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Simulation and Analysis of Step Light Mid Part using Mold Flow Analysis

Simulation and Analysis of Step Light Mid Part using Mold Flow Analysis

how their designs will be resulted after 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. Today, many manufactures have proven mold flow analysis (MFA) to be the medium between a flawless design and production. Taguchi method is used for optimizing the molding process parameters. This thesis presents use of taguchi method for Design of Experiment in plastic injection Molding. The study applies Taguchi’s L9 orthogonal array design technique to study the effect of process settings of plastic injection molding on part quality. Experimental trial data is used to compare the results with moldflow simulation. The optimum levels for mold surface temperature, melt temperature, injection time and v/p switch over are determined.

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Optimizing the Die Design Parameters of a Two Cavity Injection Moulding Tool for a Fan Blade Back Cover using Mold Flow Analysis

Optimizing the Die Design Parameters of a Two Cavity Injection Moulding Tool for a Fan Blade Back Cover using Mold Flow Analysis

packing stage, and reflects how much material is still melt and left unpacked. Higher Sink marks, index value shows higher potential shrinkage. However, whether or not the shrinkage would result in sink mark depends on geometry characteristics. The Sink marks, index generated indicates the likely presence and location of sink marks (and voids) in the part. This is shown in Figure11. The Sink marks, index indicates a degree of severity of depth as affected by the material, part geometry, position relative to the injection location and mold filling conditions. Changing any of these would allow you to determine its contribution to the sink marks severity. Generally, if the thickness of a rib is less than or equal to 60% of the main wall section, then there are likely to be no significant sink marks. The parameters observed from mold flow analysis are shown in the following table 2.

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Simulation and Analysis of Step Light Mid Part using Mold Flow Analysis

Simulation and Analysis of Step Light Mid Part using Mold Flow Analysis

how their designs will be resulted after 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. Today, many manufactures have proven mold flow analysis (MFA) to be the medium between a flawless design and production. Taguchi method is used for optimizing the molding process parameters. This thesis presents use of taguchi method for Design of Experiment in plastic injection Molding. The study applies Taguchi’s L9 orthogonal array design technique to study the effect of process settings of plastic injection molding on part quality. Experimental trial data is used to compare the results with moldflow simulation. The optimum levels for mold surface temperature, melt temperature, injection time and v/p switch over are determined.

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Injection Molding Methods Design, Optimization, Simulation of Plastic Flow Reducer  Part by Mold Flow Analysis

Injection Molding Methods Design, Optimization, Simulation of Plastic Flow Reducer  Part by Mold Flow Analysis

The confidence of fill result from the plastic filling analysis displays the probability of plastic filling a region within the cavity under conventional injection molding conditions. If the cavity does not fill (short shot), the changes must be made to the processing conditions, injection locations, design of the parts, or choice of the plastic. Table shows the risk of the part filling base on colors.

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Improving the 
		injection molding of small optical elements by integrating reverse 
		engineering and mold flow analysis

Improving the injection molding of small optical elements by integrating reverse engineering and mold flow analysis

The reverse engineering techniques used in this study include digitization of the object, CAD model reconstruction from digitized points, and error comparison between two sets of data. Regarding digitization, the part surface is digitized by a camera-type scanning device- COMET 400. The accuracy of this scanner is 5.7 m and its repeatability is 2.2 m. The part is scanned from multiple views. Each scan can yield a set of triangular meshes. A registration process is implemented to align all sets of points. All overlapped points are then removed to yield the final set of triangular meshes, expressed as a data format *.stl. Both injection part and mold are digitized. The scanned data are saved separately for further analysis later. Figure-2 illustrates the photo of the LED lens used in this study and the scanned points, expressed as triangular meshes.

