This A Wi-Fi router is a device that performs the function of a wireless access point, it is used to provide
access to the internet or a private computer. It is the hardware device that provide basic infrastructure for a home
or small office network.Proposed to make a single impression semi-automatic family mould to design top and
bottom cover for Wi-Fi router to make it more aesthetic, to reduce material cost, better heat dissipation, and to
reduce the tooling cost, to make the product more competitive in the market.It is proposed select the suitable plastic
material, to modify the existing plastic product design and to develop a suitable two plate family mould of one
impression each using SIEMENS NX software. It is also proposed to make detailing of mould parts and its assembly
for manufacturing using SIEMENS NX software. The analysis was done in AUTODESK MOLDFLOW. The mould
cost, raw material cost and processing cost per component are to be estimated to find the cost per component and to
compare it with the existing component part.
DESIGN OF MOULD TOOL & COOLING CHANNEL OPTIMIZATION OF REMOTE CONTROL TOP PANELIjripublishers Ijri
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.
This project deals with the modeling of cooler tank parametric model as per the client requirement. Finding the best manufacturing process preparing mould base for the same, analyzing different manufacturing process by doing CNC program by changing milling parameters (feed, speed, cutters….).So that optimum parameters for manufacturing will be suggested which is useful to reduce the costs and efforts. Plastic flow analysis will be conducted to check the material flow and filling. So that reduction in the pre-machining cost will be done by rectifying the problem. FEM Based analysis will be conducted on mould structure to reduce weight of the mould. And thermal analysis will be conducted to suggest optimized cooling channel design. Modeling, mould base preparation, manufacturing, cnc programming will be done
OPTIMIZED DIE STRUCTURE DESIGN OF PLASTIC INJECTION MOULD USING FEM TECHNIQUEIjripublishers Ijri
The Aim of this thesis work is to reduce weight and cost of the injection mold by removing unwanted materials and using
low cost materials at non-stress region areas.
A general large size model will be prepared to design the mold structure using theoretical method.
Complete level of mold parts and assembly will be prepared to conduct analysis.
Structural analysis will be conducted on mould to find stress locations and non-effective locations.
Modifications will be done on mold according to obtained results.
RECENT DEVELOPMENTS AND DESIGN OF TOOLS FOR PUNCHING AND CUTTINGIAEME Publication
Intensive utilization of computers is especially emphasized in the field of industrial
production, where use of computer applications achieves significant savings in regard
to the time required for manufacturing of products. Shortening of the production time
decreases the production costs and new products are faster introduced to the market,
thus making the company more competitive. In addition to the shorter time for
production, better precision and accuracy is also accomplished, resulting with better
product quality at the end.
Due to the fact that, for the reason of cost-effectiveness of manufacturing of tools,
processing of sheet metal on presses is primarily performed in the course of serial
production, this paper focuses on an analysis of the use of computers in the process of
design of tools for punching and cutting of sheet metal on presses. The presented
methodology encompasses all phases in the process of design of tools – from planning
the work piece until the final design of the tool for punching and cutting, with an
emphasis on the activities performed exclusively by computer applications.
The result of this research is a 3D geometrical model of a tool for punching and
cutting, with an explanation of characteristics of its construction parts, calculation of
its executive parts, analysis and simulation of operation of the tool, and finally the
conclusion on the representation and importance of the utilization of computer
applications in the process of design of such tools
Sand casting conventional and rapid prototyping manufacturing approacheseSAT Publishing House
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
FDM Modeled Polymer Tooling for Plastic Injection MoldingIJAMSE Journal
Rapid Prototyping is being accepted globally by industries for its potential in saving on process time and cost. Rapid Tooling helps Rapid Prototyping grow beyond its conventional Feel & Fit status to Feel Fit Function status and is increasingly becoming popular. However, potential of rapid prototyping for normal
production run is still not being realized. In that situation Rapid Tooling becomes a viable alternative. The greatest opportunity for rapid tooling implementation is the use of Additive Manufacturing (AM) technology. Further, polymer based direct rapid tooling provide large cost reduction and can also be
readily accessible by industries. With the advances in materials along with the new access and low cost plastic based- AM equipment, direct use Polymer Rapid Tools (PRTs) would be a far more advantageous option in creating injection molds for low and highly flexible production. However, the use of polymer
based direct rapid tooling by industries is curtailed due to the issues with the dimensional stability of the polymer based rapid tooling molds. Apart from dimensional tolerances, there are also issues with the life of these polymer based mold as they wear fast and are also not able to sustain high injection pressures in an Injection molding machine. Another, major problem with the polymer based rapid tooling is the poor thermal conductivity of polymeric materials due to which there is an increase in the cooling time and ultimately leading to decrease in productivity. Therefore, before proposing polymer based rapid tooling as a solution to industries to cut down the product development time and bring down the costs, a thorough study of the issues related to the same is imperative. This paper investigates the dimensional accuracy of striker component produced by ABS mold inserts. For dimensional accuracy a reverse engineering technique3D scanning is used which is compared with CAD file and inspected with COMET plus software. Further, the outputs are validated with vernier caliper. The mold insert is manufactured by Fused Deposition Modeling (FDM) technology which is used on injection molding machine
DESIGN OF MOULD TOOL & COOLING CHANNEL OPTIMIZATION OF REMOTE CONTROL TOP PANELIjripublishers Ijri
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.
