Generally, the model developed in this investigation predicted quite well the values of the parameters measured experimentally. In certain cases, deviations were observed, but these were due to known factors which have been described in the previous section. This model represents the first link in a chain that is just beginning. The end use of the program will be in DOC feed-forward control applications for injection molding cycles. Several improvements can be made on this model. First, a more detailed analysis should yield a better relationship between the volumetric flow rate and the pressure at a given point. This is necessary because the volumetric flow rate should be smoothly decreased in order to keep the runner entrance pressure at the constant preset injection pressure. In this investigation, a power law relationship was used. This exponential relationship proved to decrease the volumetric flow rate faster than it should have. This caused some oscillations in the predicted temperature and pressure values. It was observed from the experimental data that a linear relationship could do the job, and that the volumetric flow rate should be decreased at each time interval as the pressure increased, instead of waiting until the preset injection pressure was reached as it was done in this investigation. Second, a non-linear regression fit should be performed on the experimental data available for heat capacity and thermal conductivity. The regression equations could be used in the model. This will reduce the consistently high temperatures predicted by the model. Third, the model should be extended to take into account the heat transferred to the wall of the channels. In this investigation a constant wall temperature was assumed in order to simplify the initial development of the model. At this point the finite difference grid used in the model could be extended to include the metal containing the cooling channels where the temperature is known. The inclusion of this feature could be accomplished with a small programming effort. Finally better packing and cooling models could be developed. The cooling model proved to be the poorest of the proposed models. An extra effort to develop a better cooling model was not considered to be necessary, because this investigation was more concerned with the filling and packing stages, which are the critical stages for gate design purposes. / Ph. D.

Tooling design for manufacturing processes refers to direct tooling for making a part such as molds and dies for injection molded parts and metal stampings, or for supporting machining operations such as jigs and fixtures. This paper summarizes some of the R&D activities in those areas over a period of 20 years in the Department of Mechanical Engineering, National University of Singapore. It is notable that increasing use of computer tools has turned what is used to be known as a “black art” into a discipline embracing both heuristic and scientific analyses. / Singapore-MIT Alliance (SMA)

Made available in DSpace on 2015-04-22T22:10:14Z (GMT). No. of bitstreams: 1 Andre Rocha.pdf: 1356381 bytes, checksum: 9b7278c11bb3486328c62eb993f63451 (MD5) Previous issue date: 2008-05-30 / In the production of components and final products in Pólo Industrial de Manaus (PIM) the plastic injection process is significantly present. Otherwise, PIM does not produces injection molds but acquire those from other Brazillian states or countries. It allied to PIM logistics and fiscal characteristics takes to question about how wide have being the economic analises to molds acquisition. In this way, this research identifies the Total Ownership Costs (TCO) of plastic injection mold, equationated in a basic model to help purchase decision process, for managers in industrial companies in PIM. For that it was developed an applied and descriptive research, based on bibliographic sources for costs understanding, TCO and plastic injection mold characterization; identification of mold s costs and administrative and economic characterization of plastic injection industries installed in PIM. There was identified 19 elements which reach the various costs happend during and after acquisition of a mold, it together with statistic data about costs in Brazil, allowed to define the importance level for each one in the process, determinanting the five ones more significants, which are: Mold price, logistic, losses from production stop due to mold failure, maintenance material and people. The structure in which this research was developed became by it self a route that guides step by step the implementation of mold TCO in an industry. It starts with definition of expenses types which shall be considered and how to obtain those, then it is determinated a mold evaluation method in industry, being concluded with the classification process, selection and sintesis of TCO elements. / Na produção de insumos e bens finais do Pólo Industrial de Manaus (PIM) o processo de injeção plástica é de presença marcante. No entanto, o PIM não fabrica os moldes e sim os adquire dos demais estados brasileiros e exterior. Isto aliado às peculiaridades logísticas e fiscais do PIM leva ao questionamento de quão abrangente tem sido a análise econômica para as aquisições de moldes. Neste sentido, este estudo identifica o Custo Total de Propriedade (TCO) de um molde de injeção plástica, equacionado em um modelo básico, para auxílio ao processo de tomada de decisão de compra, dos gerentes das empresas industriais instaladas no PIM. Para tal desenvolveu-se uma pesquisa aplicada e descritiva, a partir de fontes bibliográficas para entendimento de custos, caracterização do TCO e de moldes de injeção plástica; identificação dos custos de um molde e caracterização administrativa e econômica das indústrias de injeção plástica instaladas no PIM. Foram identificados 19 elementos que englobam os diversos custos ocorridos durante e após a aquisição de um molde de injeção plástica, que em conjunto com dados estatísticos sobre custos no Brasil, permitiram definir o grau de importância de cada um no processo, determinando-se os cinco mais relevantes, que são: Preço do molde, logística, perdas por parada de produção por falhas no molde, material e pessoal de manutenção. A estrutura em que a pesquisa foi desenvolvida por si só tornou-se um roteiro que guia passo a passo a implantação do TCO de moldes em uma indústria. Inicia-se pela definição de quais tipos de gastos devem ser considerados e como apurá-los, em seguida é determinado um método de avaliação do molde na indústria, concluindo-se com o processo de classificação, seleção e síntese dos elementos que comporão o TCO

