design of mould tool & cooling channel optimization of remote control top panel

1

International Journal of Research and Innovation (IJRI)

DESIGN OF MOULD TOOL & COOLING CHANNEL OPTIMIZATION OF REMOTE CONTROL TOP PANEL

V.Venkata Krishna Mohan, D.Gopichand Mother Theresa Institute of Technology(mist) Sanketika Nagar Sathupally Khammam,India

*Corresponding Author: V.Venkata Krishna Mohan, Mother Theresa Institute of Technology(mist) Sanketika Nagar Sathupally Khammam,India Published: Sep 22, 2014

Volume No: IIssue No. : III

Citation:V.Venkata Krishna Mohan, D.Gopichand (2014) DE-SIGN OF MOULD TOOL & COOLING CHANNEL OPTIMI-ZATION OF REMOTE CONTROL TOP PANEL

Problem Description

UN proper cooling effects on surface finish of the component and warpage may occur, due to that part dimensions may get deformed than generic/modeld part.

Generally different types of cooling channels are

used in the field of plastic part manufacturing, it directly effects on surface finish and warpage of the component, even material properties also effect on the same.

Methodology

The following methods are followed to rectify the above problem

Plastic flow analysis will be done using various plas-tic materials.

Thermal analysis will be done on different types of cooling channel systems, to suggest the optimum to ensure sufficient cooling and fill quality.

Introduction To CadComputer Aided Design (CAD) is a technique in which problem solving will be done in the combina-tion of man and machine for high precision work flow.

Abstract

A plastic material is any of a wide range of synthetic or semi-synthetic organic solids that are moldable. Plastics are typically organic polymers of high molecular mass, but they often contain other substances. They are usually synthetic, most commonly derived from petrochemicals, but many are partially natural.

Molding is the process of manufacturing by shaping liquid or pliable raw material using a rigid frame called a mold or matrix. This itself may have been made using a pattern or model of the final object.

Cooling channels are used in mold tool to reduce the temperature of the object to help molten material to solidify quickly before the ejection. It is quite useful to increase the production rate.

The aim of this project work is to design mold structure and optimize cooling channel system to reduce effect of warpage of remote control top panel.

Literature survey and data collection will be done to understand working process of cooling channels, effects of warpage on plastic part’s, mold optimization.

3D model of remote control top panel will be prepared and die design calculations will be done to model the entire mold step.

Assembly of complete mold will be prepared for further process.

Analysis will be carried out on mold cooling channel’s for evaluation and Analysis will be done on different model’s to obtain optimum structure and cooling channel system.

Conclusion will be mode according to the obtained results

Peer Review- 1401-1402


2


Computer Aided Design is an interactive process, where the exchange of information between the designer and the computer is made as simple and effective as possible. Computer aided design en-compasses a wide variety of computer based meth-odologies and tools for engineering activity plan-ning, analysis, detailing, drafting, construction, manufacturing, monitoring, management, process control and maintenance. CAD is more concerned with the use of computer-based tools to support the entire life cycle of engineering system.

Introduction To Creo Parametric 2.0 (Creo 2.0)

CREO PARAMETRIC is one of the most popular PLM software founded by Parametric Technology Corpo-ration which consists of CAD/CAM/CAE. So that designer can easily check their part/product design compatibility with FEM and CAM segments and also they can check plastic flow for injection mold-ings parts to reduce production/component errors.

CREO PARAMETRIC is completely feature based modeling tool with ribbon mode which is very easy to understand by the users.

Summary of capabilities

Like any software it is continually being developed to include new functionality. The details below aim to outline the scope of capabilities to give an over-

view rather than giving specific details on the indi-vidual functionality of the product.

Engineering Design

Creo parametric 2.0 offers a range of tools to enable the generation of a complete digital representation of the product being designed. In addition to the general geometry tools there is also the ability to generate geometry of other integrated design disci-plines such as industrial and standard pipe work and complete wiring definitions. Tools are also available to support collaborative development.

A number of concept design tools that provide up-front Industrial Design concepts can then be used in the downstream process of engineering the prod-uct. These range from conceptual Industrial design sketches, reverse engineering with point cloud data and comprehensive freeform surface tools.

