CHAPTER 1

1.0 PRO/ENGINEER
Pro/ENGINEER is a feature-based, parametric solid modeling system with
many extended design and manufacturing applications. As a comprehensive
CAD/CAE/CAM system, covering many aspects of mechanical design, analysis and
manufacturing, Pro/ENGINEER represents the leading edge of CAD/CAE/CAM
technology.
1.2 OBJECTIVES
1.
2.
3.
4.
5.

To create a solid part

To create work piece
To perform the machining operation setup
To define the machining operation
To View tool path simulation and cutter location file

1.3 SPECIAL FEATURES IN PRO-E

1. Regenerative feature in available in Pro-E. ( If any alteration in part drawing the
it automatically regenerate in all places where the component is used.
2. Basic Parametric Surfacing
1.4 ADVANTAGES OF PRO-E
1.
2.
3.
4.
5.
6.
7.
8.

Most Complete Solution, Most Robust Functionality

Advanced Geometry Creation
Assembly Performance Tools
Easily Reuse Legacy Data
Production-Ready Drawings
Data Reuse and Standards
Easiest to Use
100% Focus on Product Design Engineers

1.5 MANUFACTURING TOOLS AVAILABLE IN THE SOFTWARE

1. Face milling
2. Volume and local milling
3. Roughing
4. Plunge milling
5. Profile milling
6. Surface milling
7. Finishing
8. Trajectory milling
9. Hole making
10. Thread milling
11. Area turning
1

12. Profile turning

13. Grooving
1.6 ASSEMBLY PROCEDURE
STEP 1: First open the pro engineer software. File ->set working directory. To save
your file name.
STEP 2:File->new select part to draw the component . Remove tick mark to use
default system template. Select mmns - part solid ok. So that mm will be followed
and ok.
STEP 3: For generating 3d model. Select the plane (front). Select ->extrude
placement define front plane sketch will appear. First draw the center line it will be
must. Rectangle tick two sides means go to options and select tick mark.
STEP 4: For editing the component go for model tree ->extrude click + edit definition.
To material removal change the direction of arrow inside and remove material.
Sketch ->reference line
Sketch orientation ->plane. To draw any line in surface go to sketch reference and
select reference line wherever we want.
STEP 5: Assemble of component
Parts should be in same folder ( for assembly).
File ->new->assembly.
Dimensions should be in yellow colour not in black. For that click middle button after
select that line and change dimensions.
Already dimensions means just click double ->click ->ok.
For circle click center button and ok.
STEP 7: Assembly
New ->assembly ->mmns ->ok.
2

For importing the component options assemble left side.

STEP 8: For first component it should not be moved .so select fix option and click tick
from top option.
STEP 9: For second component
Select ->mate opposite side.
Align ->same side.
(Always the status must be fully constrained). For selecting or connecting the same
axis of both.
STEP 10: For vertical component
Placement ->coincident angle is selected and inserted for connecting hole.
Placement ->new constraint for every arresting movement.

Use tangent (for

connecting circular and flat surfaces)

STEP 11: For mating the components. Edit the definition notice the constraint status is
partially constrained. In the dashboard select the placement. Now click the new
constraint. Select mate as constraint type. Verify the offset is set to coincident and
finally select the surface on component.
STEP 12: Notice the component snap to its new location and also add notice the
constraint and click tick mark. Similarly for align ,edit the constraint from mate to align
in the dialog box and verify offset is coincident and click the component and tick mark.

1.6.1 Assembly drawing

Fig 1.1 shows the assembly of machine vice. It consists of three main
parts i.e., a base, sliding jaw and fixed jaw. A movable jaw slides on the
ways of the body. The fixed jaw is formed on the other fixed support. The
screw is used to clamp the work part rigidly. So the entire assembly required
highly accurate mating with respect to each other.
3

