Injection Molding Analysis Research Articles

Design and Analysis of Plastic Injection Mold for Hexagon Socket Head Cap Screw

Plastic is a majorly used material for making customer goods. It is appealing to customers as well as manufacturers. Properties like durability, light weight and moldability make it a suitable choice for consumer goods which are made by mass production. Plastic materials are soft, but they possess adequate strength to be utilized for different engineering applications. After the development of various grades of plastic, it has replaced metals from different engineering applications in the recent past. This article aims at analyzing the suitability of making Hexagon Socket Head Cap Screws (HSHCS) out of a plastic material by injection molding processes. These screws are widely used as threaded fasteners at different places. They are preferably made of ferrous metals and possess semi complex design. They are mass produced by following a series of manufacturing operations. This article will observe the manufacturability of HSHCS by injection molding process. Based on the observation a model mold will be prepared to make HSHCS. The software used for modeling the parts is Autodesk Fusion 360 and that for the simulation of process parameters is Autodesk Moldflow Adviser 2023. Index Terms: Hexagon Socket Head Cap Screws, plastic mold, manufacturability, threaded fasteners, injection molding, simulation.

Evaluation of Formability Dependent on the Location of Injection Gate of Vertical Machining Center ATC Tool Port Using Injection Molding Analysis

Evaluation of Formability Dependent on the Location of Injection Gate of Vertical Machining Center ATC Tool Port Using Injection Molding Analysis

Optimal Design of Mold Layout and Packing Pressure for Automobile TCU Connector Cover Based on Injection Molding Analysis and Desirability Function Method

Optimal Design of Mold Layout and Packing Pressure for Automobile TCU Connector Cover Based on Injection Molding Analysis and Desirability Function Method

A Study on Injection Molding Analysis of a Plastic Rack Gear

A Study on Injection Molding Analysis of a Plastic Rack Gear

Design of Feed System and Process Conditions for Automobile Lamp Garnish Lens with Injection Molding Analysis

Design of Feed System and Process Conditions for Automobile Lamp Garnish Lens with Injection Molding Analysis

CAE Analysis and Structure Optimization Design of Injection Mold for Charge Upper Cover

CAE Analysis and Structure Optimization Design of Injection Mold for Charge Upper Cover - written by Mubarak Abdullah Ali Mohsen Al-Hadad , Quan Wang published on 2019/11/11 download full article with reference data and citations

Metal Injection Molding Analysis for Developing Embroidering Machine Rotary Hooks

Metal Injection Molding Analysis for Developing Embroidering Machine Rotary Hooks

Design and Checking Analysis of Injection Mold for a Plastic Cup

A special injection mold was designed for the structural characteristics of a plastic cup part. The mold was simulated by Moldflow software and verified by calculating the stripping force, the pulling force and the clamping force of the mold so that to determine the appropriate injection parameters. It has been proved that the injection mold is effective and practical in the actual producing and can meet the quality requirements during the course of using it, which solved some problems for injection molding of this kind of parts and can provide some reference for the production of other products in the same industry.

사출-구조 연성해석을 통한 Glass Fiber 배향성이 충격 파괴에 미치는 영향

사출-구조 연성해석을 통한 Glass Fiber 배향성이 충격 파괴에 미치는 영향

A Study on the Injection Molding Analysis of the Metal Powder Material

A Study on the Injection Molding Analysis of the Metal Powder Material

사출성형해석을 통한 자동차 레버쉬프트의 사출공정에 관한 연구

ABSTRACT The production processes were reviewed through the injection analysis of the shift lever as a core component o f an auto lever installed in the automatic transmission of cars. The injection analysis was carried out for the shift lever and rod among the components in a shift lever module. The shift lever and rod are designed for injection molding with the insertion of a tube, a pin cable plate, and a steel rod for securing the strength of the product. The charging time, failure of injection molding, weld line, air trap, and deformation were reviewed according to this insert. Analyses on various gate positions were carried out for reviewing the cultivation and deformation of fiber around major components, such as the generation section of manipulation feeling and assembly section, so that optimal gate conditions might be reviewed and reflected in the mold design. Finally, we plan to compare the analysis results with the production of trial products.Key Words : Injection Molding Process(사출성형공정), Injection Molding Analysis(사출성형해석), Lever Shift(레버쉬프트), Weld Line(웰드라인), Deformation Pattern(변형패턴), Air Trap(에어트랩)

사출성형 해석을 이용한 게이트 위치 최적화

게이트 위치는 제품 품질 및 생산성 등에 큰 영향을 미치기 때문에 사출성형에 있어서 게이트 위치를 결정하는 것은 대단히 중요하며 이를 위하여 사출성형 CAE가 적용되고 있다. 사출성형 해석의 증가와 3차원 유한요소의 사용은 더 많은 계산 시간을 필요로 하게 되면서, 컴퓨터 자원을 적게 사용하면서도 빠른 시간 내에 게이트 위치 최적화를 수행하는 것은 중요한 이슈가 되었다. 본 논문에서는 유동 균형과 웰드라인을 고려하기 위하여 유동 거리에 기반한 최적화 기법을 제시하였 다. 그리고 원판 형상의 모델에 적용하여 웰드라인이 응력집중이 예상되는 슬릿홀을 피하면서도 유동 균형을 유지하는 결과 를 도출하였다.