Manufacturing

By using the fundamental abilities of the software with regards to the single data source principle, it provides a rich set of tools in the manufacturing en-vironment in the form of tooling design and simu-lated CNC machining and output.

Tooling options cover specialty tools for molding, die-casting and progressive tooling design.

Modeling of remote

The above image shows the 2d sketch of remote using trimmed circles and arcs

3


The above image shows the fillets using round option

The above image shows the completed image of remote

The above image shows 2d drafting of remote

4


Injection Moulding

In manufacturing processes Injection moulding plays a crucial role for producing plastic compo-nents by using thermo plastic and thermo setting. After completion of product design as per client re-quirement done by an engineer, molds are prepared by tool maker. For less number of components Alu-minum is the better option. For large production better to use steel alloys to maintain good surface finish, dimensional stability. Maximum of compo-nents are made by thermo plastic which are recy-cled (or) reusable.

plasticsMaterial is fed into a heated barrel, mixed, and forced into a mold cavity where it cools and hardens to the configuration of the mold cavity

Commonly open top components are produced in injection molding which is having minimum thick-ness of 0.5mm, for good quality of product the wall thickness should be more than 2mm.

For remote control panel better to use recycled poly-propelene due to good impact resistence, low cost and eco-friendly and it has good structural stability.

Process Characteristics

• Utilizes a ram or screw-type plunger to force molten plastic material into a mold cavity • Produces a solid or open-ended shape which has conformed to the contour of the mold • Uses thermoplastic or thermoset materials • Produces a parting line, sprue, and gate marks • Ejector pin marks are usually present

Injection molding is used to create many things such as wire spools, packaging, bottle caps, auto-motive dashboards, pocket combs, and most other plastic products available today. Injection molding is the most common method of part manufacturing. It is ideal for producing high volumes of the same object. Some advantages of injection molding are high production rates, repeatable high tolerances, and the ability to use a wide range of materials, low labour cost, minimal scrap losses, and little need to finish parts after molding. Some disadvantages of this process are expensive equipment investment, potentially high running costs, and the need to de-sign moldable parts.

Design

Molds separate into two sides at a parting line, the A side, and the B side, to permit the part to be ex-tracted. Plastic resin enters the mold through a sprue in the A plate, branches out between the two sides through channels called runners, and enters each part cavitythrough one or more spe-cialized gates. Inside each cavity, the resin flows around cores and conforms to the cavity geom-etry to form the desired part. The amount of resin required to fill the sprue, runner and cavities

of a mold is a shot. When a core shuts offagainst an opposing mold cavity or core, a hole results in the part. Air in the cavities when the mold closes escapes through very slight gaps between the plates and pins, into shallow plenums called vents. To permit removal of the part, its features must not overhang one another in the direction that the mold opens, unless parts of the mold are designed to move from between such overhangs when the mold opens. Sides of the part that appear parallel with the direction of draw are typically draft with to ease release of the part from the mold, and examination of most plastic household objects will reveal this. Parts with bucket-like features tend to shrink onto the cores that form them while cool-ing, and cling to those cores when the cavity is pulled away. The mold is usually designed so that the molded part reliably remains on the ejector side of the mold when it opens, and draws the runner and the sprue out of the side along with the parts. The part then falls freely when ejected from the side. Tunnel gatestunnel sharply below the parting sur-face of the B side at the tip of each runner so that the gate is sheared off of the part when both are ejected. Ejector pins are the most popular method for removing the part from the side core, but air ejection, and stripper plates can also be used de-pending on the application. Most ejector plates are found on the moving half of the tool, but they can be placed on the fixed half if spring loaded. For thermoplastics, coolant, usually water with cor-rosion inhibitors, circulates throughpassageways bored through the main plates on both sides of the mold to enable temperature control and rapid part solidification.

Plastic Advisor In Creo Parametric

Problems found after tooling development are al-ways expensive and frustrating. For plastic part design and manufacture, there is a better way. By simulating the plastic-filling process for injection-molded parts, Pro/ENGINEER Plastic Advisor ena-bles engineers to design for manufacturability, un-cover problems, and propose remedies, reducing development time and expense.