Sliding
jaw

Fixed
jaw

Scre
w

Body

Fig 1.1 Assembled view of machine wise

1.7 PROCEDURE FOR MILLING OPERATION (PRO-E SIMULATION)

Step 1: Select FILE -> NEW ->Manufacturing-> select mm nc
Step 2: Assemble reference model-> default (constrain the location of the reference
model)
Step 3: Automatic work piece -> enter the thickness value for part to be machined.
Step 4: Set the coordinate system. (The coordinate system must match the mill
orientation and part zero) Pick work piece to create coordinate system in. Pick 3
reference planes.
Step 5: MFG Setup Operation
Define NC machine. Click NC machine icon. Machine. Enter the parameters
as given
below
Machine type: Mill
Number of Axis: 3
Step 6: Define Machine Zero. Click Reference Machine Zero icon.
4

Step 7: Define retract plane. Click Retract Surface icon. Retract Selection window
pops up.
Choose Along Z Axis, and in the panel of Enter Z Depth, input 1, click OK to close the
Window
Step 8: Define the machining operations. The setup consists of defining the type of
tool to use and machining parameters (tools size, cutting speed, etc.), and specify the
volume of material to be removed.
Step 9: Volume roughing
Select Volume roughing-> DONE.
Enter the tool diameter, tool length in the tool setup window. In the edit parameters of
sequence window to enter the cutting feed, step depth, clearance and spindle speed.
Select the Mill window Tool icon and then select the sketch tool. To define this mill
volume by sketching the area to mill.
Select the sketching plane on the top surface of the part. Orient the part to match the
sketching environment.
PLAY PATH >> SCREEN PLAY.
Step 10: Profile milling
Select profile milling-> DONE.
Make sure the following setup operations are checked: Tool, Parameters and Surfaces.
Select DONE.
Choose the surfaces that make up the outside edge of the part. Use the control key to
make multiple selections.
Choose PLAY PATH >> SCREEN PLAY and see that the tool profiles around the
edges selected.
Step 11: similar operations are to be performed using the same procedure.
Step 12: NC code generation
Edit -> CL data-> output set-> create-> write part name-> ok -> -> select all in menu
manager window. Done sel -> done return.
Tool command -> CL data -> post processor -> select the Fanuc NC code 20.

The Pro-e simulation was done for complete machining for given component is
shown in Fig 1.3. The material for block is made up of cast iron. Based on material and
tool the following process parameters was selected is shown in table 1.1. source
( Chand S, Machine Drawing)

Fig 2.1 Pro e model for machine base

Table 1.1 Process parameters for milling operation

Parameter
Cut feed
Step over
Step depth
Clearance distance
Spindle speed
Tool diameter (End mill cutter)

values
200 mm/min
2 mm
1 mm
2 mm
200 rpm
12 mm

Fig 1.3 (a) Facing (b) Volume roughing (c & d) Pocketing (e) Surface milling (f) Profile milling
(g) Drilling (h) Finishing operation

NC CODE
(Date:02/21/16 Time:12:33:43)
G98G80G90G49G17
(MFG0005)
T1M6 (volume rough)
S2000M3

G0X-3.016Y-.516
G43Z1.H1
G1Z-1.F50.
X81.527
Y.479

X-3.016
Y1.474
X81.527
Y2.469
X-3.016
Y3.464
X81.527
Y4.459
X-3.016
Y5.454
X81.527
Y6.449
X-3.016
Y7.444
X81.527
Y8.439
X-3.016
Y9.434
X81.527
Y10.429
X-3.016
Y11.424
X81.527
Y12.419
X-3.016
Y13.414
X81.527
Y14.409
X-3.016
Y15.404
X81.527
Y16.399
X-3.016
Y17.395
X81.527
Y18.39
X-3.016
Y19.385
X81.527
Y20.38
X-3.016
Y21.375
X81.527
Y22.37
X-3.016
Y23.365
X81.527

Y24.36
X-3.016
Y25.355
X81.527
Y26.35
X-3.016
Y27.345
X81.527
Y28.34
X-3.016
Y29.335
X81.527
Y30.33
X-3.016
Y31.325
X81.527
Y32.32
X-3.016
Y33.315
X81.527
Y34.31
X-3.016
Y35.305
X81.527
Y36.3
X-3.016
Y37.295
X81.527
Y38.29
X-3.016
Y39.285
X81.527
Y40.28
X-3.016
Y41.275
X81.527
Y42.27
X-3.016
Y43.265
X81.527
Y44.26
X-3.016
Y45.255
X81.527
Y46.25
X-3.016
Y48.24

