Mold Manufacturing Process Research Articles

The wear resistance improvement of fibre reinforced polymer composite gears

This paper presents experimental investigations into the wear performance of non-reinforced POM (Polyoxymethylene) and 28% GFR POM (glass fibre reinforced POM) gear pairs; polymer running against polymer is a little studied but important system. All the gears were manufactured locally by injection moulding. The injection mould design and manufacturing process are briefly described and progress in the control of injection moulding processes for polymer and fibre reinforced polymer gears is discussed. A specifically designed polymer composite gear test rig was used for this research. Performance differences for the POM and GFR POM gears are observed, notably their loading capacity and failure modes. Both POM and GFR POM gear pairs, showed a clear wear transition torque for a given running speed. Above the transition torque the wear rate accelerated rapidly causing thermal failure, while below the transition torque the gears had a very low specific wear rate. Significant performance enhancements were seen for the GFR POM gears, with an increase of around 50% in load carrying capacity when compared to the non-reinforced POM gears. The wear mechanisms are briefly discussed, noting that most data available for polymer gear design is not representative of these polymer against polymer pairings.

A Simulation Study on Improving Formability of SUS304 Sheet Metal Deep Drawing Process

In the traditional mold manufacturing process, manual methods are mostly used to design, fabricate and then perform forming test to find out the reasonable processing mode for the product. Thanks to the development of technology, the forming design can be greatly reduced by using commercial software. This study uses a combination of ABAQUS software and TAGUCHI algorithms to calculate and design products. By using simulation tool, the fracture, safety, wrinkles as well as stress and strain on the surface of the product can be easily predicted after forming process. So that, the forming process were firstly simulated and executed on the software to find out important parameters. The variance analysis (ANOVA) was then performed to assess the effect of each parameter. Finally, the optimum solution for the product was selected based on ranking levels of each parameter.

Study of the Milling Tools when Machining X37CrMoV5-1 after Heat Treatment

Abstract This paper targets the usage of advanced techniques for hard milling. The main idea is to properly improve and optimise the processes of milling hard treated steels such as X37CrMoV5-1 used in injection mould manufacturing process with the help of CAD/CAM software. This particular material has good mechanical properties, good toughness and ductility. The generated tool paths in WorkNc should decrease the wear and optimise the machining time. At the same time, the manufacturing must have the advanced process equipment and method due to the requirements of the design performance and machining efficiency.

노즐 유로 설계 최적화 및 정밀 금형 가공 기술을 통한 미세입자 분사기술 연구

Recently, the spray type cosmetics and household goods market has grown rapidly due to the spray dispenser products and the development of precision mold technology. Spray products are becoming more widespread, market demands for various types of spray dispensers are expanding, and a variety of design and functional dispensers are being developed to apply the application. In this paper, we propose a method to verify mold design of spray nozzle structure and data. Also we studied how to reduce the verification cost and time, and studied limitations of current 3D printing technology what needs to be improved in the future. In addition, we describe the method of manufacturing spray nozzle (Orifice) by the optimized mold design and machining through the precision mold manufacturing process, and it is possible to spray micro particles changing the internal structure of the orifice of spray pattern.

Study of Property Change of Pulp Mold depending on the Conditions of Wet Pulp Mold Manufacturing Process

Study of Property Change of Pulp Mold depending on the Conditions of Wet Pulp Mold Manufacturing Process

Effects of Different Backing Materials of Hybrid Rapid Tooling on the Demolding Time in the Hot Embossing Process

Fresnel lenses are becoming more and more important because they are widely used as optical elements for concentrating solar power. Micro-hot embossing is a promising approach to fabricate Fresnel lenses. Precision optical elements must be more quickly and cheaply introduced to the market due to the pressure of global competition. The thermal conductivity of Aluminum (Al)-filled epoxy resins is lower than that of conventional mold steel materials. This work demonstrates a technique for fabricating hybrid rapid tooling with different backing materials to investigate the demolding efficiency in the hot embossing process. It was found that the Al was strongly recommend as backing material for fabricating hybrid rapid tooling due to cost, demolding time efficiency and dimensional accuracy of the embossed parts. Demolding efficiencies for the hot embossing mold with backing materials of copper, aluminum and steel about 78 %, 68 % and 50 % can be enhanced compared to that of the conventional rapid tooling. The replication rate exceeding 96 % in the hot embossing mold manufacturing process can be reached. The transcription rate exceeding 93 % in the hot embossing process can be obtained.DOI: http://dx.doi.org/10.5755/j01.ms.24.3.13897