CREO Plastic Advisor simulates mold filling for in-jection molded plastic parts. Advanced features provide valuable manufacturability insight - in-sight that can significantly reduce late-cycle design changes and mold reengineering costs.

CREO Plastic Advisor simulates mold filling for in-jection molded plastic parts. Advanced features provide valuable manufacturability insight - in-sight that can significantly reduce late-cycle design changes and mold reengineering costs.

Features & Benefits

• Animates plastic injection fill process and auto-matically creates Web reports within Pro/ENGI-NEER browser

5

International Journal of Research and Innovation (IJRI) • Access library of common plastic materials and automatically select from typical injection-molding machine parameters • Identify optimal injection locations to reduce cycle time and improve product appearance • Identify potential mold-filling problems such as short shots, air traps, and weld lines • Improve design quality and reduces manufactur-ing cycle times and rework of molds

Materials

Polypropylene (pp)Acrylonitrile Butadiene System (ABS)High Density Polyethylene (HDPE)Polyvinyl Chloride (PVC)Polybutylene terepthalate (PBT)

Plastic Flow analysis of remote control panel using polypropylene (pp)

The above image shows fill time

The above image shows confidence of fill

6


The above image shows injection pressure

The above image shows pressure drop

The above image shows flow front temp

7


The above image shows quality prediction

The above image shows surface temp variance

Plastic Flow analysis of remote control panel using Acrylonitrile Butadiene System (ABS)


8





9


Plastic Flow analysis of remote control panel using High Density Polyethylene (HDPE)




10



Plastic Flow analysis of remote control panel using Polyvinyl Chloride (PVC)



11




Plastic Flow analysis of remote control panel using polybutylene terepthalate (PBT)


12





13


MOULD EXTRACTION

A die is usually made in two halves and when closed it forms a cavity similar to the casting desired. One half of the die that remains stationary is known as cover die and the other movable half is called “ejector die”.The die casting method is used for castings of non-ferrous metals of comparatively Low fusion tem-

perature. This process is cheaper and quicker than permanent or sand mould casting. Most of the au-tomobile parts like fuel pump, carburetor bodies, Horn heater, wipers, brackets, steering wheels, hubs and crank cases are made with this process. Core: The core which is the male portion of the mold forms the internal shape of the molding.Cavity: The cavity which is the female portion of the mold, gives the molding its external form.

Parting Line Creation

The above image shows the parting surface

Core and cavity preparation

The above image shows the work piece creation

14


The above image shows the cavity part

The above image shows the core part

Mold Tool Design For Remote Control Top Panel

The above image shows cavity

15


The above image shows core

The above image shows mould assembly

The above image shows exploded view

16


2D Drafting For Mold Tool Design

BILL OF MATERIALS

17


Optimized Cooling Channels For Remote Control Top Panel

The above image shows linear

The above image shows horizontal

The above image shows vertical

18


The above image shows spiral

Introduction To Ansys

ANSYS is general-purpose finite element analysis (FEA) software package. Finite Element Analysis is a numerical method of deconstructing a complex system into very small pieces (of user-designated size) called elements. The software implements equations that govern the behaviour of these ele-ments and solves them all; creating a comprehen-sive explanation of how the system acts as a whole. These results then can be presented in tabulated,

or graphical forms. This type of analysis is typically used for the design and optimization of a system far too complex to analyze by hand. Systems that may fit into this category are too complex due to their geometry, scale, or governing equations. ANSYS is the standard FEA teaching tool within the Mechanical Engineering Department at many colleges. ANSYS is also used in Civil and Electrical Engineering, as well as the Physics and Chemistry departments.