A Study on Injection Molding Analysis and Structural Analysis with Truck Brake Pedal

Injection molding process one of the most important methods to produce plastic parts with high efficiency and low cost. Today, Injection molded parts have been increased dramatically the demand for high strength and quality applications. In this study, truck brake pedal is made of Cast iron and plastic materials to replace the frame for the optimization process that minimizes the runner and the gate dimension will determine the size and shape. Runner and gate dimensions of change based on availability of the product. I will discuss the injection molding. This report investigates that the optimum injection molding condition for minimum of runner and gate position. The FEM Simulation CAE tool, MOLDFLOW, is used for the analysis of injection molding process.

Plastic End Cap Injection Tool Design and Molding Analysis Based on Software Ug and Moldflow

Software UG is used to design plastic end cap injection tools and to do injection molding analysis. Firstly, use the modeling function of the software to design the structure of a plastic product. Secondly, design the mold according to characteristics of the product and generate a tool drawing. Finally, use moldflow software to analyze injection system of a 2-cavity tool, the best position of feed gate and plastic flow in the cavities, to improve the type, size and position of the feed gate and distribution of runners, as well as to reduce the cycle time and processing cost to the largest extent. This paper is to adopt Moldflow software to analyze the temperature, pressure and filling of the designed injection molding, and determine the design structure of the molding through improving the molding design according to the analysis results.

우레탄레진(TSR-755)을 적용한 시작형 사출금형 연구

본 연구에서는 우레탄레진(TSR-755)을 이용하여 레이저 조형으로 시작형 몰드를 가공하고, 상용패키지(Unigraphics)를 이용하여 자동차 단자함 케이블 케이스를 설계한 후 사출성형해석(Simpoe-Mold)을 사용하여 충전, 보압, 냉각, 변형해석을 수행하여 게이트 위치 선정 및 냉각 사이클 등을 검토 하였다. 해석결과, 세라믹소재 가공 후 사출금형에 인서트시켜 성형 시 열전도도 및 냉각시간을 줄여 줌을 확인할 수 있으며, 게이트 및 냉각라인 선정을 빠른 시간에 결정할 수 있어 생산성 향상을 가져올 것으로 나타났다. In this study, we used the commercial package (Unigraphics) to construct a junction box cable car when laser plastic parts have been processed using urethane resin(TSR-755) as a starting mold material. After construction, we carried out the filing, packing, cooling, and deforming analyzation using Injection Molding Analysis (Simpoe-Mold) to determine the gate positioning and automatic cooling cycle through the examination. The results show that inserting into the injection mold after processing ceramic has reduced the time of thermal conductivity of molding and cooling; and quick selection of gates and cooling lines could possibly cause an improvement of productivity.

New Design and Injection Molding Analysis of a Low Smoke Zero Halogen Cable Trunk

The traditional production process of a cable trunk is plastic extrusion with PVC or other halogen containing materials. However, they have many disadvantages such as easy burning, producing toxic gases and smokes. A low smoke zero halogen (LSZH) cable trunk was designed and developed in the present study and the injection molding process was adopted to produce the LSZH cable trunk. Numerical simulations were applied to investigate the effects of the important process parameters on the warpage of the cable trunk. Comparing the simulation results under different process conditions and consideration both of the volumetric shrinkage and the total warpage displacement, it is found that the process parameters, including mold temperature 75°C, melt temperature 265°C, injection pressure 190 MPa, packing pressure 152 MPa, cooling water temperature 50°C and injection time 3 s, are the optimal process conditions for the injection molding process of the new designed cable trunk.

CAE-Based Injection Molding Analysis of Mobile Phone Battery Cover

In this thesis, CAE software is used to carry out the injection molding analysis of mobile phone battery cover and simulate the filling and cooling process so as to determine the formability of plastic parts and product quality. In the process of product design, it can also predict possible defects so as to optimize mold structure, save production costs, and improve quality and efficiency of cell phone battery cover design.

The Reverse Design and Injection Molding Analysis of Plastic Product Based on Imageware and Moldflow

The process and method of reengineering design are introduced in the paper. Using the reverse engineering Imageware software, the helmet points cloud data were processed， the characteristic curve net was divided and the curve surface was reconstructed. Then the 3D model of the helmet established with Imageware was input in Moldflow. With the help of Moldflow simulating analysis software, injection molding is simulated and analyzed by calculated for helmet. According to the result of analyze fill, cool and warp, the structure of mould is optimized and designed and high quality product is obtained. The fast design for product and mold is realized.

초발수 곡면표면 실리콘 사출금형성형기술

In this study, silicone injection molding technology with curved thermoplastic insert was developed to produce super-hydrophobic surface. Thermoplastic insert part and injection mold design of base plastic cover were performed to produce cost effective hydrophobic surface part. An optimization process of part thickness for thermoplastic insert part was performed with transient thermal analysis under silicone over-molding process condition. Structural thermal analysis of silicone injection mold was also performed to obtain uniform temperature condition on the surface of micro-patterned mold core. Super-hydrophobic surface for the silicone injection molded part with thermoplastic insert could be verified from the measurement of contact angle. It was shown that the averaged contact angle was over 140°.

Thermal and stress analysis of rapid electric heating injection mold for a large LCD TV panel

Abstract Rapid electric heating cycle injection molding technology has been used widely in injection engineering application. Using this technology, excellent products with no weld marks, flow marks and other surface defects can be produced. However, as the special mold structure and its worse working process, the rapid electric heated injection (EHI) mold is easy to fail than that of the conventional injection mold along with the injection process carried out repeatedly. In this paper, an EHI mold for a large liquid crystal display (LCD) TV panel was first presented. Then the heat transfer process of the mold during the working process was studied. Lastly, through finite element simulation, the reasons that cause the large thermal stress and deformation of the mold were analyzed. The practical failure of the mold proved that the analysis presented in the paper was right.