Indirect additive processing of ferrous metals offers the potential to freeform fabricate parts with good surface finish and minimal dimensional variation from the computer solid model. The approach described here is to mix a ferrous powder with a transient binder followed by selective laser sintering (SLS) in a commercial polymer machine to create a “green” part. This part is post-processed to burn off the transient binder and to infiltrate the porous structure with a lower melting point metal/alloy. Commercially available SLSed ferrous components contain copper-based infiltrant in a ferrous preform. The choice of copper alloy infiltrant has led to inferior mechanical properties of these components limiting their use in many non-injection-molding structural applications, particularly at elevated temperature. In the present work, an attempt has been made to replace the copper-based infiltrant considering cast iron as a potential infiltrant because of its fluidity, hardness and stability at comparatively high temperature. A critical consideration is loss of part structural integrity by over-melting after infiltration as chemical diffusion of alloying elements, principally carbon, occurs resulting in a decrease in the melting temperature of tool steel preform. A predictive model was developed which defines the degree of success for infiltration based on final part geometry and depending on the relative density of the preform and infiltration temperature. The processing regime is defined as a function of controllable process parameters. An experimental program was undertaken using commercially available LaserForm[superscript tm] A6 tool steel that was infiltrated with ASTM A532 white cast iron. Guided by Ashby densification maps, pre-sintering of the A6 tool steel SLS part was performed to increase the part initial relative density prior to infiltration. The final infiltrated parts were analyzed for geometry, microstructure and hardness. The model may be extended to other ferrous powder and infiltrant compositions in an effort to optimize the properties and utility of the final infiltrated part. / text

This thesis describes the optimalization of technological parameters during commissioning of injection mold manufacturing. In the introduction, there is general literary studies of plastics, injection molds, injection holding machine, injection holding technology and their effect on quality. The practical part includes an analysis of current state, calculation of injection parameters, moldflow analysis and sampling on the machine. Finally, there is choice of optimal injection holding parameters, design of workplace and technical-economic evaluation.

