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Injection Molding Methods Design, Optimization, Simulation of Plastic Toy Building Block by Mold Flow
Analysis, Manmit Salunke, Rushikesh Kate, Vishwas Lomate, Gajanan Sopal, Journal Impact Factor (2015):
SIMULATION OF PLASTIC TOY BUILDING BLOCK BY MOLD
8.8293 Calculated by GISI (www.jifactor.Com)
FLOW ANALYSIS
Manmit Salunke1, Rushikesh Kate2, Vishwas Lomate3, Gajanan Sopal4
1,2,3
Assistant Professor, Department of Mechanical Engineering, J.S.P.M.S B.I.T,
Barshi, Solapur, Maharashtra, India
4
Associate Professor, Department of Mechanical Engineering, J.S.P.M.S B.I.T,
Barshi, Solapur, Maharashtra, India
ABSTRACT
Mold flow simulation helps designers to see how their designs will be resulted after injection
molding process without needing to do the Injection Molding process. The use of simulation
programs saves time and reduces the costs of the Molding system design. Injection molding design
simulation holds an important role in analyzing the outcome of the design. In this paper plastic toy
building block part is analyzed and studied to solve the problems frequent rejections due to as
shrinkage, weld lines, air traps, and sink marks. All the designs were simulated with Autodesk Mold
flow Adviser. Autodesk Simulation Mold flow effectively eliminates the use of trial and error
method by validating and optimizing the design of plastic before production. This not only improves
the quality but also help us to guide about the selection of machines and the production planning.
Keywords: Injection moulding, Mould design, Mold flow simulation, Optimization Plastic Injection
mould, Mould Flow Plastic Advisor (MPA)
1. INTRODUCTION
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Injection Molding Methods Design, Optimization, Simulation of Plastic Toy Building Block by Mold Flow
Analysis, Manmit Salunke, Rushikesh Kate, Vishwas Lomate, Gajanan Sopal, Journal Impact Factor (2015):
8.8293 Calculated by GISI (www.jifactor.Com)
Nowadays, Computer Aided Design is not limited to sketching and drafting, but also helps to
create analysable models as needed for computer based process simulation. Moldflow software, used
solution for Digital Prototyping, provides injection molding simulation tools for use on digital
prototypes. Providing in-depth validation and optimization of plastic parts and associated injection
molds, Moldflow software helps study the injection molding processes in use today. The Autodesk
Simulation Moldflow results help to identify the main problem areas before the part is manufactured
that are particularly difficult to predict with traditional methods. In conventional optimization
process includes actual shop floor trials in which pattern, feeder size, shape and location cores,
mould layout, gating etc are required to be changed in each iteration which is associated with
machining cost, tooling cost, modification cost, melting cost, fettling and transportation cost as well
as energy, materials, time are wasted in each trial until and unless the required results are obtained.
Analysis is essential for designing and mould making through simulation step-up and result
interpretation to show how changes to wall thickness, gate location, material and geometry affects
manufacturability and also experiments with what-if scenarios before finalizing a design. Injection
Moulding simulation software into the mould design process in order to analyze the product, foresee
the possible defects, and optimize the design to achieve the maximum outcome of the products with
minimum cycle time in each production cycle.
3. PROBLEM DEFINITION
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 op-timize the
design in the mould design process.
3. To achieve the minimum production cycle time
4. To construct a rapid prototyping of the mould cavity design into a standard mould plate.
Fig. 1.1 a) 2D dimension of part Fig. Fig. 1.1 b) Actual toy building block
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Injection Molding Methods Design, Optimization, Simulation of Plastic Toy Building Block by Mold Flow
Analysis, Manmit Salunke, Rushikesh Kate, Vishwas Lomate, Gajanan Sopal, Journal Impact Factor (2015):
8.8293 Calculated by GISI (www.jifactor.Com)
Fig.1.1c) Old design (2mm thikness at middle cavity) Fig. 1.1 d) new design (1mmuniform thikness)
5.3Mold Data
Mold material Tool Steel P-20
Mold dimensions X: 300.00 (mm) Y: 150.00 (mm) Z: 50.02(mm)
Mold plate dimensions A plate: 25.02 (mm) B plate: 25.00 (mm)
5.4Material Data
Family abbreviation-ABS Familyname -
Family abbreviation-LDPE
Acrylonitrile
Familyname-polyethylenes (PE) copolymers (abs, Trade name -(10% Rubber)
Mold Temperature Range 20-70 C 25-80C
Melt Temperature 220C 230C
Ejection Temperature 80C 88 C
Maximum Shear Stress 0.11 MPa 0.28 MPa
Maximum Shear Rate 400001/s 12000 1/s
Modulus Of Elasticity 124 MPa 3500 MPa
Poison Ratio 0.41 0.36
Shear Modulus 43.97 MPa 1287 MPa
Melt Density 0.73537 g/cm3 0.94933 g/cm3
Specific Heat 4230 J/Kg-C 2400 J/Kg-C
Heating/Cooling Rate -0.3333c/s -0.3333c/s
www.iaeme.com/ijmet.asp 35 editor@iaeme.com
Injection Molding Methods Design, Optimization, Simulation of Plastic Toy Building Block by Mold Flow
Analysis, Manmit Salunke, Rushikesh Kate, Vishwas Lomate, Gajanan Sopal, Journal Impact Factor (2015):
8.8293 Calculated by GISI (www.jifactor.Com)
Fill analysis for single part toy shows part have good quality when ABS material preffered.