Effects of the Vacuum Moulding Process on the Mechanical Properties of Cotton/Epoxy Composite

A study on the effect of the vacuum assisted resin transfer moulding (VARTM) manufacturing process on the mechanical properties of cotton/epoxy composite is presented in this investigation. Woven cotton was used as reinforcing material embedded in epoxy resin. The woven cotton was treated with sodium hydroxide for one hour at concentrations of 0% to 20%. The tensile test showed that the untreated material had the highest ultimate strength and Young’s modulus. Observation of the fracture surface by scan electronic microscopy (SEM) was compared to the hand lay-up process as well as the results of the tensile test. The comparison showed that the VARTM process presents better mechanical properties than the hand lay-up process due to the reduction in discontinuities observed by means of optical microscopy.

A cost-effective approach for rapid fabricating cooling channels with smooth surface

Conformal cooling stands for cooling channels that conform to the surface of the mold cavity. Production rate and molded part quality can be improved by the mold with conformal cooling channels. Molds with a complex cooling channel system have been developed by rapid tooling technology. However, the mold manufacturing process is not environmentally friendly. In addition, fabrication process for a wax cooling channel with complex geometrical shapes is time consuming. In this study, a low-cost wax filament with high toughness and low melting point is developed for fabricating cooling channels using fused deposition modeling technique. The optimal process parameters for fabricating wax patterns are investigated. The cooling channels with smooth surface are fabricated. The results obtained are very practical and provide the greatest application potential in the precision rapid tooling industry.

Research on Teaching Method of Mold Course Based on CAD/CAE/CAM Technology

The teaching of the traditional mold courses focus on the illustration of theoretical knowledge. Therefore, associating the design, evaluation, and manufacture links as a whole is difficult. Students cannot shape system knowledge, thereby making the study difficult. In addition, traditional teaching cannot meet the current enterprise needs of talents who have mold CAD/CAE/CAM technology. This study presents a teaching method that applies CAD/CAE/CAM technology to mold teaching. First, the positive effects of these technologies on the mold design and manufacturing process are introduced. Thereafter, lamp cover is used as an example to establish a series of computer-aided teaching development processes using existing software for mold design, mold flow analysis, and machining simulation. Lastly, survey results demonstrate that the effects of the proposed teaching method are better than the traditional method. Moreover, students and enterprises are substantially recognized in this teaching method.

Mechanical and vibration response of insulated hybrid composites

Electrically nonconductive composites are required in various engineering applications ranging from radome, antenna and many more. This research aims at investigating the mechanical properties of electrically non-conductive hybrid composites (thin carbon non-crimp fabric, Kevlar and E-glass fabrics) in combination with thermosetting epoxy resin. The composites comprise of multi-axial textile reinforcement carbon fabrics in the middle section with symmetrical quasi-isotropic layup, sandwiched with Kevlar fibre for improved impact performance and E-glass fibre at the outermost parts for electrical insulation. The fabrics are injected with room-temperature-cure epoxy using economical and energy saving resin transfer moulding manufacturing process. Electrical continuity tests and mechanical properties including vibration damping response, flexure and impact were studied to investigate the performances of the manufactured hybrid composites. Three hybrid laminate configurations were manufactured, and experimental results showed that hybrid composite with more number of Kevlar layers performed better for vibration and flexure testing. For impact performance, results showed that the absorbed impact energy improved with the inclusion of more glass layers, whereas configuration with more Kevlar layers experienced greater peak load to failure. The details of the composites fabrication, manufacturing and experiments conducted and the related findings with underlying reasons for the improvement offered by particular group of laminate configuration are discussed in the article.

A Brief Review on injection moulding manufacturing process

The term quality has become a “catch all” term used in describing the various characteristics of an object. It is nearly impossible to define the term consistency. The quality is any particular or specific characteristics of a product development design object that contains or relates information about the object. This is primarily a chunk of geometry distinguished by its ability to perform a function with one or more other. In this primary processing conditions are studied from concept development to manufacturing of the product. Effect of different factors studied on the basis of processing parameters. Since quality and productivity are the two important contradictory objectives in any machining process. Some extent of quality has to be compromised while assurance giving for high productivity. Similarly productivity will be decreased while the efforts are channelized to enhance quality. To ensure high quality and productivity, it is necessary to optimize machining parameters. Various responses of quality of injection moulding process has been studied on the basis of performance parameters and methods. This paper aims to present plastic injection moulding process conditions. The processing conditions satisfied quality based product manufacturing.