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INJECTION MOLDING METHODS DESIGN, ANALYSIS AND SIMULATION OF PLASTIC CUP BY MOLD FLOW ANALYSIS

INJECTION MOLDING METHODS DESIGN, ANALYSIS AND SIMULATION OF PLASTIC CUP BY MOLD FLOW ANALYSIS

3. 3.Manmit Salunke “Injection molding methods design, optimization, Simulation of plastic toy building block by mold Flow analysis” International Journal of Mechanical Engineering and Technology, ISSN 0976 – 6340 (Print) ISSN 0976 – 6359 (Online)Volume 6, Issue 6, June (2015), pp. 33-41 Article ID: 30120150606004

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Design of Micro Cooling Channel for Plastic Injection Moulding by using Mold Flow Advisor

Design of Micro Cooling Channel for Plastic Injection Moulding by using Mold Flow Advisor

In the sense of cooling circuit design micro channel is the word used for cooling circuit having very small diameter of about 1mm -2mm. It have been proven with the analysis that micro-channel cooling effects are more closely conform to the theoretical minimum cooling time while the standard cooling channel results are closer to the adjusted theoretical value. The effectiveness of micro channel cooling is high because of minimal pitch gap of cooling circuit. Through these channels the flow of coolant is possible throughout the area near to the part surface. Moreover, due to less diameter of channels it is not effecting the strength of the mold therefore we can provide micro channels near as possible to the surface of the core and cavity.

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Design And Analysis Of Casting Mold Using CAD Tool

Design And Analysis Of Casting Mold Using CAD Tool

This project presents the design of casting mold using CAD tools. SolidWorks is used to perform the details drawing of the mold. The analysis of temperature and pressure is presented by using simulation ANSYS. As a result, the design of investment casting mold is proposed. Stainless steel H13 is selected as the material of the mold.

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Design And Analysis Of Gating In Plastic Paper Clip Mold

Design And Analysis Of Gating In Plastic Paper Clip Mold

Paper clip is commonly used by student and also officer to hold sheets of paper together. There are various type of paper clip which is different in material, size and shape. This project is about studying the design and analysis of gating in plastic paper clip mold which to get optimum gate size and injection location for plastic paper clip.

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Numerical Simulation on Effects of Electromagnetic Force on the Centrifugal Casting Process of High Speed Steel Roll

Numerical Simulation on Effects of Electromagnetic Force on the Centrifugal Casting Process of High Speed Steel Roll

gravity, centrifugal force and also, electromagnetic force. When molten metal in the centrifugal mold rotated at high speed with a stationary magnetic field, the electro- magnetic force compels molten metal to flow in the op- posite direction of the rotating mold, resulting in elec- tromagnetic stirring, which can enhance solidification structure and improve casting quality [6-8]. Under gravi- ty, the molten metal poured into rotating mold taking the form of parabola. Then, the friction force between mol- ten metal and mold, the viscous force of molten metal and the centrifugal force generated by the high speed revolution make molten metal into hollow roll. The moving of molten metal is determined by the force, and also, the temperature. Therefore, it is necessary to ana- lyze the behavior of molten metal by coupling tempera- ture field, flow field and magnetic field. The mass equa- tion, momentum equation, energy equation and electro- magnetic force equation which describe the moving of the molten metal are listed as below, respectively.

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Modeling and Simulation of Solidification in Alloy Steel Sand Castings

Modeling and Simulation of Solidification in Alloy Steel Sand Castings

ProCAST is a modular system and allows the coupling of various modules. Based on Finite Element technology, ProCAST provides a complete solution covering a wide range of simulation. The purpose of this stage is to generate a finite element model, to setup the calculation, to run the analysis and, to interpret the results. The primary working flow of ProCAST was divided into three main parts, to begin with: “Pre-Processing”; in addition: “Solving” to run the analysis; and finally was the step “Data Output” to interpret the results and each step includes several sub-steps. The principal process of ProCAST is indicated in figure 6.