This project deals with the modeling of cooler tank parametric model as per the client requirement. Finding the best manufacturing process preparing mould base for the same, analyzing different manufacturing process by doing CNC program by changing milling parameters (feed, speed, cutters….).So that optimum parameters for manufacturing will be suggested which is useful to reduce the costs and efforts. Plastic flow analysis will be conducted to check the material flow and filling. So that reduction in the pre-machining cost will be done by rectifying the problem. FEM Based analysis will be conducted on mould structure to reduce weight of the mould. And thermal analysis will be conducted to suggest optimized cooling channel design. Modeling, mould base preparation, manufacturing, cnc programming will be done
OPTIMIZED DIE STRUCTURE DESIGN OF PLASTIC INJECTION MOULD USING FEM TECHNIQUEIjripublishers Ijri
The Aim of this thesis work is to reduce weight and cost of the injection mold by removing unwanted materials and using
low cost materials at non-stress region areas.
A general large size model will be prepared to design the mold structure using theoretical method.
Complete level of mold parts and assembly will be prepared to conduct analysis.
Structural analysis will be conducted on mould to find stress locations and non-effective locations.
Modifications will be done on mold according to obtained results.
RECENT DEVELOPMENTS AND DESIGN OF TOOLS FOR PUNCHING AND CUTTINGIAEME Publication
Intensive utilization of computers is especially emphasized in the field of industrial
production, where use of computer applications achieves significant savings in regard
to the time required for manufacturing of products. Shortening of the production time
decreases the production costs and new products are faster introduced to the market,
thus making the company more competitive. In addition to the shorter time for
production, better precision and accuracy is also accomplished, resulting with better
product quality at the end.
Due to the fact that, for the reason of cost-effectiveness of manufacturing of tools,
processing of sheet metal on presses is primarily performed in the course of serial
production, this paper focuses on an analysis of the use of computers in the process of
design of tools for punching and cutting of sheet metal on presses. The presented
methodology encompasses all phases in the process of design of tools – from planning
the work piece until the final design of the tool for punching and cutting, with an
emphasis on the activities performed exclusively by computer applications.
The result of this research is a 3D geometrical model of a tool for punching and
cutting, with an explanation of characteristics of its construction parts, calculation of
its executive parts, analysis and simulation of operation of the tool, and finally the
conclusion on the representation and importance of the utilization of computer
applications in the process of design of such tools
Sand casting conventional and rapid prototyping manufacturing approacheseSAT Publishing House
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
FDM Modeled Polymer Tooling for Plastic Injection MoldingIJAMSE Journal
Rapid Prototyping is being accepted globally by industries for its potential in saving on process time and cost. Rapid Tooling helps Rapid Prototyping grow beyond its conventional Feel & Fit status to Feel Fit Function status and is increasingly becoming popular. However, potential of rapid prototyping for normal
production run is still not being realized. In that situation Rapid Tooling becomes a viable alternative. The greatest opportunity for rapid tooling implementation is the use of Additive Manufacturing (AM) technology. Further, polymer based direct rapid tooling provide large cost reduction and can also be
readily accessible by industries. With the advances in materials along with the new access and low cost plastic based- AM equipment, direct use Polymer Rapid Tools (PRTs) would be a far more advantageous option in creating injection molds for low and highly flexible production. However, the use of polymer
based direct rapid tooling by industries is curtailed due to the issues with the dimensional stability of the polymer based rapid tooling molds. Apart from dimensional tolerances, there are also issues with the life of these polymer based mold as they wear fast and are also not able to sustain high injection pressures in an Injection molding machine. Another, major problem with the polymer based rapid tooling is the poor thermal conductivity of polymeric materials due to which there is an increase in the cooling time and ultimately leading to decrease in productivity. Therefore, before proposing polymer based rapid tooling as a solution to industries to cut down the product development time and bring down the costs, a thorough study of the issues related to the same is imperative. This paper investigates the dimensional accuracy of striker component produced by ABS mold inserts. For dimensional accuracy a reverse engineering technique3D scanning is used which is compared with CAD file and inspected with COMET plus software. Further, the outputs are validated with vernier caliper. The mold insert is manufactured by Fused Deposition Modeling (FDM) technology which is used on injection molding machine
“CONCEPT VALIDATION AND DESIGN SYNTHESIS OF CAR DASHBOARD AS PER PLASTIC TRIM...Jayesh Sarode
The evolution of dashboard has led to increased
vehicle occupant comfort and convenience as new systems
become available. The project work aims to develop the work
to apply theoretical and practical tools/techniques to solve
real life problems related to industry and current research in
this project automobile (Car) dashboard upper cover is
selected for a design. For doing so conceptual design tool is
used. I am created a five different concepts using different
benchmarking & brainstorming. Select a best option using
different tools in six sigma like trade off analysis. Threedimensional
CAD software (such as CATIA) is used to develop a
CAD model same as concept. The aim is to achieve the essential
function at the lowest overall cost while maintaining
customers’ optimum value assurance. In this project I try to
develop a such dashboard design which follow a design
guidelines, And analyze and discuss the results to Obtain valid
conclusions which follows a design Standards.