A statistical analysis of nanocavities replication applied to injection moulding

The purpose of this paper is to investigate both theoretically and experimentally how nanocavities are replicated in the injection moulding manufacturing process. The objective is to obtain a methodology for efficiently replicate nanocavities.From the theoretical point of view, simulations are carried out using a submodeling approach combining Solidworks Plastics for a first macrosimulation and Fluent solver for a subsequent nanosimulation. The effect of the four main factors (melt temperature, mould temperature, filling time and cavity geometry) are quantified using an statistical 24 factorial experiment. It is found that the main effects are the cavity length, the mould temperature and the polymer temperature, with standardized effects of 5, 3 and 2.6, respectively. Filling time has a negative 1.3 standardized effect.From the experimental point of view, Focused Ion Beam technique is used for mechanizing nanocavities in a steel mould. The replication achieved in polycarbonate injection is quantified using an Atomic Force Microscope. It is observed how both the geometry and the position of the cavities in the mould affect its replication.

Modification of glass reinforced epoxy composites by ammonium polyphosphate (APP) and melamine polyphosphate (PNA) during the resin powder molding process

Abstract The aim of the studies was to manufacture glass reinforced epoxy composites using technology based on hot pressing with improve flame resistance with good mechanical properties. Ammonium polyphosphate (APP) and melamine polyphosphate (PNA) were used as flame retardants with ranging from 5 to 20 wt %. The thermal and mechanical properties of the composites were determined in the course of TGA analysis, flammability UL-94 test, limiting oxygen index (LOI) technique, Fourier Transform Infrared Spectroscopy, ultrasonic test and static tensile test. The flame retardancy of modified composites was significantly improved with addition of ammonium polyphosphate and melamine polyphosphate. Moreover, in most cases addition of flame retardants increased strength of composites. This study confirmed that fast and highly efficient Resin Powder Molding manufacturing process allows to produce high quality composites.

Software for Auto-Generating Electrode Block Order Sheet: Study Case in Mold Machining Workshop

<p>In a mold manufacturing process, few to hundreds electrode is required for the EDM process. The electrode production is time consuming and it prone to errors when it comes to creating Electrode Block Order Sheet. New software was developed to create automated process to generated Electrode Block Order Sheet that reduce the time consumption and eliminate human errors during the process. By the application of the software, time consumption to create Electrode Block Order Sheet is reduced by 80% and human error involved in the process is eliminated.<br />Keywords. EDM, mold, software, automation, electrode, manufacture</p>

Cure-dependent thermomechanical modelling of the stress relaxation behaviour of composite materials during manufacturing

This study contributes to the understanding of the mechanism behind process-induced distortions and stresses related to the Resin Transfer Moulding manufacturing process. The objective is to comprehend the phenomena and to identify related parameters. During the manufacturing process, engineering constants of the matrix are changing and are influenced by the existence of a large number of effects. A viscoelastic material model has been derived. This developed material model integrates a dependency of the time–temperature–polymerisation and fibre volume content on the relaxation behaviour of residual stresses in a transversally isotropic reinforced material. The model is validated using a test case on the coupon level and results / limitations are discussed.

(430) Bioequivalence and food effect of a novel, abuse-deterrent (AD), extended-release (ER) morphine product candidate compared with a currently available non-AD, ER morphine product

Abuse-deterrent (AD) formulations of opioids have been deemed an important component of risk mitigation for opioid abuse. A novel morphine AD extended-release (ER), injection-molded tablet (ADER-IMT) product candidate has been developed using proprietary Guardian™ technology (Egalet Corporation, Wayne, PA) utilizing an injection molding manufacturing process that produces hard tablets that are resistant to rigorous physical and chemical manipulations. The bioequivalence of morphine ADER-IMT and a marketed non-AD morphine ER product were assessed in two phase 1, randomized, open-label, single-dose, crossover studies in healthy adults aged 18–55 years. In study 1 (n=66), fasted subjects received oral morphine ADER-IMT (30 mg), morphine ER (30 mg), or morphine ADER-IMT (2 × 15 mg) in 3 sequential periods. In study 2, one cohort (n=40) received morphine ADER-IMT (60 mg) or morphine ER (60 mg) under fasting conditions in 2 treatment periods; a second cohort (n=25) received morphine ADER-IMT (60 mg) under fed conditions in an additional treatment period. In both studies, all subjects received naltrexone 50 mg before and after each study drug administration. Pharmacokinetic parameters for morphine included area under the plasma concentration vs time curve (AUC) from time 0 to the time of the last quantifiable concentration (AUC0-t), AUC from time 0 extrapolated to infinity (AUC0-inf), and maximum plasma concentration (Cmax). Bioequivalence criteria were from Food and Drug Administration guidelines. In study 1, (fasting conditions) bioequivalence was demonstrated among all 3 treatments (morphine ADER-IMT [30 mg], morphine ER [30 mg], and morphine ADER-IMT [2 × 15 mg]) for all 3 pharmacokinetic parameters. In study 2, bioequivalence (fasting conditions) was demonstrated between morphine ADER-IMT (60 mg) and morphine ER (60 mg); further, the fed/fasted analysis demonstrated no clinically relevant food effect for morphine ADER-IMT (60 mg). Morphine ADER-IMT was generally well tolerated with no unexpected adverse events. Funded by Egalet Corporation.