The Pro-e simulation was done for complete machining of pedestal bearing body
shown in Fig 1.3. The material for block is made up of cast iron. Based on material and
tool the following process parameters was selected is shown in table 1.2. source
( Chand S, Machine Drawing)
Table 1.2 Process parameters for milling operation

Parameter
Cut feed
Step over
Step depth
Clearance distance
Spindle speed
Cutter diameter

values
200 mm/min
2 mm
1 mm
2 mm
200 rpm
12 mm

Fig 1.4 Pro-E model for pedestal bearing body

Fig 1.5 (a) Facing (b) Volume roughing (c & d) Pocketing (e) Surface milling (f) profile milling

(g) Drilling (h) Finishing operation

NC CODE

%
(Date:02/23/16 Time:12:28:18)
G98G80G90G49G17
( MFG0001) face milling
T1M6
S1500M3
G0X250.Y4.
G43Z1.H1
G1Z-1.F100.
X-2.
Y6.
X250.
Y8.
X-2.
Y10.
X250.
Y12.
X-2.
Y14.
X250.
Y16.
X-2.
Y18.
X250.
Y20.
X-2.
Y22.
X250.
Y24.
X-2.
Y26.
X250.
Y28.
X-2.
Y30.
X250.
Y32.
X-2.
Y34.
X250.
Y36.
X-2.
Y38.
X250.
Y40.
X-2.
Y42.
X250.
Y44.
X-2.

Y46.
X250.
Y48.
X-2.
Y50.
X250.
Y52.
X-2.
Y54.
X250.
Y56.
X-2.
Y58.
X250.
Y60.
X-2.
Y62.
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Y64.
X-2.
Y66.
X250.
Y68.
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Z1.
G0X250.Y4.
G1Z-2.F100.
X-2.
Y6.
X250.
Y8.
X-2.
Y10.
X250.
Y12.
X-2.
Y14.
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Y16.
X-2.
Y18.
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Y20.
X-2.
Y22.
X250.
Y24.
X-2.
Y26.
X250.

Y28.
X-2.

Y30.
X250

1.8 PROCEDURE FOR TURNING OPERATION (PRO-E SIMULATION)

Step 1: Select FILE -> NEW ->Manufacturing-> select mm nc
Step 2: Assemble reference model-> default (constrain the location of the reference
model)
Step 3: Automatic work piece -> enter the thickness value for part to be machined.
Step 4: Set the coordinate system. (The coordinate system must match the mill
orientation and part zero) Pick work piece to create coordinate system in. Pick
horizontal axis and vertical plane as reference.
Step 5: MFG Setup Operation
Define NC machine. Click NC machine icon. Machine. Enter the parameters as given
below
Machine type: lathe
Number of Axis: 2
Step 6: Define Machine Zero. Click Reference Machine Zero icon.
Step 7: Define retract plane. Click Retract Surface icon. Retract Selection window pops
up.
Choose Along Z Axis, and in the panel of Enter Z Depth, input 1, click OK to close the
Window
Step 8: Define the machining operations. The setup consists of defining the type of tool
to use and machining parameters (tools size, cutting speed, etc.), and specify the
volume of material to be removed.
Step 9: Select AREA turning -> done. Tool setup window will open. Enter the cutting
parameter values. Select turn profile -> sketch -> select reference -> draw line ( It
indicates the tool path).
Step 10: For grooving operation same procedure to be carried out. Except the cutting
parameters and tool.
Step 11: NC code generation

Edit -> CL data-> output set-> create-> write part name-> ok -> -> select all in menu
manager window. Done sel -> done return.
Tool command -> CL data -> post processor -> select the Fanuc NC code 20.
Turning operation
To perform the turning operation for given component using pro-e simulation.