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A review of roll to roll nanoimprint lithography

A review of roll to roll nanoimprint lithography

Additionally, air bubble entrapment issues are also commonly observed in P2P NIL, particularly in large- area, single-step processes [21,26] as air is easily trapped in the gaps between resist and mold cavities, resulting in defects on the imprinted structures. The risk of defects is increased when the mold contains depressions or when the resist is deposited as droplets rather than spin- coated, which allows air to be trapped easily [10], which results in the need to conduct the imprinting process under vacuum to prevent trapping of air bubbles as ob- served in [5,8,21]. However, vacuum or reduced atmos- phere chambers are difficult to be implemented in a system with a continuous web feed. Hiroshima and the team had been working on this matter and introduced the usage of pentafluoropropane as ambient to solve the bubble defect problem [27-29].

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Fluid Flow, Inclusion removal and Slag Entrapment in Molten Steel Continuous Casting Mould

Fluid Flow, Inclusion removal and Slag Entrapment in Molten Steel Continuous Casting Mould

As the results, these problems affect the productivity as well the improvement of the final product quality, which are permanent requirements concerning the continuous casting process, this was the motivation signal to conduct this research. Thus optimization and control of the fluid flow pattern in the continuous casting mold to remove inclusions prevent slag entrainment is quite necessary to the steel industry.Some variables like the nozzle and mold geometry, steel flow rate,submergence depth, flux layer properties andargon injection rate can control the flow pattern in the mold. The nozzle play asignificantrole for controlling flow pattern in mold, therefore, by using various designs of the nozzle, it would be an easy and low-cost way to improve the fluid flow in the mold[2] [5]. The fluid flow in the continuous casting mold can be inspected by physical modeling,industrial trials or mathematical modeling[2] [3].

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Design Optimization of Mold for Dust Proof Cap

Design Optimization of Mold for Dust Proof Cap

Abstract: Mould Design helps designers to improvement and quality of an injection molded part is dependent on many factors. These processes consider geometric parameters subjected to with the mold design and gate value system modification as well as process parameter such as molding condition during the filling phase. In the complete paper. The problem of optimization mold was addressed in this paper; the optimization problem can be broken into the subparts. The process is divided by using 3D printing product design for mold manufacturing effectively eliminates the use trial and error method by optimizing and validating the design of plastic products before production. This not only improves the quality but also helps to guide about the selection of machines and production planning An approximate feasible molding space (AFMS) is first determined to constrain the search space for the optimization. Quality is quantified as a function of simulation output and constitutes the objective function that must be minimized.

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Study on the Liquid Metal Flow Field in Narrow Side Patter Mold of Slab Continuous Casting

Study on the Liquid Metal Flow Field in Narrow Side Patter Mold of Slab Continuous Casting

When the liquid metal flows passes the static magnetic field region, a braking force is generated. The magnet field can suppress the surface fluctuation and brake the flow below the SEN, then the flow pattern and velocity distribution in the mold are optimized, promoting the formation of a plug flow in the mold. Therefore, the solidification defects will be eliminated, and high quality production is realized 13-17 .

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Study And Analysis The Effectiveness CAD-CAM  System In Mold Design

Study And Analysis The Effectiveness CAD-CAM System In Mold Design

Daeil Mold Co. which produce mold tool especially for home appliance, automotive industries and parts for client, is a Korean company that use the CAD/CAM system to increase the production. Korean Prime Minister awarded the company as a number of prizes for exporting of goods. The use of CAD/CAM system in the company enabled Daeil Mold to make the two different departments become one department. The decision for combination of the two departments reduced delivery time of parts from one department to another. Due to the company’s experience, these CAD/CAM systems are proved to help in improvement of injection molding manufacturing.

