DFMPro For Injection Molding Oct09

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Automated design for manufacturing tool integrated within SolidWorks and Pro/ENGINEER

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DFMPro For Injection Molding Oct09

  1. 1. DESIGN FOR INJECTION MOLDING Get your Designs Right the First Time!
  2. 2. Importance of Plastics <ul><li>Plastic materials or polymers have a great advantage that by using different combinations of elements, one can create almost any property desired for an end product. </li></ul><ul><li>These new polymers have similar properties to existing conventional materials but they offer greater design freedom and cost incentives for manufacturing. </li></ul><ul><li>Replacing metals with reinforced plastic materials of similar properties, it is possible not only to reduce weight and component costs but also operational costs. </li></ul><ul><li>Companies striving to cut out manufacturing and assembly steps and to succeeded so by using thermoplastic processing, such as injection molding, thus producing multifunctional and readily assembled parts in a single pass. </li></ul>© Geometric Limited | www.geometricglobal.com
  3. 3. Design of Injection molded parts <ul><li>Injection molding is a major part of the plastics industry and is a big business worldwide, consuming approximately 32 % of all plastics </li></ul><ul><li>It is particularly advantageous when intricate parts must be produced in large quantities </li></ul><ul><li>Design for parts for injection molding is important not only to ensure that the part is molded without any defects but also to improve tool life and reduce cycle time and manufacturing cost </li></ul><ul><li>Many plastic manufacturers provide design guidelines for injection molded parts </li></ul><ul><li>Additionally DFM reviews are practiced world wide in many organizations </li></ul>© Geometric Limited | www.geometricglobal.com
  4. 4. DFM Reviews – Traditional Method <ul><li>Detection of manufacturing problems in the design stage </li></ul><ul><li>Background </li></ul><ul><li>Issues related to product design go undetected until manufacturing trials </li></ul><ul><li>Later on, they are expensive and time consuming to correct </li></ul><ul><li>Easy to correct during design phase, but are difficult to detect at this stage </li></ul><ul><li>Existing Practices </li></ul><ul><li>Maintaining DFM checklists, guidelines-handbooks </li></ul><ul><li>Periodic training of designers </li></ul><ul><li>Manual reviews of design (by self / peers / seniors) </li></ul><ul><li>Consultations with manufacturing experts </li></ul>© Geometric Limited | www.geometricglobal.com DESIGN MANUFACTURING OVER-THE-WALL ENGINEERING
  5. 5. DFM Reviews – Problems with Traditional Method © Geometric Limited | www.geometricglobal.com Manual reviews are cumbersome, prone to errors (and boring!) Time Consuming Process Inconsistent Design Quality Need for Proximity (between design & manufacturing engineers) No tools to enforce the checks
  6. 6. DFMPro Product © Geometric Limited | www.geometricglobal.com
  7. 7. DFMPro: Functionalities <ul><li>Supported Modules </li></ul><ul><li>Prismatic Machining </li></ul><ul><li>Turning </li></ul><ul><li>Sheet Metal </li></ul><ul><li>More than 30 rules provided for these 3 modules as part of Standard Package </li></ul><ul><li>Facility to customize and add new rules </li></ul>© Geometric Limited | www.geometricglobal.com
  8. 8. New Module -- DFMPro for Injection Molding © Geometric Limited | www.geometricglobal.com <ul><li>The new injection molding module in DFMPro will help designers in automatically validate the design of plastic parts </li></ul><ul><li>Design checks include standard rules and guidelines which not only improve the moldability of the designs but also improve the life of the mold. </li></ul><ul><li>Certain included guidelines can also increase the operational life of the part and reduce it’s manufacturing cost </li></ul><ul><li>Additionally, using DFMPro customization capabilities, users can create and apply their own rules for design validation </li></ul><ul><ul><li>Organizations can protect their IP by adding new rules to DFMPro in-house </li></ul></ul>