Fig 1.6 Pro-e model for pin

Fig 1.7 (a) Area turning (b & c) Grooving (d) Profile turning
NC CODE
%
(Date:02/21/16 Time:15:45:00)
G98G80G90G49G17
( / MFG0002)
S1500M3
G0Z22.939
X106.71Y0.
G1X104.61F100.
Z-447.826
X106.673
G0Z22.939
G1X103.647F100.
Z-447.826
X105.71
G0Z22.939
G1X102.684F100.
Z-447.826
X104.747
G0Z22.939
G1X101.721F100.
Z-447.826
X103.784
G0Z22.939
G1X100.758F100.
Z-447.826
X102.821
G0Z22.939
G1X99.795F100.
Z-447.826
X101.858
G0Z22.939
G1X98.832F100.
Z-447.826
X100.895
G0Z22.939
G1X97.87F100.
Z-447.826
X99.932
G0Z22.939
G1X96.907F100.

Z-447.826
X98.97
G0Z22.939
G1X95.944F100.
Z-447.826
X98.007
G0Z22.939
G1X94.981F100.
Z-447.826
X97.044
G0Z22.939
G1X94.018F100.
Z-447.826
X96.081
G0Z22.939
G1X93.055F100.
Z-447.826
X95.118
G0Z22.939
G1X92.092F100.
Z-447.826
X94.155
G0Z22.939
G1X91.129F100.
Z-447.826
X93.192
G0Z22.939
G1X90.166F100.
Z-447.826
X92.229
G0Z22.939
G1X89.203F100.
Z-447.826
X91.266
G0Z22.939
G1X88.24F100.
Z-447.826
X90.303
G0Z22.939
G1X87.277F100.
Z-447.826

X89.34
G0Z22.939
G1X86.315F100.
Z-447.826
X88.377
G0Z22.939
G1X85.352F100.
Z-447.826
X87.415
G0Z22.939
G1X84.389F100.
Z-447.826
X86.452
G0Z22.939

G1X83.426F100.
Z-447.826
X85.489
G0Z22.939
G1X82.463F100.
Z-447.826
X84.526
G0Z22.939
G1X81.5F100.
Z-447.826
X83.563
G0Z22.939

G1X80.5F100.

1.9 MOLD FLOW

Moldflow Plastic Insight is an in depth process simulation tools to predict and
eliminate potential manufacturing problems and optimize part design, mould design and
the moulding process itself. Moldflow software is used to optimize the mould design
process and foresee possible issue in production process.
1.10 NEED OF MOLD FLOW PLASTIC INSIGHT
Ideally, CAE analysis provides insight that is useful in designing parts, molds,
and molding processes. Without it, we rely on previous experience, intuition,
prototyping, or molding trials to obtain information such as polymer melt filling patterns,
weld-line and air-trap locations, required injection pressure and clamp tonnage, fiber
orientation, cycle time, final part shape and deformation, and mechanical properties of
molded parts, just to name a few. Without CAE analysis, other equally important design
data, such as spatial distributions of pressure, temperature, shear rate, shear stress,
and velocity, are more difficult to obtain, even with a well-instrumented mold.
1.11 OBJECTIVE
There are several objectives for the purpose of this thesis;
1. To analyze the behaviour of thermoplastic material during the production cycle
from the filling phase until the ejection phase
2. To foresee the possible problem for a product design; and therefore able to
3.
4.
5.
6.
7.
8.

optimize
the design in the mould design process
To achieve the minimum production cycle time
Balance the runner system design
Reduce material stress levels
Predict weld line locations
Validate pressure and temperature distribution within the mold

9. Optimize processing conditions including melt temperature, injection rate, and

cavity pressure.
1.12 Analysis Capabilities
1.
2.
3.
4.
5.
1.13
a)
b)
c)
d)

Plastic filling analysis

Runner balance analysis
Sink mark analysis
Cooling quality analysis
Gate location analysis
FEATURES AVAILABLE IN MOLD FLOW PLASTIC INSIGHT
Meshing technology
Dual domain
3D
Mid plane

b) CAD interoperability
1. CAD solid models
2. Parts
3. Assemblies
c) Simulation capabilities
1. Filling
2. Weld line, air trap, sink mark
3. Gate location
4. Molding window
5. Venting analysis
6. Design of experiments (DOE)
7. Crystallization analysis
8. Runner balancing
9. Packing
10. Cooling
11. Conformal cooling
12. Transient mold cooling or heating
13. Rapid temperature cycling
14. Warpage
15. Fiber orientation
16. Core shift