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Simulation of fluid flow and solididification in the funnel type crystalizer of thin slab continuous cast

Simulation of fluid flow and solididification in the funnel type crystalizer of thin slab continuous cast

the upper hole. The liquid steel enters upward to the mold and then flows down in peripheral of the nozzle. The top recirculation zone is formed by the steel that reaches the narrow wall of the mold and then flows towards the steel/slag interface. The intensity of the recirculation is a key factor for avoiding instabilities at the interface. In another section (b), located on the same level with lower hole, the high velocity molten steel moves down into the mold. On the other side of this section, upward flow of the upper recirculation zone can be seen. The outlet flow from the lower port of the nozzle then touches the corner walls (c) while it still intends to go down the mold and creates the lower recirculation zone. Finally, the steel flows downwards in section (d) and comes to the mold bottom.

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Experimental Verification and Accuracy Improvement of Gas Entrapment and Shrinkage Porosity Simulation in High Pressure Die Casting Process

Experimental Verification and Accuracy Improvement of Gas Entrapment and Shrinkage Porosity Simulation in High Pressure Die Casting Process

etc. 4,5) In these years SOLA-VOF method has been mostly used, and it is used in this study because of the short calculation time and calculation accuracy. In the analysis method, velocity and pressure in rectangular mesh is defined, and the temporary predicted value is calculated by explicit solution of motion equation. And modification operation of pressure and velocity value is iteratively executed until satisfaction of continuity equation. In this way the velocity of each element is calculated by SOLA method, and the free surface shape in next time step is calculated by VOF method. Molten metal flow is simulated by those procedures. Staggered grid is used in this work, and pressure is defined in the center of grid, and velocity is defined on the boundary. In complete slip condition on the boundary, normal component of velocity on the boundary is zero, and tangential component have no gradient in normal direction on the boundary. On the other hand, in non-slip condition all components of velocity on the boundary are set zero. Solidification is calculated by finite difference method, and latent heat is calculated by temperature recovery method. 6) Application program in this work is developed on base of commercial casting software TopCAST (version 2005). 7)

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Design of Spoon Mold using Flow Analysis and Higher End Design Software

Design of Spoon Mold using Flow Analysis and Higher End Design Software

Mold flow provides acceptable information results such as fill time, injection pressure and pressure drop. With this result, users can avoid the imperfection of the plastic in actual injection such as sink mark, indecision, over packing, air traps. Mold with minimum modifications and it will also reduce the mold setup time. With this analysis and simulation it will help to lessen time and cost. The productivity is increased up to 56.62% and production time is decreased up to 56.8%.The Mold can be filled completely and gives reliable results. Users should undertake sufficient verification and testing to determine the suitability for their own particular purpose. The Design of the Mold and the processing factors has an effect over the quality of the part produced. Defects can bereduced through improved design of the mold with the study of simulation of flow through the mold. The material, size, obscurity (complexity) and the rate of production required should be considered for evolving the right Mold design for the given component. From the analysis simulation, Mold flow provides acceptable information results such as fill time, injection pressure and pressure drop. With this result, users can avoid the imperfection of the plastic in actual injection such as sink mark, indecision, over packing, air traps. The analysis will also help the mold designer to design a perfectmold with minimum modifications and it will also reduce the mold setup time. With this analysis and simulation it will help to lessen time and cost.

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Performance of 3D printed polymer mold for 
		metal injection molding process

Performance of 3D printed polymer mold for metal injection molding process

Metal injection molding (MIM) is preferred choice for mass production of intricate and complex parts. However, machining of intricate and complex mold for low volume of part production could be very time consuming, skill intensive and expensive. For low volume requirement of MIM parts, typically for prototyping, design validation and visual inspection, mold experiences small number of MIM cycles and once demand is met, mold is rendered useless. Contrary to traditional machining, polymer molds made through additive manufacturing (AM) process, called Rapid Tooling (RT), could comparatively be a swift and economic approach. For low to medium number of MIM cycles, 3D printed polymer molds could potentially yield performance, comparable with machined metal mold. Present study investigates enhancement of various approaches for 3D printed polymer molds for their potential use in MIM. Consequently, 3D printed polymer molds proved promising for prototype and low volume manufacturing of MIM parts.

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