  9. 9. DFMPro : Injection Molding Rules <ul><li>Uniform wall thickness </li></ul><ul><li>Rule </li></ul><ul><li>The base wall thickness in the part should be within the user specified range. </li></ul><ul><li>  </li></ul><ul><li>Explanation </li></ul><ul><li>The wall plays a part both in design concept and embodiment. It must be thick enough to do its job; but it must also be thin enough to cool quickly and thick enough to allow efficient mould filling. </li></ul><ul><li>Usage </li></ul><ul><li>Users can provide the applicable range of allowable wall thickness for checking the design </li></ul>© Geometric Limited | www.geometricglobal.com
  10. 10. DFMPro: Injection Molding Rules <ul><li>Recommended Rib Parameters </li></ul><ul><li>Rule </li></ul><ul><li>Rib Parameters must be as per recommendations for ease of manufacturing and obtaining desired part quality. </li></ul><ul><li>  </li></ul><ul><li>Explanation </li></ul><ul><li>Ribs need to be designed in correct proportion to avoid defects such as short shots and avoid sink marks and filling problems. </li></ul><ul><li>Usage </li></ul><ul><li>Users can provide the desired rib parameters for checking the design </li></ul>© Geometric Limited | www.geometricglobal.com
  11. 11. DFMPro: Injection Molding Rules <ul><li>Mold Wall Thickness </li></ul><ul><li>Rule </li></ul><ul><li>The mold wall thickness should be greater than a </li></ul><ul><li>particular user specified value. </li></ul><ul><li>  </li></ul><ul><li>Explanation </li></ul><ul><li>If features like ribs, bosses are placed close to each other </li></ul><ul><li>or the walls of the parts, thin areas are created which can be hard to cool and can affect quality. If the mold wall is too thin, it is also difficult to manufacture and may result in a lower life for the mold due to problems like hot blade creation and differential cooling. </li></ul><ul><li>Usage </li></ul><ul><li>Users can provide the minimum allowable wall thickness for checking the design </li></ul>© Geometric Limited | www.geometricglobal.com
  12. 12. DFMPro: Injection Molding Rules <ul><li>Undercut Detection </li></ul><ul><li>Rule </li></ul><ul><li>Undercuts should be avoided for ease of manufacturing. </li></ul><ul><li>  </li></ul><ul><li>Explanation </li></ul><ul><li>Undercuts typically require additional mechanisms just adding to mold cost and complexity. In addition, the part must have room to flex and deform. </li></ul><ul><li>Usage </li></ul><ul><li>Users can choose whether to check the design for undercuts </li></ul>© Geometric Limited | www.geometricglobal.com
  13. 13. DFMPro: Injection Molding Rules <ul><li>Minimum Radius at Base/Tip of Boss </li></ul><ul><li>Rule </li></ul><ul><li>The minimum radius at the tip/base of a boss </li></ul><ul><li>should be at least as per specified value.   </li></ul><ul><li>Explanation </li></ul><ul><li>A fillet of a certain radius value should be provided at the base/tip of boss to reduce stress. </li></ul><ul><li>Usage </li></ul><ul><li>Users can specify the desired base fillet radius as a ratio of wall thickness and tip radius as a absolute value or a ratio </li></ul>© Geometric Limited | www.geometricglobal.com
  14. 14. DFMPro: Injection Molding Rules <ul><li>Minimum Draft Angle </li></ul><ul><li>Rule </li></ul><ul><li>Draft angles should be provided on the inside and outside of part walls in the direction of draw.  </li></ul><ul><li>Explanation </li></ul><ul><li>A fillet of a certain radius value should be provided at the base/tip of boss to reduce stress. </li></ul><ul><li>Usage </li></ul><ul><li>Users can specify the desired base fillet radius as a ratio of wall thickness and tip radius as a absolute value or a ratio </li></ul>© Geometric Limited | www.geometricglobal.com
  15. 15. DFMPro: Injection Molding Rules <ul><li>Maximum Cutout Area </li></ul><ul><li>Rule </li></ul><ul><li>The ratio of cutout area to nominal wall thickness should be less than a particular user specified value. </li></ul><ul><li>Explanation </li></ul><ul><li>Large openings in injection molded parts can lower the strength of the part. Reduce the size of the opening or reinforce the opening using strengthening ribs in the cross section. </li></ul><ul><li>Usage </li></ul><ul><li>Users can specify the desired base fillet radius as a ratio of wall thickness and tip radius as a absolute value or a ratio </li></ul>© Geometric Limited | www.geometricglobal.com
  16. 16. THANK YOU © Geometric Limited | www.geometricglobal.com The copyrights/ trademarks of all products referenced herein, are held by their respective companies. http://dfmpro.geometricglobal.com For any queries: [email_address]

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