O uso de componentes injetados de plástico aumentou nos últimos anos na maioria dos segmentos industriais. Como resultado, os processos envolvidos no projeto e na fabricação de moldes de injeção ganharam uma significativa atenção devido a grande complexidade, necessidade de baixo custo e, principalmente, curto tempo de manufatura. O uso de técnicas de Prototipagem e Ferramental Rápido (Rapid Prototyping/Rapid Tooling) surgiram como opções para esse setor, visando à rápida obtenção de peças protótipos. Porém, um dos desafios ainda presente está em garantir que as peças protótipos resultantes dessas técnicas atendam todas as dimensões solicitadas em aplicações reais. Este trabalho aborda a aplicação de materiais alternativos para a fabricação de moldes híbridos de injeção, dentro do conceito de Ferramental Rápido, com o objetivo de contribuir para uma melhor compreensão da influência desses materiais na qualidade final das peças protótipos obtidas. Um molde experimental, instrumentalizado com sensores de temperatura e, com uma das cavidades intercambiável, foi projetado e manufaturado para a injeção de uma peça de referência. As diferentes propriedades dos materiais utilizados na cavidade intercambiável, principalmente as propriedades térmicas, foram analisadas, bem como a influência dessas no produto final. Doze configurações diferentes (material da cavidade temperatura do molde) foram definidas para a obtenção de amostras. O experimento foi definido com o apoio de simulação matemática computacional. As amostras obtidas foram analisadas com relação as suas propriedades mecânicas (resistência ao impacto e à tração), propriedades físicas (dimensionamento, estudo morfológico e de cristalinidade) e propriedades químicas onde o grau de contaminação por metais pesados foi avaliado. As conclusões obtidas nesse trabalho mostram a importância da influência do material da cavidade do molde, e apresentam uma correlação das diferentes variáveis de processo com as propriedades obtidas nas peças protótipos injetadas através de técnica de Ferramental Rápido. / Submitted by Marcelo Teixeira (mvteixeira@ucs.br) on 2014-05-14T19:23:43Z No. of bitstreams: 1 Dissertacao Deives R Bareta.pdf: 9212045 bytes, checksum: 2808a91c52ab325c093e19f6e0199ed0 (MD5) / Made available in DSpace on 2014-05-14T19:23:43Z (GMT). No. of bitstreams: 1 Dissertacao Deives R Bareta.pdf: 9212045 bytes, checksum: 2808a91c52ab325c093e19f6e0199ed0 (MD5) / The application of plastic components has grown significantly in most of industrial segments during last years. This has attracted considerably attention for the injection mould design and manufacturing processes, which is one of the most expensive phases of injected plastic components development process. Techniques such as Rapid Prototyping/Rapid Tooling have appeared as potential solution in the field. However, one issue not resolved is how the prototypes obtained by these techniques can attend all features demanded by a true prototype. This research explores the application of softer alternative material to hybrid prototype injection moulds within the concept of rapid tooling, providing a better understanding about the influence of these materials in the final properties of plastic injected prototypes. An experimental injection mould, assembled with temperature sensors, and with interchangeability of the moulding blocks (core and cavity) has been designed and manufactured based on a tubular reference component. The different properties of the core materials, in special thermal, have been analyzed, as well as their influence on the reference component. A set of twelve configurations (core material mould temperature) have been defined to obtain the samples. Mathematical computational simulation was used to identify the more appropriate injection moulding parameters. The final samples have been analyzed in terms of mechanical properties (stress-strain and impact), physical properties (dimensions, morphology and crystallinity) and chemical properties. The conclusions show the influence of alternative materials, applied to core injection mould, on the final injected components. Also, a relationship between the different injection moulding parameters and the final prototype component properties are discussed.