Injection moulds are divided into two types based on runner design i.e. Cold runner moulds and Runner less moulds i.e. hot runner moulds. In cold runner moulds, for multi cavity and multi point injection moulds, there is wreckage of material in runner area. Sometimes wreckage of material is more than component weight. For avoiding the above problem, the technique used is hot Runner moulds. Hot runner mould is the advanced manufacturing methods for multi cavity type moulds. These types of moulds are widely used for large production rate. While producing plastic components using normal standard multi cavity mould, we are facing the problems like partial filling, cavities in components, less product quality, injection pressure and temperature drop age and warpage etc. Thus we are redesigning the Ceiling Fan Regulator Knob by doing some modification in and this will be beneficial for our using purpose. We are making design of the component, mould flow analysis using software Solidworks. Pravin Borkar | Prof. Vaibhav Bankar ""Design of Ceiling Fan Regulator Knob"" Published in International Journal of Trend in Scientific Research and Development (ijtsrd), ISSN: 2456-6470, Volume-3 | Issue-3 , April 2019, URL: https://www.ijtsrd.com/papers/ijtsrd22825.pdf
Paper URL: https://www.ijtsrd.com/engineering/mechanical-engineering/22825/design-of-ceiling-fan-regulator-knob/pravin-borkar
Design and Developing of Two Wheeler Handle Gripper Using 3D Printing Technologyijtsrd
This paper provides information about design and developing of two wheeler handle gripper using the 3D printing. This technology allows to build a part in such a wat that thermoplastic material through nozzle deposited layer by layer and manufacture with high degree of freedom unachievable with the traditional manufacturing method. These two wheeler handle grippers TWHG play important role in providing grip to driver during vehicle running and idle conditions, it is difficult to make firm grip between hand and handle without handle gripper on two wheeler handle. For this paper purpose handle gripper model is created in CATIA V5, it is fully three dimensional modelling software, by using this model of handle grippers 3D printed handle grippers are created by the method of fused deposition process of rapid prototyping technology. S. Suresh | Duppelly Vamshi | Boda Rahul | Dharavath Ashok Kumar ""Design and Developing of Two-Wheeler Handle Gripper Using 3D Printing Technology"" Published in International Journal of Trend in Scientific Research and Development (ijtsrd), ISSN: 2456-6470, Volume-3 | Issue-3 , April 2019, URL: https://www.ijtsrd.com/papers/ijtsrd23311.pdf
Paper URL: https://www.ijtsrd.com/engineering/mechanical-engineering/23311/design-and-developing-of-two-wheeler-handle-gripper-using-3d-printing-technology/s-suresh
Implementation and Selection of Optimum Layout Design in Cellular Manufacturi...AM Publications
Laying out a factory involves deciding where to put all the facilities, machines, equipment and staff in the
manufacturing operation and layout determines the way in which materials and other inputs flow through the operation.
The objective of this work is to find the best layout designs with an intention of minimize the material movement and cost
to improve the over efficiency of a diligence and such extension of our work is we planned to implement this optimized
layout design in any of the industry to achieve some good results in their production. In this paper we proposed to make
a deliberate case study in a process industry to study the existing layout design. We have design the optimum layout
considering different layouts like with an aim of minimize the cost by reducing the total travelling distance of materials
and change the existing layout design for selected process industry this optimum layout design is executed using through
ARENA simulation software with different form of machine layouts.
Geometric Modeling, Design and Analysis of Custom-Engineered Milling Cuttersijtsrd
The geometric modeling of the cutting tools is an important aspect for the design and manufacturing engineers from the viewpoint of shape realization. The geometry of cutting tools? surfaces based on two-dimensional (2D) projected geometry approach has certain limitations. This definition is also inadequate due to inaccuracy and non-applicability of the model for further manipulation. To address these issues, an accurate three-dimensional (3D) surface-based generic definition for a few families of custom-engineered milling cutters has been developed. The proposed geometric definition of the customized cutter is developed in terms of biparametric surface patches using proposed 3D rotational angles rather than the conventional 2D angles. The non-uniform rational B-spline (NURBS) curve(s) and generation of sweep surfaces based on it are utilized for the shape generation of cutting elements of the generic cutters. This representation scheme enables tooth shapes to be controlled by manipulating control polygons and sweep trajectories and in the process varied tool geometries can be generated. Further, an interface is developed that converts the proposed 3D parametric definition of the cutter into an intermediate neutral CAD format. This helps in rendering the cutter model in any CAD modeling environment. R. R. Karthi | B. Tamilarasu | S. Mukesh | K. M. Naveen Kumar"Geometric Modeling, Design and Analysis of Custom-Engineered Milling Cutters" Published in International Journal of Trend in Scientific Research and Development (ijtsrd), ISSN: 2456-6470, Volume-2 | Issue-3 , April 2018, URL: http://www.ijtsrd.com/papers/ijtsrd10986.pdf http://www.ijtsrd.com/engineering/mechanical-engineering/10986/geometric-modeling-design-and-analysis-of-custom-engineered-milling-cutters/r-r-karthi
IJERA (International journal of Engineering Research and Applications) is International online, ... peer reviewed journal. For more detail or submit your article, please visit www.ijera.com
DESIGN OF MOULD TOOL & COOLING CHANNEL OPTIMIZATION OF REMOTE CONTROL TOP PANELIjripublishers Ijri
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.