1.14 General procedure

1. Start Moldflow
File -> new-> name

2. Import the Model

File-> import-> fusion -> ok
3. Mesh the model
Mesh-> generate mesh
Select the remesh the model option-> mesh
4. Specify Analyses to be Performed
There are many analyses available and the one(s) of interest has to be specified.
Since the analyses are different some are run separately. The general procedure is to
specify a list of analyses and then run them separately. Also, different analyses are
available for 2-dimensional and 3-dimensionsal models.
Analysis -> Set Molding Process -> Thermoplastic Injection Molding
Analysis -> Set Analysis Sequence -> More.
a. Fill
b. Fill + warp
5. Specify Material
Analysis -> set materials
Select Material in main menu. Toggle Specific Material ON.
a) Enter material manufacturer and trade name - these might be available in pull down
list
b) Material properties, processing conditions, material model parameter values, etc.
are available for a large number of materials and may be available for the material
to be used.
e.g., Manufacturer -> CMOLD Generic Estimates
c) Trade name -> PP Generic Estimates
Details... in Select Materials dialog box
The material characteristics provided are useful information for process and mechanical
behavior modeling. And, recommended process limits may be shown, e.g., Maximum shear
stress, Maximum shear rate There are no Shrinkage Properties available - so a Shrink analysis
cannot be run.
OK in Thermoplastics material information box
OK in Select Material dialog box.
6. Specify Injection Location(s)
Analysis -> Set Injection Locations (select the appropriate injection location(s).)
Right click-> finish injection location
Analysis -> Analyze Now

Run a full analysis in Select Analysis Type input box and OK

Analysis Log shows progress of simulation and when mold cavity is 100% filled
Analysis Complete! and
OK
7. Report of Analysis Results
Report -> Report Generation Wizard
Choose the Study of interest

(a) Body cover (b) Pressure distribution(c) Fill time (d) Pressure (e) Temperature at flow end
(f) Weld lines (g) Temperature (h) Shear stress at wall

CHAPTER 2
INVESTIGATION OF PROCESS PARAMETERS FOR AN

THIN WALLED INJECTION MOLDING PARTS FOR CONTROLLING

WARPAGE
2.0 INTRODUCTION
Plastic injection molding process is the most common process for economically
mass producing of plastic parts of various complex geometries and shapes. Some of
the major problems facing injection molders today are how to reduce cycle time, part
warpage and shrinkage alongside lowest costs. However, using computer simulation
software, it is possible to design and simulate for different mold temperatures and
packing pressure of the plastic part.
2.1 LITERATURE REVIEW
Injection molding is a process whereby a solid thermoplastic material is heated
until it reaches a state of fluidity, is then transferred under pressure(injected) into a
closed hollow space (mold cavity),and then cooled in mold till it reaches a solid state,
conforming the shape of mold cavity. Assuring the proper mold temperature for a
specified polymer is a very important issue as well as keeping the temperature constant
and equal across the cavity surface. Differences in mold temperature can lead to the
problems with manufactured parts like warpage [1,2]. The reason of this are stresses in
the parts. Since polymer with higher temperature exhibits more intensive shrinkage than
in lower temperature, the temperature differences created during part cooling in the
Mold lead to part distortion. The deformation of a simple injection molded part due to
less and high temperatures are shown in Fig. 2.1. Part becomes concave from the Mold
hot side and convex from the Mold cold side. The main cause of warpage is the
difference in internal stresses produced in the material due to differential shrinkage. Also
the different temperature can also affect polymer flow in runners of multi cavity mold and
this can lead to non-simultaneous filling of the mold cavities.