www.iaeme.com/ijmet.asp 36 editor@iaeme.com
Injection Molding Methods Design, Optimization, Simulation of Plastic Toy Building Block by Mold Flow
Analysis, Manmit Salunke, Rushikesh Kate, Vishwas Lomate, Gajanan Sopal, Journal Impact Factor (2015):
8.8293 Calculated by GISI (www.jifactor.Com)
6. SIMULATION RESULT
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Injection Molding Methods Design, Optimization, Simulation of Plastic Toy Building Block by Mold Flow
Analysis, Manmit Salunke, Rushikesh Kate, Vishwas Lomate, Gajanan Sopal, Journal Impact Factor (2015):
8.8293 Calculated by GISI (www.jifactor.Com)
6. E Injection Pressure.
6. F RESSURE DROP
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Injection Molding Methods Design, Optimization, Simulation of Plastic Toy Building Block by Mold Flow
Analysis, Manmit Salunke, Rushikesh Kate, Vishwas Lomate, Gajanan Sopal, Journal Impact Factor (2015):
8.8293 Calculated by GISI (www.jifactor.Com)
www.iaeme.com/ijmet.asp 39 editor@iaeme.com
Injection Molding Methods Design, Optimization, Simulation of Plastic Toy Building Block by Mold Flow
Analysis, Manmit Salunke, Rushikesh Kate, Vishwas Lomate, Gajanan Sopal, Journal Impact Factor (2015):
8.8293 Calculated by GISI (www.jifactor.Com)
Total part weight 20.629 (g) 21.024 (g) 21.143 (g) 21.208 (g)
Cycle time 15.01 15.68 (s) 15.69 (s) 35.00 (s)
www.iaeme.com/ijmet.asp 40 editor@iaeme.com
Injection Molding Methods Design, Optimization, Simulation of Plastic Toy Building Block by Mold Flow
Analysis, Manmit Salunke, Rushikesh Kate, Vishwas Lomate, Gajanan Sopal, Journal Impact Factor (2015):
8.8293 Calculated by GISI (www.jifactor.Com)
Cooling Quality
Maximum and minimum temperature 7.8 (C) (C) & - 5.1 (C) & -2.5
variance 5.1 C & -1.2 C 7.4 C (C) 7.3 (C) & -9.5 C
Maximum and minimum cooling time 0.49 (s) & - 1.47 (s) & -1.19 0.49 (s) & -0.57 1.65 (s) &-1.25
variance 0.57 (s) (s) (s) (s)
Cool tab
Maximum temperature, part 49.2 (C) 49.4 c 49.3 (C) 53.5 c
Minimum temperature, part 32.6 (C) 32.5 c 32.6 (C) 34.7 c
Average temperature, part 41.1 (C) 40.9 c 41.1 (C) 45.2 c
Mold exterior temperature 27.4 (C) 27.3 c 27.4 (C) 28.6 (C)
1) Considering initial design for plasic toy, 2mm thikness at moddle cavity, simulation result
showing cooling time of part not uniform and have very high value .Fill analysis shows poor
quality for part. So model is redesigned for unform wall thiknes 1mm .Then simulation result
shows better quality of part.
2) After fill analysis shows part have lower quality for LDPE material and high quality for ABS
material .Different four cases of runner sprue and gate system are analyzed by using ABS
material for plasic toy.
3) In case IV have large filling time and more runner system volume so wastage of material is
high. Case II have lower filling time but more shrinkage.
4) Case I have lower cycle time, high confidence of fill, high quality. So have good optimum
design solution for defect free part.
8. CONCLUSION
The filling time and the cooling time of a four cavity design does not increase to four
times longer than having a single cavity. So the cycle time for four cavities design is the most
optimum and efficient to be used in the production process. The analysis work shows the parameters
such as sink marks, fill time, weld line, air traps etc. that will affects the quality of the finished
product. Plastic Flow Simulation Simulate the flow of melted plastic to help optimize part and mold
designs, reduce potential part defects, and improve the molding process and decrease the cycle time
and to improve the Quality of the Product.
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www.iaeme.com/ijmet.asp 41 editor@iaeme.com
Injection Molding Methods Design, Optimization, Simulation of Plastic Toy Building Block by Mold Flow
Analysis, Manmit Salunke, Rushikesh Kate, Vishwas Lomate, Gajanan Sopal, Journal Impact Factor (2015):
8.8293 Calculated by GISI (www.jifactor.Com)
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