Design_and_Simulation_of_Plastic_Injection_Moulding_Process.pdf

PertanikaJ Sci thisisbecausealmost70 oftheplasticproductshapesaresimilar so changeableinsertsareusedinthis case Coreinsertwillbeaspermanentinsertand changethesliderandcavityinsertforTG Clip versionandTG Stick version Plate 11 showsthecavityandcoreinsertforTG ClipandStick version PertanikaJ Sci thismeansitcanenhancequalityinthe moulddesignbyreducinginthenumberoferrors ApplicationofCAD CAM andtheMethods for Mould Design Inthis project thetypeofCAD CAM softwareemployedisPro Engineer2000i Prof Moldesign isanextensionofPro Engineertothemouldmanufacturingenvironment covering all aspectsofproductionmoulddesignsuchasmouldbases runnersystem creation waterlines ejector pin holes shrinkageandhundredsofotherfeatures The Plate 14formouldassemblyisusingPro Moldesigntocreateanddesignthe mould ProfCandPro MFGarethemanufacturingextensionsofPro EngineerintoC C productionarena andhave a widebreadthofcapabilities coveringfrom3 to 5 axis milling 2and4 axis wire EDM turning laser flame etc Afterdesigningallthemoulds Pro NCandPro MFGforthemanufacturingwill playanimportantroleagainintheprocessofcreatingthedetail drawingneededand generatingC toolpathstomachinetheactualmould TheCtoolpathsarederived fromtheproductmodeldatabase Productpathscompletedin3 Dmodelwill be directly extractedfromthemoulddesigndatabaseformanufacturing forexample coreinserts fromthemoulddatabasethatwanttodosomemanufacturing Before startingCAD CAMsomeoftheimportantfeatureshave tobeconsideredlike toolfeedrate spindle speed stepdepth materialto mill Plungerspeed coordinatesystem andwhatkindof endmill used TostartCAD CAM dimensionofwork piece has tobedecidedfirstandthensetting thecoordinatesystem tothework piece Thework piececoordinatemustbeofthesame setting withthecoordinateintheCNCmachine Thewrongsetting will cause the machinetocrashwiththeworkpiece Decidewhatkindofmanufacturingprocess to use forexampleprofiling volume pocketing hole makingandconventionalsurface After selectingthemanufacturingprocess ProfC will convertcomputercodeto PertanikaJ Sci so using CAD CAM willenhance qualityoftheworkinthemoulddesignandreducethenumberoferrorsin manufacturing Fromtheanalysis simulation Moldflow provides sufficientinformationresults such as fill time injectionpressureandpressuredrop With this result userscanavoidthe defectoftheplasticinactualinjectionsuchas sink mark hesitation airtraps and overpacking Theanalysis will alsohelpthemoulddesignerto design aperfectmould withminimummodificationsanditwill alsoreducethemouldsetuptime With this analysisandsimulationitwillhelptoreducetimeandcost 98 PertanikaJ Sci Techno SupplementVa 12No 2 2004 DesignandSimulationofPlasticInjectionMouldingProcess Pr I Design Model II Workpiece I 1ManufacturingModelj MachineTools Workcells I FixtureSetupSetUpManufacturingDatabase 1 Tools 1 SetUpOperation II 1 o MFG 1 Define NCSequences 1 1I 1 I CreateCLData Files I 1 ProduceIn Process Model II Post Process 1 1 I Drive NCMachineTool I Fig 3 Summarizes the Pro MFG process REFERENCES FRADos J 1976 Plastic Engineering Handbook TheSocietyojthe Plastic Industry Fourthedition Van NostRandReinholeCompany MoldflowHelpFiles CAMPBELL P D Q 1996 Plastic Component Design First edition New York USA Industrial Press Inc Pro MFGandPro NC CHECKUsers guide Release 18 ROSATO D Y 1986 Injection