Fig 2.1 Warpage of injection molded part due to different mold temperature
Source (Chih Nian et al, (2015) Warpage control of thin-walled injection molding using local
mold temperatures)

According to Jacques [1], the warpage of a molded part results from the
asymmetrical stress distribution over the thickness of the part from unbalanced cooling.
Therefore, the thinnest part is the most sensitive to warpage. Several methods have
been proposed by Shoemaker et al. [2] to reduce the warpage of thin-walled parts by
considering the part design shape, mold system design, cooling system, and molding
parameters. In designing thin-walled parts, the mold temperature should be kept
uniform in the cavities and cores to ensure a consistent cooling rate within the entire
part. The mold temperature was found to have the greatest effect on the occurrence of
warpage in thin-walled parts. Hence, reducing warpage is one of the top priorities to
improve the quality of injection- molded parts.
Azaman et al. [3] investigated the Shrinkages and warpage in the processability
of wood-filled Polypropylene thin wall part. The warpage increases until 50C and
decreases for mold temperatures over 50C. The minimum warpage at the midpoint of
the thin-walled part is 0.0093 mm at 40C; The warpage is 0.0469 mm at 50C. The
distribution of the warpage at mold temperature 40 C is better than that at the higher
mold temperatures. The ideal mold temperature range is from 40 to 45 C for a molded
shallow, thin-walled part using lignocellulosic polymer composite. The effect of packing
pressure was also studied. Increase in the packing pressure up to 0.85 P reduces the
warpage at the midpoint surface of the shallow, thin-walled part. For the distribution of
warpage in the range of 0.125 0.825 mm and 0.0780.453 mm for the thin-walled part
with applied packing pressure of 0.45Pinject and 0.65Pinject, respectively.

Chih Nian et al. [4] proposed the netural axis theory for Warpage control of thinwalled injection molding using local mold temperatures. The maximal temperature was
located above the neutral axis and caused relatively substantial shrinkage during
cooling, suggesting that the short edge will warp, forming a concave shape after
cooling. By contrast, the maximal temperature is located below the neutral axis, which
will warp into a convex shape. Therefore, the neutral axis theory can be considered to
explain the warpage behavior depicted in the simulation (Fig. 2.2). Moreover, if the
temperatures of female and male mold plates are adjusted to enable the maximal
temperature to be located exactly on the neutral axis, the warpage caused by uneven
shrinkage can be eliminated. Z-directional warpage in the long edge with respect to a
uniform mold temperature setting (70 C mold temperature) and a local mold
temperature setting (80 C and 30 C mold temperatures for female and male mold
plates, respectively). The female plate was deformed in the range of 0.881.0 mm,
whereas the male plate was less deformed in the range of 0.630.7 mm.

Fig 2.2 Warpage of the long edge w.r.t. with various mold temperature settings .

Mustafa Kurt et al. [5] investigated the cavity pressure and mold temperature
strongly affect the shrinkage of the product in the y- and x-directions and its cyclicity.
Specifically, the higher the cavity pressure and mold temperature, the smaller the
shrinkage in the y- and x-directions and the lower the error of cyclicity of product. Also
the results shows that the, dominant factor responsible for increasing the mold
temperature is the melt temperature. When the melt temperature was increased from
185C to 200 C, the cavity pressure also increased. when the melt temperature was
increased from 185C to 225 C, the mold temperature increased from 50.56 C to

56.88 C. When the packing pressure was increased from 850 bar to 900 bar at a
temperature of 200 C.
Huszar et al. [6] investigated the impact of material selection and gate location on
part warpage and injection pressure.

Polystyrene (PS) could effectively be used to

reduce the warpage by as much as 50% compared to the Polypropylene (PP). As being
an amorphous grade, the variation of shrinkage and thermal expansion are smaller,
whereas it has higher elastic and shear moduli representing a greater resistance
against deflection compared to PP. The effect of gate location on different position (top,
snap, middle and bottom) was also studied. The results shows, an asymmetrical fibre
distribution would be generated if the middle gate location was applied. Contrary to this,
symmetrical fibre distribution could be achieved with the top gate location. The tendency
for warpage was observed by numerical analysis and showed excellent agreement with
experimental validation. With the middle gate location the angle of deformation was
estimated to be = 87, while elimination of warpage was achieved with the top gate
location with deformation angle being =90. From that study it was clear that the
differential fibre orientation did not cause warpage, but the asymmetrical distribution of
fibre orientation did. The snap and bottom gate location cause a flow problem called
hesitation also leads to non uniform flow.
2.2 PROBLEM DEFINITION
The recent trend in the industry is to manufacture thin, light weight and green
products. Plastic parts that are thin ( less than 1.5mm) and feature a high ratio of flow
length to thickness (greater than 100) form quickly solid layers when molten polymer
enters mold cavities, thereby facilitating a short shot caused by the sharp decrease in
the flowing channel. Thin-walled plastic parts are particularly prone to severe warping
because of their weak mechanical structures. The effects of improper molding condition
settings and uneven cooling result in sectional shrinkage variations. The main cause of
warpage in injection-molded parts is the uneven volumetric shrinkage from high to low
temperatures. Reducing volumetric shrinkages and warpage during the injection
molding process is a challenging problem in the production of molded thin-walled parts.
Since the modification for the injection product is irrelevant for reducing the warping