“CONCEPT VALIDATION AND DESIGN SYNTHESIS OF CAR DASHBOARD AS PER PLASTIC TRIM...Jayesh Sarode
The evolution of dashboard has led to increased
vehicle occupant comfort and convenience as new systems
become available. The project work aims to develop the work
to apply theoretical and practical tools/techniques to solve
real life problems related to industry and current research in
this project automobile (Car) dashboard upper cover is
selected for a design. For doing so conceptual design tool is
used. I am created a five different concepts using different
benchmarking & brainstorming. Select a best option using
different tools in six sigma like trade off analysis. Threedimensional
CAD software (such as CATIA) is used to develop a
CAD model same as concept. The aim is to achieve the essential
function at the lowest overall cost while maintaining
customers’ optimum value assurance. In this project I try to
develop a such dashboard design which follow a design
guidelines, And analyze and discuss the results to Obtain valid
conclusions which follows a design Standards.
Injection moulds are divided into two types based on runner design i.e. Cold runner moulds and Runner less moulds i.e. hot runner moulds. In cold runner moulds, for multi cavity and multi point injection moulds, there is wreckage of material in runner area. Sometimes wreckage of material is more than component weight. For avoiding the above problem, the technique used is hot Runner moulds. Hot runner mould is the advanced manufacturing methods for multi cavity type moulds. These types of moulds are widely used for large production rate. While producing plastic components using normal standard multi cavity mould, we are facing the problems like partial filling, cavities in components, less product quality, injection pressure and temperature drop age and warpage etc. Thus we are redesigning the Ceiling Fan Regulator Knob by doing some modification in and this will be beneficial for our using purpose. We are making design of the component, mould flow analysis using software Solidworks. Pravin Borkar | Prof. Vaibhav Bankar ""Design of Ceiling Fan Regulator Knob"" Published in International Journal of Trend in Scientific Research and Development (ijtsrd), ISSN: 2456-6470, Volume-3 | Issue-3 , April 2019, URL: https://www.ijtsrd.com/papers/ijtsrd22825.pdf
Paper URL: https://www.ijtsrd.com/engineering/mechanical-engineering/22825/design-of-ceiling-fan-regulator-knob/pravin-borkar
Design and Developing of Two Wheeler Handle Gripper Using 3D Printing Technologyijtsrd
This paper provides information about design and developing of two wheeler handle gripper using the 3D printing. This technology allows to build a part in such a wat that thermoplastic material through nozzle deposited layer by layer and manufacture with high degree of freedom unachievable with the traditional manufacturing method. These two wheeler handle grippers TWHG play important role in providing grip to driver during vehicle running and idle conditions, it is difficult to make firm grip between hand and handle without handle gripper on two wheeler handle. For this paper purpose handle gripper model is created in CATIA V5, it is fully three dimensional modelling software, by using this model of handle grippers 3D printed handle grippers are created by the method of fused deposition process of rapid prototyping technology. S. Suresh | Duppelly Vamshi | Boda Rahul | Dharavath Ashok Kumar ""Design and Developing of Two-Wheeler Handle Gripper Using 3D Printing Technology"" Published in International Journal of Trend in Scientific Research and Development (ijtsrd), ISSN: 2456-6470, Volume-3 | Issue-3 , April 2019, URL: https://www.ijtsrd.com/papers/ijtsrd23311.pdf
Paper URL: https://www.ijtsrd.com/engineering/mechanical-engineering/23311/design-and-developing-of-two-wheeler-handle-gripper-using-3d-printing-technology/s-suresh
Implementation and Selection of Optimum Layout Design in Cellular Manufacturi...AM Publications
Laying out a factory involves deciding where to put all the facilities, machines, equipment and staff in the
manufacturing operation and layout determines the way in which materials and other inputs flow through the operation.
The objective of this work is to find the best layout designs with an intention of minimize the material movement and cost
to improve the over efficiency of a diligence and such extension of our work is we planned to implement this optimized
layout design in any of the industry to achieve some good results in their production. In this paper we proposed to make
a deliberate case study in a process industry to study the existing layout design. We have design the optimum layout
considering different layouts like with an aim of minimize the cost by reducing the total travelling distance of materials
and change the existing layout design for selected process industry this optimum layout design is executed using through
ARENA simulation software with different form of machine layouts.
Geometric Modeling, Design and Analysis of Custom-Engineered Milling Cuttersijtsrd
The geometric modeling of the cutting tools is an important aspect for the design and manufacturing engineers from the viewpoint of shape realization. The geometry of cutting tools? surfaces based on two-dimensional (2D) projected geometry approach has certain limitations. This definition is also inadequate due to inaccuracy and non-applicability of the model for further manipulation. To address these issues, an accurate three-dimensional (3D) surface-based generic definition for a few families of custom-engineered milling cutters has been developed. The proposed geometric definition of the customized cutter is developed in terms of biparametric surface patches using proposed 3D rotational angles rather than the conventional 2D angles. The non-uniform rational B-spline (NURBS) curve(s) and generation of sweep surfaces based on it are utilized for the shape generation of cutting elements of the generic cutters. This representation scheme enables tooth shapes to be controlled by manipulating control polygons and sweep trajectories and in the process varied tool geometries can be generated. Further, an interface is developed that converts the proposed 3D parametric definition of the cutter into an intermediate neutral CAD format. This helps in rendering the cutter model in any CAD modeling environment. R. R. Karthi | B. Tamilarasu | S. Mukesh | K. M. Naveen Kumar"Geometric Modeling, Design and Analysis of Custom-Engineered Milling Cutters" Published in International Journal of Trend in Scientific Research and Development (ijtsrd), ISSN: 2456-6470, Volume-2 | Issue-3 , April 2018, URL: http://www.ijtsrd.com/papers/ijtsrd10986.pdf http://www.ijtsrd.com/engineering/mechanical-engineering/10986/geometric-modeling-design-and-analysis-of-custom-engineered-milling-cutters/r-r-karthi
IJERA (International journal of Engineering Research and Applications) is International online, ... peer reviewed journal. For more detail or submit your article, please visit www.ijera.com
DESIGN OF MOULD TOOL & COOLING CHANNEL OPTIMIZATION OF REMOTE CONTROL TOP PANELIjripublishers Ijri
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.