Foreword of guest editor

In this exciting special issue on ‘‘nanoimprint lithography,’’ we got great supports from the nanoimprint community. We received invited and contribution papers from both academia and industry from three continents. On behave of the board of editors of Applied Physics A and guest editors of this special issue, we would like to thank their supports and great scientific achievements. This issue covers a broad range of topics, from nanoimprint process to applications of nanoimprint, from theoretical investigation to experimental demonstrations, from mold manufacturing process to new nanoimprint resist, and from patterning on flexible substrates to patterning of 3D structures. After 20 years of fast growth, great progress has been made. Nanoimprint lithography has grown from a ‘‘smart invention’’ to a technology on the ITRS roadmap and with applications much beyond semiconductors. Twenty years is a milestone. We wish this special issue can, at least partially, take a snapshot of this vibrant technology at this moment. This snapshot not only celebrates the achievements over the last 20 years, but also gives the community an opportunity to contemplate on how to move the technology forward for the better years ahead. Enjoy your special issue on nanoimprint lithography from Applied Physics A. Let’s push hard and the next special issue will be even better!

Eco-Casting of Aeolian Blades and Solar Panels With Composites Materials Via RTM Technology

The technique used for manufacturing composite wind turbine blades and solar panels must be sure of environment-friendly. In order to achieve this objective, the closed mould manufacturing process that takes into account environment preservation and health protection besides assurance quality will be the subject of this article. The requirements of sustainable development and ecodesign are the objectives to be fulfilled with an acceptable degree of tolerance in relation to the new regulations and eco-standards.Keywords: composite materials; ecodesign; RTM process; permeability; sustainable development; renewable energy

A study on fiber orientation influence on the mechanical response of a short fiber composite structure

This paper deals with the structural analysis of composite materials with non-homogenous orientation of the reinforcement. During this research, a short fiber-reinforced polymer matrix composite is studied. In this case, inhomogeneity of the reinforcement orientation caused by injection molding manufacturing process is analyzed. The main objective of the paper is the investigation of an influence of process-induced orientation of the reinforcement on mechanical properties of the material in comparison with unidirectional and random reinforcement orientation. In particular, natural frequencies and transient response of an exemplary composite component are investigated. To specify effective properties of the composite, Mori–Tanaka’s micromechanical model is assumed. Orientation distribution of the reinforcement is determined by injection molding simulation. To determine elastic material properties dependent on non-homogenous orientation of the reinforcement, an orientation averaging procedure is taken into account. Therefore, during this study, effectiveness of the orientation averaging procedure and different closure approximations influence on the results are studied. Orientation averaging results are compared with numerical results obtained by finite element-based homogenization of composites with prescribed second-order orientation tensor. Finally, the obtained material parameters were applied into a macroscale finite element model, and numerical simulation with different boundary conditions was conducted.

The navigation process of mould-manufacturing scheduling optimisation by applying genetic algorithm

Plastic injection mould manufacturing process is a job-shop scheduling problem (JSSP) and a non-polynomial (NP) problem. This study developed a mould-manufacturing scheduling navigation system in which the genetic algorithm (GA) was applied to optimise the mould-manufacturing scheduling problem. A navigation process ranging for manufacturing process planning and manufacturing scheduling was planned, and scheduling management was planned, while considering the processing restrictions needed to effectively manage and arrange all the components to be processed in a more reasonable way. The study used the searching capabilities of GA for determining the sequence of component processing with limited machines during mould manufacturing, and computed the makespan of the components currently planned in the factory. Compared with the makespan of manual planning in real cases, the proposed system can save up to 50% of the working time, and the quality of the solution can provide production management staff with a better reference in improving actual scheduling jobs. The proposed system can be used to effectively plan and manage component processes, accelerate the scheduling and shorten mould manufacturing time, in order to achieve the objectives of reducing the production cost and improving the competitiveness of an enterprise.