problem, the attention should be put before injecting the product that is during the
designing and analyzing process for the product design.
2.2 PROBLEM OBJECTIVE
1. To study the influence of mold temperatures and packing pressure on the
warpage and shrinkage of thin walled injection molded components.
2. The objective of this project is to Identified the optimum condition of parameter
that minimizes the warpage within dimensional tolerance.
2.3 METHODOLOGY
1. A thin wall component is to be created using Pro-E and it will import on mold flow
plastic insight 3.1.
2. To simulate the injection molding process using mold flow plastic insight.
3. The simulation is to be performed using set analysis (Fill + Cool + Fill + Pack
+Warp) for this models. And to analyze the results with respect to volumetric
shrinkage and warpage.
2.4 AVAILABILITY OF RESOURCES
1. For analysis the material flow Moldflow Plastic Insight 3.1 (MPI) is to be used. By
varying different mold temperatures and packing pressures, the corresponding
warpage & shrinkages are note by simulation.
2. For experimentation, L&T injections molding equipment (DeTech 40/320-IU120)
is available in tool and die centre.
2.5 MATHEMATICAL MODEL
The mass, momentum and energy conversation governing equations for the nonisothermal, generalized Newtonian fluid are given by Equation. (1) to(10). Difference in
the temperature of the mold halves can have a dramatic affect on warpage. Typically
such differences are determined by cooling analysis.
Continuity Equation

. ( )=0

(1.1)
Momentum equation

( t + . )= p+

Energy equation

+ g

(1.2)

 cp

T
2T
( t + . T =k )

(1.3)
The viscosity model of fluid
o (T , p)

( , T , p )=
o

(1.4)

(T,p)

Tb
( T exp ( p)

exp
(1.5)

Then
.= 2
(1.6)
Boundary and initial conditions
=0;

T=

Tw

p
n

=0

(on

mold

wall)

(1.7)

z =

T
z

(on

centre

line)

(1.8)
p=0 (on fluid front)
p=

pm

(x,

(1.9)
y,

z,

t);

Tm

t=

(1.10)
whereas,
T -Time
B - Viscosity coefficient
c pSpecific heat

K -Thermal conductivity

-Velocity vector

(on

inlet)

M -flow index
N -normal direction
P -pressure
Pn- inlet pressure
T t-emperature
Tm -freezing temperature

-Laplace operation vector

Viscosity

-Density

. -Shear rate

-Partial derivative
Tb -reference temperature
Tw- mold temperature
X, y, z -Cartesian coordinate

o Refreance velocity

-Refrence stress

The mold temperature is a critical measure for cooling speed value and injection
part properties. This critical value can be established according to heat exchange that
takes place into the mold.
(a) Between the injected thermoplastic and the mold material Q;
(b) Heat exchange between the mold and the environment QT;
(c) Between the mold components and environments QE.
Q + QE + QT = 0

(1.11)

Heat balance expressed in this equation can be considered as a basic equation of the
cooling process.
Q>0
QE < 0
QT < 0
Where: TM Output value or the mold temperature.
2.6 SIMULATION TRAILS
2.6.1 Trail -1
Mold flow plastic insight was used to model the thin walled molded parts, as
shown in fig. 2.3. A shallow, thin-wall part was created as a 3D design. The general
dimensions of the part were 55 mm 50 mm - 0.7 mm. Mold Flow Insight 3.1 was used to
simulate the injection molding process. The fixed post-filling parameters are shown in
table 2.1. The simulation was performed using set analysis (Fill analysis) for given
models. The results with respect to warpage is shown in fig 2.4.