Design and Analysis of Ceiling Cable Holder Baseijtsrd
Injection moulds are classified into two types based on runner design i.e. Cold runner moulds and Runner less moulds i.e. hot runner moulds. In cold runner moulds, for multi cavity and multi point injection moulds, there is wreckage of material in runner area. Also wastage of material is more than component weight. To overcome the above problem, the technique used is hot Runner moulds. Hot runner mould is one of the improved manufacturing techniques for multi cavity type moulds. These types of moulds are commonly used for large production rate. While producing plastic components using normal standard multi cavity mould, we are facing the problems like partial filling, cavities in components, less product quality, injection pressure and temperature reduction and war page etc. Thus we are redesigning the holder base by doing some modification in and this will be beneficial for our using purpose. We are making design of the component, mould flow analysis using software Solid works. Nitish Kumar Mishra | Prof. Vaibhav Bankar ""Design and Analysis of Ceiling Cable Holder Base"" Published in International Journal of Trend in Scientific Research and Development (ijtsrd), ISSN: 2456-6470, Volume-3 | Issue-4 , June 2019, URL: https://www.ijtsrd.com/papers/ijtsrd23840.pdf
Paper URL: https://www.ijtsrd.com/engineering/mechanical-engineering/23840/design-and-analysis-of-ceiling-cable-holder-base/nitish-kumar-mishra
Conceptual design of injection mold tool for the chair hand rest componenteSAT Publishing House
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
Conceptual design of injection mould tool for main body part of an air inflatoreSAT Publishing House
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
This project deals with the modeling of cooler tank parametric model as per the client requirement. Finding the best manufacturing process preparing mould base for the same, analyzing different manufacturing process by doing CNC program by changing milling parameters (feed, speed, cutters….).So that optimum parameters for manufacturing will be suggested which is useful to reduce the costs and efforts. Plastic flow analysis will be conducted to check the material flow and filling. So that reduction in the pre-machining cost will be done by rectifying the problem. FEM Based analysis will be conducted on mould structure to reduce weight of the mould. And thermal analysis will be conducted to suggest optimized cooling channel design. Modeling, mould base preparation, manufacturing, cnc programming will be done
Technology for Plastic Mold Tooling - Direct Metal Deposition HCL Technologies
This whitepaper highlights the benefits of DMD(Direct Metal Deposition) technology in mold cycle time reduction. It presents a comparative analysis conducted for cycle time performance of a mold consisting of a conventionally machined tool steel insert to a mold fitted with a Chromium Copper insert with a coating of tool steel deposited by the DMD process.
Injection molding methods design optimization simulation of plastic toy build...IAEME Publication
Mold flow simulation helps designers to see how their designs will be resulted after injection molding process without needing to do the 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.
Process optimization of pressure die casting to eliminate defect using cae so...eSAT Journals
Abstract
Die Casting is the manufacturing process by which a liquid material is pressurized in to the mould, which contains a hallow
cavity of the desired shape, and then molten metal is allowed to solidify. The solidified part is known as casting which is ejected
or broken out to complete the process. Objective in this project is to develop tools, dies and gating system. Identify defects such as
gas defects, shrinkage cavities, and mould material defects, pouring material defects, metallurgical defects etc. and take measures
to reduce flaws by using CAE software. To reduce the amount airs entrapped in the mould by changing the gating system, runner
and overflow location and optimize the gating system and process parameters for best quality product and improved productivity.
Defects can be formed easily at critical location during pressure die casting of aluminium alloy part. It has defective effect on the
casting. Mould filling and solidification process of a part was simulated using Z-cast software.
Key Words: Casting, HPDC, Z-cast, CAE Software, Simulation.
Student information management system project report ii.pdfKamal Acharya
Our project explains about the student management. This project mainly explains the various actions related to student details. This project shows some ease in adding, editing and deleting the student details. It also provides a less time consuming process for viewing, adding, editing and deleting the marks of the students.
Welcome to WIPAC Monthly the magazine brought to you by the LinkedIn Group Water Industry Process Automation & Control.
In this month's edition, along with this month's industry news to celebrate the 13 years since the group was created we have articles including
A case study of the used of Advanced Process Control at the Wastewater Treatment works at Lleida in Spain
A look back on an article on smart wastewater networks in order to see how the industry has measured up in the interim around the adoption of Digital Transformation in the Water Industry.
Water scarcity is the lack of fresh water resources to meet the standard water demand. There are two type of water scarcity. One is physical. The other is economic water scarcity.
