMOLDSBASICALLY,ANINJECTIONMOLDSETCONSISTSOFTWOPRIMARYCOMPONENTS,THEFEMALEMOLDANDTHEMALEMOLDTHEMOLTENPLASTICENTERSTHECAVITYTHROUGHASPRUEINTHEFEMALEMOLDTHESPRUEDIRECTSTHEMOLTENPLASTICFLOWINGTHROUGHRUNNERSANDENTERINGGATESANDINTOTHECAVITYGEOMETRYTOFORMTHEDESIREDPARTSIDESOFTHEPARTTHATAPPEARPARALLELWITHTHEDIRECTIONOFTHEMOLDOPENINGARETYPICALLYANGLEDSLIGHTLYTOEASEREJECTIONOFTHEPARTFROMTHEMOLDTHEDRAFTANGLEREQUIREDFORMOLDRELEASEISPRIMARILYDEPENDENTONTHEDEPTHOFTHECAVITYANDTHESHRINKAGERATEOFPLASTICMATERIALSTHEMOLDISUSUALLYDESIGNEDSOTHATTHEMOLDEDPARTRELIABLYREMAINSONTHEMALEMOLDWHENITOPENSEJECTORPINSOREJECTORPLATEISPLACEDINEITHERHALFOFTHEMOLD,WHICHPUSHESTHEFINISHEDMOLDEDPRODUCTORRUNNERSYSTEMOUTOFAMOLDTHESTANDARDMETHODOFCOOLINGISPASSINGACOOLANTTHROUGHASERIESOFHOLESDRILLEDTHROUGHTHEMOLDPLATESANDCONNECTEDBYHOSESTOFORMACONTINUOUSPATHWAYTHECOOLANTABSORBSHEATFROMTHEMOLDANDKEEPSTHEMOLDATAPROPERTEMPERATURETOSOLIDIFYTHEPLASTICATTHEMOSTEFFICIENTRATETOEASEMAINTENANCEANDVENTING,CAVITIESANDCORESAREDIVIDEDINTOPIECES,CALLEDINSERTSBYSUBSTITUTINGINTERCHANGEABLEINSERTS,ONEMOLDMAYMAKESEVERALVARIATIONSOFTHESAMEPARTGENERALMOLDDESIGNPROCESSCONTAINSTWOPARTS19PARTDESIGNANDMOLDDESIGNTHEPARTDESIGNPROCESSCONTAINSFIVEMAJORPROCEDURESDEFININGMAINPULLINGDIRECTION,DEFININGCOREANDCAVITY,CALCULATINGSHRINKAGERATE,DEFININGDRAFTANGLE,ANDTHENDEFININGPARTINGLINETHEMOLDDESIGNPROCESSMAINLYINCLUDESCHOOSINGAMOLDBASE,POSITIONINGTHEMOLDEDPART,DESIGNINGCOREANDCAVITY,DESIGNINGCOMPONENTS,DESIGNINGCOOL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P3MODULARDESIGNOFINJECTIONMOLDSTHROUGHTHEDIVISIONOFMOLDFUNCTIONINTOSEVERALFUNCTIONALMODULES,THEINJECTIONMOLDOFASPECIFICCONTAINERCANBERAPIDLYANDEASILYDEVELOPEDBYMODULESTACKINGMODULESTOBEDESIGNEDINCLUDEMALEMOLDMODULE,FEMALEMOLDMODULE,HOTRUNNERMODULE,ANDOTHERSSTEP4PRODUCTANDUNITCODINGEACHSTRUCTURALUNITISASSIGNEDACOMPONENTCODE,WHICHISTHENINTEGRATEDWITHTHEPRODUCTCHARACTERISTICSTOYIELDAPRODUCTCOMPLEXIDENTIFICATIONCODECONSEQUENTLY,MUTUALLYEXCHANGEABLEUNITSAREAVAILABLEINTHEPRODUCTDEVELOPMENTSTAGEFURTHERMORE,NOTITLECODESPECIFICATIONSMATERIALSAMOUNTAUXILIARY1CUPSHAPEDMALEMOLDBASE62NL450H450T60S55C1HEATTREATMENT2CUPSHAPEDFEMALEMOLDBASE192NL450H450T130S55C1HEATTREATMENT3CLAMPINGPLATE32NL450T50120S55C14MANIFOLD42NL330H90T43SKD6115HOTTIP21N14L90BERYLLIUMCOPPER46HOTTIPBUSHINGS23N20L60FDAC47CUPSHAPEDMALEMOLDINSERT191N150H130SUS42048COOLINGUNITOFMALEMOLD192T90H130SDK114HEATTREATMENT9CUPSHAPEDBASEFEMALEMOLDINSERT191N150H110SUS420410CUPSHAPEDFEMALEMOLDINSERT192N130H20SKD114HEATTREATMENT11LEADERPIN611540L260SK3412LEADERPINBUSHING612155L100SK34FIG8BOMOFACUPSHAPEDINJECTIONMOLDINTJADVMANUFTECHNOL2011531107THECODESYSTEMSIMPLIFIESMOLDMAINTENANCEANDPRODUCTMANAGEMENTSTEP5LISTOFMODULAROBJECTSACCORDINGTOTHESTRUCTURALSPECIFICATIONSFROMSTEP3,ALLCOMPONENTSOFANINJECTIONMOLDARELISTEDINBOMFORINSTANCE,THEBOMOFACUPSHAPEDINJECTIONMOLDASANEXAMPLEISILLUSTRATEDINFIG8THISSTEPFACILITATESEASEOFHANDLINGDURINGTHESUBSEQUENTQUOTATIONANDPRODUCTIONSCHEDULINGPROCESSSTEP6COMPONENTDRAWINGSINCEDIMENSIONSOFSTRUCTURALUNITSAREFORSEMIPRODUCTS,THEBOMINFORMATIONLISTEDINSTEP5SIMPLYISTHEINITIALSTAGEOFMOLDDESIGNTHEREBY,ALLSTRUCTURALUNITSOFANINJECTIONMOLDDESIGNEDFORCUSTOMERREQUIREMENTANDSPECIFICATIONHAVETOBEDRAWNINTHEFORMATOFENGINEERINGDRAWINGFORENGINEERINGPURPOSESSTEP7STRUCTURALUNITMANUFACTURINGFOLLOWINGTHEINFORMATIONOFBOMANDCOMPONENTDRAWINGGENERATEDINSTEPS5AND6,RESPECTIVELY,THISSTEPENABLESTHEFACTORYFLOORTOFURTHERMANUFACTURETHEINJECTIONMOLDSTEP8MOLDASSEMBLYANDINSPECTIONTHISSTEPINSPECTSEACHUNITMANUFACTUREDINSTEP7TOASSUREMOLDQUALITYBASEDONTHEASSEMBLYDRAWINGOFAMOLD,THELOCATIONOFRELATEDMODULESANDSTRUCTURALUNITSISACCURATELYASSEMBLEDFORINSTANCE,FIG9PRESENTSTHEASSEMBLYDRAWINGOFACOFFEECUPINJECTIONMOLD,WHICHISUSEDTOCONFIRMTHERELATIONSHIPOFEACHCOMPONENTSTEP9MOLDTESTINGANDMASSPRODUCTIONAFTERCOMPLETINGTHEABOVEEIGHTSTEPS,THISFINALSTEPISPERFORMEDTOTESTTHEMOLDONTHEINJECTIONMOLDINGMACHINEANDIMPLEMENTMASSPRODUCTION5VERIFICATIONANDDISCUSSIONTHISSTUDYEMPLOYSACUPSHAPEDBEVERAGECONTAINERTOEXPERIMENTALLYASSESSTHEPERFORMANCEOFTHEMODULARDESIGNAPPROACHSINCETHESPECIFICATIONOFSTRUCTURALUNITSENABLESPREPROCESSINGOFTHEINITIALUNITSHAPEANDONLYREQUIRESLOCALPREPROCESSINGTOOBTAINPRECISEDIMENSIONSDURINGMOLDDEVELOPMENT,THETOTALMOLDDEVELOPMENTTIMEWILLBESIGNIFICANTLYREDUCEDTABLE1LISTSMOLDDEVELOPMENTFORACUPSHAPEDCONTAINERANDREVEALSTHATTHEMOLDDEVELOPMENTTIMEEMPLOYINGAMODULARDESIGNISSOME36LESSTHANWITHTHECONVENTIONALPROCESSWHEREASTHESTANDARDIZATIONOFCOMPONENTSPECIFICATIONSENABLINGBATCHPURCHASINGOFMATERIALSWHICHARECOMBINEDWITHEFFICIEN
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