Fig. 2.3 A shallow, thin-walled part

Table 1.1 The fixed processing parameter settings used for analyzing the effects of some post
filing parameters (polypropelene)

Parameters
Mold surface temperature
Cooling time
Injection pressure
Injection time
Melt temperature

value
50 c
20 sec
110 Mpa
1.5 sec
180 c

2.6.2 Trial -2
The material for the lens as chosen as polycarbonate. It having high ductility,
impact resistance and comparatively light weight. The fixed process parameter as
shown in table 2.2. The effect of gate location was analyzed and the results were
shown in fig 2.5.

Fig. 2.3 Pro-E model for lens

Table 1.2 The fixed processing parameter settings used for analyzing the effects of some post
filing parameters (poly carbonate)

Parameters
Mold surface temperature
Cooling time
Injection pressure
Injection time
Melt temperature

value
80 c
50 sec
90 Mpa
2.0 sec
280 c

Injection

Fig 2.4 Filling simulation (a) Pressure at injection location (b) Deflection (all effects) (c) Pressure

(end filling) (d) Volumetric shrinkage at ejection

Fig 2.4 Filling simulation (a) Deflection (total deflection effects) (b) Fill time

2.7 Trial 3
For the impeller blade the analysis was done using mold flow plastic insight. The
factors affecting the warpage was analyzed for the same component. The fig 2.6 shows
the flow + warp analysis results at various process conditions. The material for the
component was chosen as polymer composites.

Fig 2.5 Pro-E model for impeller blade

2.8 WORK DONE SO FOR

1. Based on literature survey, the major factors (mold temperature and packing
pressure) influencing the warpage was studied. And also the effect of gate location
affect the filling process was also studied.
2. The basic mathematical model was derived for mold flow heat transfer.

3. Flow set analysis and flow + warp analysis was done for the typical components.

At mold temperature 75 0 c, injection pressure as 120 Mpa and cooling time as 20 sec

At mold temperature 80 0 c ,injection pressure as 120 Mpa and cooling time as 20 sec

At mold temperature 70 0 c, injection pressure as 120 Mpa and cooling time as 20 sec

At mold temperature 70 0 c injection pressure as 110 Mpa and cooling time as 20 sec

At mold temperature 70 0 c, injection pressure as 140 Mpa and cooling time as 20 sec

At mold temperature 70 0 c , injection pressure as 140 Mpa and cooling time as 10 sec

(a) Deflection at all effects

(b) Sink index

(c) Fill time

CHAPTER 3
3.0 REFERENCES
1. Jacques M., and Nian S, 2006, An analysis of thermal warpage in injection molded
at parts due to unbalanced cooling Polymer Engineering Science, Vol 22, pp-241245.
2. Shoemaker J., 2006, Moldflow design guide -A resource for plastics engineers ,
Hanser., Cincinnati, ISBN-13.
3. Azaman M D., and Sapuan S M, Sulaiman S, Zainudin E S, Khalina a, 2013,
Shrinkages and warpage in the processability of wood-filled polypropylene composite
thin-walled parts formed by injection molding, Materials and Design, Vol 52, pp1018
1026.
4. Chih Nian S., and YangWu C, Huang C S, 2015, Warpage control of thin-walled
injection molding using local mold temperatures, International Communications in Heat
and Mass Transfer, Vol 61, pp 102110.
5. Huszar M., and Belblidia F, Davies M H, Arnold C, Bould D,

Sienz J, 2015,

Sustainable injection moulding: The impact of materials selection and gate location on
part warpage and injection pressure, Sustainable Materials and Technologies, vol 5 ,
pp18.
6. Kurt M., and

Kamber O, Kaynak Y, Atakok G, Girit O, 2009, Experimental

investigation of plastic injection molding: Assessment of the effects of cavity pressure

and mold temperature on the quality of the final products, Materials and Design, Vol 30
pp 32173224.