Vaccine management system project report documentation..pdfKamal Acharya
The Division of Vaccine and Immunization is facing increasing difficulty monitoring vaccines and other commodities distribution once they have been distributed from the national stores. With the introduction of new vaccines, more challenges have been anticipated with this additions posing serious threat to the already over strained vaccine supply chain system in Kenya.
About
Indigenized remote control interface card suitable for MAFI system CCR equipment. Compatible for IDM8000 CCR. Backplane mounted serial and TCP/Ethernet communication module for CCR remote access. IDM 8000 CCR remote control on serial and TCP protocol.
• Remote control: Parallel or serial interface.
• Compatible with MAFI CCR system.
• Compatible with IDM8000 CCR.
• Compatible with Backplane mount serial communication.
• Compatible with commercial and Defence aviation CCR system.
• Remote control system for accessing CCR and allied system over serial or TCP.
• Indigenized local Support/presence in India.
• Easy in configuration using DIP switches.
Technical Specifications
Indigenized remote control interface card suitable for MAFI system CCR equipment. Compatible for IDM8000 CCR. Backplane mounted serial and TCP/Ethernet communication module for CCR remote access. IDM 8000 CCR remote control on serial and TCP protocol.
Key Features
Indigenized remote control interface card suitable for MAFI system CCR equipment. Compatible for IDM8000 CCR. Backplane mounted serial and TCP/Ethernet communication module for CCR remote access. IDM 8000 CCR remote control on serial and TCP protocol.
• Remote control: Parallel or serial interface
• Compatible with MAFI CCR system
• Copatiable with IDM8000 CCR
• Compatible with Backplane mount serial communication.
• Compatible with commercial and Defence aviation CCR system.
• Remote control system for accessing CCR and allied system over serial or TCP.
• Indigenized local Support/presence in India.
Application
• Remote control: Parallel or serial interface.
• Compatible with MAFI CCR system.
• Compatible with IDM8000 CCR.
• Compatible with Backplane mount serial communication.
• Compatible with commercial and Defence aviation CCR system.
• Remote control system for accessing CCR and allied system over serial or TCP.
• Indigenized local Support/presence in India.
• Easy in configuration using DIP switches.
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Maintaining high-quality standards in the production of TMT bars is crucial for ensuring structural integrity in construction. Addressing common defects through careful monitoring, standardized processes, and advanced technology can significantly improve the quality of TMT bars. Continuous training and adherence to quality control measures will also play a pivotal role in minimizing these defects.
Cosmetic shop management system project report.pdfKamal Acharya
Buying new cosmetic products is difficult. It can even be scary for those who have sensitive skin and are prone to skin trouble. The information needed to alleviate this problem is on the back of each product, but it's thought to interpret those ingredient lists unless you have a background in chemistry.
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Data file handling has been effectively used in the program.
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A Design and Analysis of Two Plate Injection Mould Tool For Wi-Fi RouterThermoplastic Product
1. Journal of Science and Technology
ISSN: 2456-5660 Volume 5, Issue 5, Sep-October 2020
www.jst.org.in DOI: https://doi.org/10.46243/jst.2020.v5.i5.pp 10-15
Published by: Longman Publishers 10 | Page
A Design and Analysis of Two Plate Injection Mould Tool For
Wi-Fi RouterThermoplastic Product
S Prasanth1
, S Akhil2
, S Ramesh3
, B Pavan Kumar4
, Y Hemanth5
,
M Sandeep6
1
(Assistant Professor, Satya Institute of Technology and Management,Vizianagaram, India).
2,3,4,5,6
(Mechanical Department, Satya Institute of Technology and Management,Vizianagaram, India)
1
Corresponding Author: Prasanthsadhu57@gmail.com)
To Cite this Article
S Prasanth, S Akhil, S Ramesh, B Pavan Kumar, Y Hemanth and M Sandeep, “A Design and Analysis of Two Plate
Injection Mould Tool For Wi-Fi RouterThermoplastic Product”, Journal of Science and Technology, Vol. 05,
Issue 05, Sep-October 2020, pp10-15
Article Info
Received: 25-04-2020 Revised: 12-07-2020 Accepted: 25-07-2020 Published: 31-07-2020
Abstract: This A Wi-Fi router is a device that performs the function of a wireless access point, it is used to provide
access to the internet or a private computer. It is the hardware device that provide basic infrastructure for a home
or small office network.Proposed to make a single impression semi-automatic family mould to design top and
bottom cover for Wi-Fi router to make it more aesthetic, to reduce material cost, better heat dissipation, and to
reduce the tooling cost, to make the product more competitive in the market.It is proposed select the suitable plastic
material, to modify the existing plastic product design and to develop a suitable two plate family mould of one
impression each using SIEMENS NX software. It is also proposed to make detailing of mould parts and its assembly
for manufacturing using SIEMENS NX software. The analysis was done in AUTODESK MOLDFLOW. The mould
cost, raw material cost and processing cost per component are to be estimated to find the cost per component and to
compare it with the existing component part.
Keyword: Single impression; Semi automatic; Cost effective; Mouldflow
_____________________________________________________________________________________
I. Introduction
This project report mainly focused on the product of “WIFI ROUTER”.This project fully concentrate to
how to make the “INJECTION MOULD “for by using the least economic processing and tooling method and it also
help to get the very deep knowledge about the “Role Of CAD/CAM Technology In Modern Mould Making
Industries “which is playing a fantastic role in the modern age.Finally the aim of the project is to estimation of the
mould which should be least economic and also introduced the new sense in CAD/CAM.