Warpage Analysis Of Remote Control Top Panel Using Coupled Field Analysis

Linear type cooling system

The above image shows imported model of remote control top panel with linear cooling system

19


The above image shows meshed model

The above image shows total deformation

The above image shows temperature

20


The above image shows total heat flux

The above image shows thermal error

Spiral type cooling system


21





22


Zigzag horizontal type cooling system




23



Zigzag vertical type cooling system



24




PP ABS HDPE PVC PbTFill time 0.96 1.38 1.19 2.57 1.50

Injection pres-sure

19.30 36.31 34.31 65.43 61.24

Pressure drop 19.30 36.31 34.31 65.43 61.24Flow front

temperature240.01 230.04 210.07 170.15 247.18

Surface tem-perature vari-

ance

4.98 4.98 4.98 4.98 4.98

Result table for plastic flow analysis

Results

25


Linear Spiral Zigzag hori-zontal

Zigzag vertical

Total deforma-tion

0.019266 0.0096524 0.019223 0.019331

Temperature 200 200 200 200Total heat flux 8.2928e-12 8.3161e-12 9.6433e-12 9.7462e-12Thermal error 1.3267e-18 1.3616e-18 3.7358e-18 3.7255e-18

Result table for optimized cooling channels

Conclusion

This project work deals with design of mold tool and cooling channel optimization of remote control top panel to suggest optimum material and cooling channel system to reduce warpage of the product.Initially literature survey and data collection was done to understand the methodology and material selection.

Remote control top panel was modeled and designed mold tool for the same using parametric software creo-2.0 (pro-engineer).

Mold flow analysis was conducted on part by vary-ing plastic materials.

As per flow analysis P.P (polypropylene) is showing good characteristics in confidence of fill and quality with in low pressure and less drop, but it requires little bit high temperature than other materials.

Thermal analysis is done in ansys work bench by varying cooling channel systems to analyze thermal behavior.

As per thermal analysis spiral system is showing good quality in providing sufficient cooling effect to the part.

As per above analysis results this project work con-cludes that remote control with P.P (polypropylene) material along with spiral cooling channel system gives good quality product due to its quality of filling and sufficient cooling effect.

References1]. P. Postawa*, D. Kwiatkowski, E. Bociaga Insti-tute of Polymer Processing and Production Manage-ment, Czestochowa University of Technology, al. ArmiiKrajowej 19c, 42-200 Czêstochowa, Poland-Corresponding author: E-mail address: [email protected]

2]. Hong-Seok Park and Xuan-Phuong Dang Uni-versity of Ulsan South Korea Z. Shayfull*1, M.F. Ghazali1, M. Azaman1, S.M. Nasir1, N.A. Faris2 1School of Manufacturing Engineering, Universiti Malaysia Perlis, Malaysia 2Politeknik Sultan Abdul HalimMu’adzam Shah (POLIMAS), Malaysia [email protected]

3].Lars-Erik Rännar ISBN 978-82-471-8270-3 (printed version) ISBN 978-82-471-8284-0 (elec-

tronic version) ISSN 1503-8181 Doctoral theses at NTNU, 2008:1134]. B. Sidda Reddy 1,*, J. Suresh Kumar2, Vijaya Kumar Reddy2 and G. Padmanabhan3 1 Depart-ment of Mechanical Engineering, R. G. M. College of Engineering & Technology, Nandyal, Kurnool (Dt), A.P-518 501, India. 2 Mechanical Engineering, J.N.T University, Hyderabad, India. 3 Mechanical Engineering, S.V. University College of Engineering, S.V. University, Tirupati, A.P. India5]. Omar A. Mohamed, S.H. Masood, AbulSaifullahFaculty of Engineering and Industrial Science, Swin-burne University of Technology, Hawthorn, Mel-bourne, Australia Corresponding Email: [email protected]

6]. Mohammad Aashiq M1, Arun A.P1, Parthiban M2 1 PGD IN TOOL & DIE DESIGN ENGINEERING-PSG IAS 2 ASST.PROFESSOR DEPARTMENT OF MECHANICAL ENGINEERING-PSG CT Coimbatore – 641004, India

7]. JiajunShen An Engineering Project Submitted to the Graduate Faculty of Rensselaer Polytechnic Institute

Authors

vadlamannati venkata krishna mohan25 Year’s Teching Experience In Govt Polytechnic College

D.GopichandQualification: m.techDesignation: assistant profressorExperience :4 yr in teaching & 2 yr experience inInfoTech as design engineer

design of mould tool & cooling channel optimization of remote control top panel

Education