O uso de componentes injetados de plástico aumentou nos últimos anos na maioria dos segmentos industriais. Como resultado, os processos envolvidos no projeto e na fabricação de moldes de injeção ganharam uma significativa atenção devido a grande complexidade, necessidade de baixo custo e, principalmente, curto tempo de manufatura. O uso de técnicas de Prototipagem e Ferramental Rápido (Rapid Prototyping/Rapid Tooling) surgiram como opções para esse setor, visando à rápida obtenção de peças protótipos. Porém, um dos desafios ainda presente está em garantir que as peças protótipos resultantes dessas técnicas atendam todas as dimensões solicitadas em aplicações reais. Este trabalho aborda a aplicação de materiais alternativos para a fabricação de moldes híbridos de injeção, dentro do conceito de Ferramental Rápido, com o objetivo de contribuir para uma melhor compreensão da influência desses materiais na qualidade final das peças protótipos obtidas. Um molde experimental, instrumentalizado com sensores de temperatura e, com uma das cavidades intercambiável, foi projetado e manufaturado para a injeção de uma peça de referência. As diferentes propriedades dos materiais utilizados na cavidade intercambiável, principalmente as propriedades térmicas, foram analisadas, bem como a influência dessas no produto final. Doze configurações diferentes (material da cavidade temperatura do molde) foram definidas para a obtenção de amostras. O experimento foi definido com o apoio de simulação matemática computacional. As amostras obtidas foram analisadas com relação as suas propriedades mecânicas (resistência ao impacto e à tração), propriedades físicas (dimensionamento, estudo morfológico e de cristalinidade) e propriedades químicas onde o grau de contaminação por metais pesados foi avaliado. As conclusões obtidas nesse trabalho mostram a importância da influência do material da cavidade do molde, e apresentam uma correlação das diferentes variáveis de processo com as propriedades obtidas nas peças protótipos injetadas através de técnica de Ferramental Rápido. / The application of plastic components has grown significantly in most of industrial segments during last years. This has attracted considerably attention for the injection mould design and manufacturing processes, which is one of the most expensive phases of injected plastic components development process. Techniques such as Rapid Prototyping/Rapid Tooling have appeared as potential solution in the field. However, one issue not resolved is how the prototypes obtained by these techniques can attend all features demanded by a true prototype. This research explores the application of softer alternative material to hybrid prototype injection moulds within the concept of rapid tooling, providing a better understanding about the influence of these materials in the final properties of plastic injected prototypes. An experimental injection mould, assembled with temperature sensors, and with interchangeability of the moulding blocks (core and cavity) has been designed and manufactured based on a tubular reference component. The different properties of the core materials, in special thermal, have been analyzed, as well as their influence on the reference component. A set of twelve configurations (core material mould temperature) have been defined to obtain the samples. Mathematical computational simulation was used to identify the more appropriate injection moulding parameters. The final samples have been analyzed in terms of mechanical properties (stress-strain and impact), physical properties (dimensions, morphology and crystallinity) and chemical properties. The conclusions show the influence of alternative materials, applied to core injection mould, on the final injected components. Also, a relationship between the different injection moulding parameters and the final prototype component properties are discussed.

Diplomová práce vznikla ve spolupráci s průmyslovým partnerem, který vyrábí elektrické komponenty pro automobilový průmysl. Tato firma se potýká s problémy často se porušujících jader v některých jejich formách na vstřikování plastů, vyrábějících převážně housingy pro konektory. Firma disponuje licencemi na komerční software pro simulaci injekčního vstřikování Moldflow a Moldex3D a také pro simulaci metodou konečných prvků Ansys. Nejprve jsou shrnuty teoretické poznatky ohledně injekčního vstřikování a jeho simulace, řešení problémů interakce těles s tekutinou a únavy materiálu. Poté je popsán proces stanovení únavové životnosti jádra formy s využitím výše zmíněného softwaru. Proces je vysvětlen na příkladu konkrétní formy ve výrobě této firmy. Je zvolen takový přístup vyhodnocení únavy, který nejvíce odpovídá současné životnosti jader, a ten je pak použit pro analýzu vlivu změny geometrie jádra a parametrů vstřikování. Změny ostatních parametrů, které simulace neumožňuje zahrnout, jsou rovněž navrhnuty a pokud možno odůvodněny jinými způsoby. Jedno z doporučení je přidání zaoblení na obě jádra, což by mohlo prodloužit životnost toho problematičtějšího z nich z 30 dnů na více než 320 dnů. Toto by mohlo znamenat úspory až 10 600 EUR ročně. Další doporučení je změnit způsob obrábění jader a také přidat jejich tepelné zpracování.