Over the years plastics replacing other materials like, metals, glass, wood, etc. because of its impressive
advantages over others such as light weight, faster production, low cost, non-corrosiveness, wide range of colour
possibilities with great design freedom to achieve aesthetic appearance and wide range of material availability to suit
the functional requirements. In addition to the above advantages plastics has great advantage of moulding many
smaller parts into one single part to reduce assembly time and to improve part strength.
Varieties of processing techniques are used to transform raw plastics into the objects that we use. Some of the
plastics processing techniques includes; Injection moulding, Blow moulding, Extrusion, Compression moulding,
Transfer moulding, Rotational moulding, Thermo forming, etc. Injection Moulding process is ideally suited to
manufacture mass produced plastic parts of complex shapes requiring precise dimensions with wide range
ofmaterial to use. In this process, hot polymer melt is forced into a cold empty cavity of a desired shape and is then
allowed to solidify under a high holding pressure. The mould is then opened and the part is ejected. The complete
injection moulding cycle includes, mould filling, cooling, and ejection.
II. Design Methodology
Design is the universal term being used everywhere. So a product design deals with conversion of ideas
into reality and aims at fulfilling human needs. The primary concept involved in design is shape, size, aesthetics and
function. This paper highlights the design procedure of a plastic product of wifi router and its injection mould design
2. A Design and Analysis of Two Plate Injection Mould Tool for Wi-Fi Router Thermoplastic Product
11 | Page
Mold
Closing/clamp
Injection
Filling
Phase
and plastic flow analysis of the product. While designing a product the designer should consider some factors such
as need, physical reliability, financial feasibility, optimality, design criterion, design process, etc. designing a plastic
product checklist has to be prepared to evaluate the product in order to evaluate the product design. The emphasis on
designing with engineering plastics are wall thickness, parting line, ribs, bosses, gussets, radii, gate size and
location, location of ejector pins, tolerances, shrinkage, surface finish etc. For production this plastic product
injectionmould is selected for this process because the material selected is polystyrene(PS). So while designing a
plastic injection mould the designer can economise the tooling of the mould by selecting standard steel grades, steel
sizes and standard machined plates. The injection mould is mainly divided into two parts,
1. Fixed half(where the melted plastic flows into the component area through this half),
2. Moving half(here the injected plastic gets cooled and ejected by using the external source of injection
moulding machine).
Finally while designing the mould the designer should consider the type the moulding machine, parting line,
ejection system, feed system, etc,.
III. CAD/CAM for Mould Design
Mould designing is practically based on requirement of opening system, runner system, moulding process,
type of material to be injected, cavity layout, etc,.this paper consists of conceptual design of the product, design of
the mould, plastic flow analysis of the product and detailing of the product and mould. For this CAD/CAM software
are used to design and analyse.
1. The designer should consider the ease of manufacturability, assembly and positive ejection of the
component within the minimal time and cost to produce a good FRP component.
2. The component was carried out in SIEMENS NX software.
3. The two plate single cavity mould design was carried out in SIEMENS NX software.
4. The plastic flow analysis is done to the component in AUTODESK MOLDFLOW software.
5. The detailing of the component was done in SIEMENS NX software.
Fig.2 shows the Flowchart for practical tool design and Manufacture. The flow chart of the methodology
followed for the manufacturing of mould design is as follows.
Fig.1 Standard Two PlateMould Fig.2 Flowchart for practical tool design and Manufacture
Fig. 3 Injection mould cycle
3. A Design and Analysis of Two Plate Injection Mould Tool for Wi-Fi Router Thermoplastic Product
12 | Page
IV. Injection Mould Cycle
Time for producing the required component during the injection mould is closed and process takes place is
called cycle time. Cycle time ranges from 20 sec to 60 sec which produces the component s at high production rate
with good dimensional ability, tolerance and surface finish.
Injection mould is most commonly used process to produce a component at lowest price, high production
rate, good surface finish, tolerance and dimensionability. The cyclic process takes place in three phases namely,
(i)filling, (ii) packing,(iii) cooling. During the first phase the melted plastic flows from the nozzle of injection mould
machine to the parts cavity to get the designed shape through locating ring, sprue bush, runner, gate, cavity. Later
packing phase starts where additional melted plastic enters to get the parts shrinkage during the process. Now the
cooling phase starts that is the melted plastic gets cooled and takes the designed or machined shape of the
component by using external cooling agents gets contact with the plastic through jackets designed in the mould.
During these phases the plastic gets shape due to its properties, machine parameters, and machine process makes
products more fabrication complex. After this phase the component gets ejected through the mould by using ejector
pins with the support of ejector plate, ejector back plate etc,.
Component Detail:
Component Name: WI-FI Router
Component Material: Poly Styrene(PS)
Shrinkage: 1.5%
Component Weight: 16.96gms
Moulding Type: Single Cavity Moulding Tool
Fig. 4 3D ComponentDetails[2] Fig. 5 Full Tool assembly [2]
4. A Design and Analysis of Two Plate Injection Mould Tool for Wi-Fi Router Thermoplastic Product
13 | Page
Fig. 6 MovingHalf [2] Fig. 7 Fixed Half[2]
V. Need for Simulation
The process of producing plastic component using injection moulding process is more complexible because it is
based on the right combination of the material, part and mould design and processing parameters. Due to this
defects may occur which leads to high costs. For this the optimal setting up of injection moulding process variables
plays a very important role. For this computer aided Engineering (CAE) tool can be used to simulate a wide variety
of phenomenon that occur during the manufacturing of plastic parts.
