Abstract
In recent years, along with the increasing demand for plastic products and the deepening of academics, mass production, weight reduction, and higher precision are progressing. In the field of design development and production technology, there is an increasing need for analysis technology related to resin flow and behavior in order to solve problems related to quality assurance such as molding defects and product strength. Especially in the resin molding process, it is an important issue to create a quality function that applies the analysis of complex multidimensional information because of the high degree of freedom in product shape and mold structure. In order to solve the quality issues regarding the strength and dimensional stability of resin materials, it is effective to apply the “Functionality Evaluation Method” in robust design which is an analytical evaluation method. In this study, we focus on the function of managing the resin filling density in the mold (the input/output relationship of the melting energy related to the resin filling characteristics) for the optimization of resin strength and dimensional stability. We propose a functional evaluation method with the ideal function of stabilizing the resin filling density based on the original definition of material mechanics. As a result of verification of the proposed method, it was clarified that it is extremely important to make the resin filling density in the mold uniform to stabilize the strength of the resin injection molded product.
Highlights
In recent years, the automobile industry has been actively promoting environmental measures even more than ever before, and as a part of this activity, the improvement of fuel efficiency by reducing the weight of parts is being promoted
We focus on the fact that the ideal function that represents the input-output relationship has a linear relationship with energy conversion
In this study, we focused on the function of controlling the resin filling density in the mold in optimizing resin strength
Summary
The automobile industry has been actively promoting environmental measures even more than ever before, and as a part of this activity, the improvement of fuel efficiency by reducing the weight of parts is being promoted. As an example of this, resin-made steel pulleys for automobiles are being actively used. European automobile manufacturers are promoting the use of resin for pulleys for power steering and idler pulleys. The plasticization rate of the transmission pulley used in drive transmission parts around the engine has reached about 30% (Fig. 1). Japanese automobile manufacturers have a low plasticization rate of pulleys of 5 to 6%, and future growth is expected. Plasticization is the replacement of steel parts with resin, the purpose of which is to reduce weight and reduce costs. The resin pulleys currently in practical use cannot be said to have sufficient characteristics as substitutes for steel pulleys in terms of strength and dimensional stability [1]∼[3]
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