The simulation of mould filling in injection process can be presented. The simulation results can be used to
correct the defects on the final part by adjusting process settings or modifying the mould design. Injection
moulding process is a challenging process for many manufacturers to produce products at lower rate. If the error
occurs the rework tooling process increases the component cost. For this the calculation should be done beforely
and correctly. For this computer aided engineering (CAE) is adopted to reduce the cost of the product to reducer
errors occurred during the process. For this AUTODESK MOULDFLOE will help the designer to estimate
required caiculations, values, and errors easily.
VI. Mould Flow Analysis
The mould flow analysis is to be done before the moulding process to get finalized to know the filling time,
injection pressure, air traps, weld lines errors etc., in AUTODESK MOULDFLOW the moldflow analysis was
done in the following process;
1. First of all 3D designed component is to be converted to STEP file format.
2. Open the autodeskmoulflowcummilator software.
3. Import the step file of the designed component.
4. Now select the injection location.
5. Select the material and start analyse by which the properties of component is known to it.
6. When the analyzing is completed start reviewing results.
By this it shows the filling time, injection pressure, air traps, confidence of fill, temperature etc,.
by this software we can also produce pack analysis, cooling analysis, wrap analysis, runner position, gate location.
Fill Analysis:
The Thermoplastic polymer flow inside the mould during filling phase is known by fill analysis. This analysis
calculates the time for filling the molted plastic material inside the mould during process from injection location.it
5. A Design and Analysis of Two Plate Injection Mould Tool for Wi-Fi Router Thermoplastic Product
14 | Page
also shows the velocity pressure switchover point. It produces the results by calculating on four laminates through
the thickness and symmetrical cooling boundary conditions are assumed.
Fig. 8 Fill time plot
Injection Pressure:
In plastic flow analysis process the injection pressure is analysed that is the pressure distribution required
for the flow path inside the mould at the time of result was shown. Actually polymer always moves in the direction
of the negative pressure gradient from higher pressure to lower pressure gradient. Thus the maximum pressure
always occur at the polymer injection locations and the minimum pressure occurs furing the filling stage when it is
in melt front. The colour at each place on the model represents the pressure at the place on the model. Fig shows two
colours that is red(highest pressure) and blue(lowest pressure).
Fig. 9 InjectionPressuredistribution
Temperature Flow Front:
For mould flow process the temperature plays a prominent role. Because it is very important to the value because to
know the tempearature at which the plastic should be melted to maintain a constant flow in the mould during fillig
process. Here the figure shows the two colours that is red (highest temperature) and blue (*lowest temperature).
6. A Design and Analysis of Two Plate Injection Mould Tool for Wi-Fi Router Thermoplastic Product
15 | Page
Fig.10 Temperature Flow Front
VII. Conclusion
Thus the existing Wi-Fi router is made in two different mould for top and bottom cover. So the mold cost is high. In
case, in our project we made the family mold for top and bottom cover of Wi-Fi router to reduce the mold cost as we
compared to the existing mold cost. With aesthetics look for component as per customer requirement.
Along with all these above mentioned information project component drawing in 2D & 3D has been drawn with
accurate dimensions mold design for the component has also been finished in 2D, with core & cavity extraction
done using 3D, core insert, cavity insert denoting feed system, cooling system, has been extracted and shown in the
report, the injection side and ejection side of the mold has also been drawn with closed views.
The mold drawing has been drawn using auto cad software, the mold drawing consists of plan view, inverted plan
view, section AA’, section BB’
A long with bill of material which consists name of the plate/part, size, no of quantity used, heat treatment and
remarks.
We have used a two plate injection family mold to manufacture this component, the material used for manufacturing
the component is Poly Styrene, we have found out product volume, feed system runner diameter, projected area, and
clamping force. The machine selected to manufacture product according to the calculations is Servo 150
injection molding machine.
VIII. References
[1] PK Bharti and MI Khan, Recent Methods for Optimization of Plastic Injection Moulding, International Journal
of Engineering Science and Technology, 2010, 2(9), 4540-4554.
[2] Technical Directory on Design and Tooling for Plastics, CIPET, Mysore, Karnataka, India (2012).
[3] RGW Pai, Injection Mould Design, 4th Edition, Affiliated East-West Press Pvt, 2014.
[4] D Mathivanan, M Nouby and R Vidhya, Minimization of Sink Mark Defects in Injection Moulding Process -
Taguchi Approach, International Journal of Engineering, Science and Technology, 2010, 2 (2), 13-22.
[5] J Nabialek and J Koszkul, Model Optimization for Mould Filling Analysis with Application CAE Package CMould, Journal of Achievements
in Materials and Manufacturing Engineering, 2006, 19 (1), 75-82.
[6]Wong CT, ShamsuddinSulaiman, Napsiah Ismail & AMS Hamouda, Design and Simulation of Plastic Injection
Moulding Process, Pertanika J, Sci&Techno Supplement, 2004,12 (2), 85-99.