This case study describes the process of redesigning a metal component for a water treatment system out of plastic. The objectives were to reduce costs through plastic injection molding while meeting structural and pressure requirements. Engineers redesigned the component, selected reinforced PA-12 plastic, optimized the design for manufacturability through moldflow analysis. They addressed challenges like porosity and sink marks through experimentation and process control. This improved quality and reduced costs compared to the metal component.
We Plast-pro having very qualified and well experienced professionals to understand and fulfill client’s requirements at its best level. We are offering some services by collaborating with experts in that domain and these experts guide & trained us to provide best and perfect services for our customers.
Plast-Pro Solutions [Pune] are known to be among the most eminent organizations involved in offering a broad array of Mold flow CAE Capabilities, Mold Cooling Analysis and Optimization, Designing Services, Product Modeling Service and Plastic Filing Case.
Forwa is a local precise injection mould maker in Dongguan with 13 year experience, 3600 sq.m workshop, 150 workers, , ISO9001 and ISO4001 certified, 45 minutes to Shenzhen port, equiped with 20 injection machine for mold trials and part production.
Specialzing in: super high precision moulds and special moulds like insert mould,double injection moulds(2K injection mould), overmould, Unscrew injection mould for OA, House electronic application, Automobile and Communication etc industry.
Minimization of the Casting Defects Using Taguchi’s Methodinventionjournals
This paper is relates with casting defects like pinholes, scabs, sand holes, slag, mould shifting, parting line defects, runner & riser defects which mainly occurs in valve casting in foundry. The research on controlling the casting defects in foundry shop which comes in various check valves -PN 10 and these causes may results the reduction of quality of casting. Here we have studied minimize the casting defects using Taguchi’s method through change in various parameters like as pouring temperature, green strength, mould hardness and permeability. These experiments were conducted based on standard acceptable and foundry men experience in this casting organization for casting check valves -PN 10 of various sizes & types Significant changes are taken during controlling the parameters. First we collected the data as casting defects from AV VALVE Pvt Ltd, Agra. Identify The major defects which are scab, cold shut and shrinkage. Complete this task we analyze the cause of this casting defects with the help of fish bone diagram. So we conclude that there are four parameters responsible for these casting defects. 1. Pouring Temperature (oC) 2. Sand Particle Size (AFS) 3.Mould Hardness Number 4. Permeability Number First we define the range of these parameters and then we perform the casting process at different trial and find that average percentage rejection is 6.25 of the casting product. Then we apply the Taguchi’s method and use of MINITAB 17 software to find out the optimum solution. These optimum solutions were applied on casting process and the calculated the percentage rejection 4.416 of the products. Thus we could improve 1.25% in casting defects.
The injection molding process itself is a complex mix of time, temperature and pressure
variables with a multitude of manufacturing defects that can occur without the right combination of
processing parameters and design components. Determining optimal initial process parameter
settings critically influences productivity, quality, and costs of production in the plastic injection
molding (PIM) industry. Up to now, most production engineers have used trial-and-error method to
determine initial settings for a number of parameters, including melt temperature, injection pressure,
injection velocity, injection time, packing pressure, packing time, cooling temperature, and cooling
time which depend on the engineers’ experience and intuition to determine initial process parameter
settings. However, the trial-and-error process is costly and time consuming.
We Plast-pro having very qualified and well experienced professionals to understand and fulfill client’s requirements at its best level. We are offering some services by collaborating with experts in that domain and these experts guide & trained us to provide best and perfect services for our customers.
Plast-Pro Solutions [Pune] are known to be among the most eminent organizations involved in offering a broad array of Mold flow CAE Capabilities, Mold Cooling Analysis and Optimization, Designing Services, Product Modeling Service and Plastic Filing Case.
Forwa is a local precise injection mould maker in Dongguan with 13 year experience, 3600 sq.m workshop, 150 workers, , ISO9001 and ISO4001 certified, 45 minutes to Shenzhen port, equiped with 20 injection machine for mold trials and part production.
Specialzing in: super high precision moulds and special moulds like insert mould,double injection moulds(2K injection mould), overmould, Unscrew injection mould for OA, House electronic application, Automobile and Communication etc industry.
Minimization of the Casting Defects Using Taguchi’s Methodinventionjournals
This paper is relates with casting defects like pinholes, scabs, sand holes, slag, mould shifting, parting line defects, runner & riser defects which mainly occurs in valve casting in foundry. The research on controlling the casting defects in foundry shop which comes in various check valves -PN 10 and these causes may results the reduction of quality of casting. Here we have studied minimize the casting defects using Taguchi’s method through change in various parameters like as pouring temperature, green strength, mould hardness and permeability. These experiments were conducted based on standard acceptable and foundry men experience in this casting organization for casting check valves -PN 10 of various sizes & types Significant changes are taken during controlling the parameters. First we collected the data as casting defects from AV VALVE Pvt Ltd, Agra. Identify The major defects which are scab, cold shut and shrinkage. Complete this task we analyze the cause of this casting defects with the help of fish bone diagram. So we conclude that there are four parameters responsible for these casting defects. 1. Pouring Temperature (oC) 2. Sand Particle Size (AFS) 3.Mould Hardness Number 4. Permeability Number First we define the range of these parameters and then we perform the casting process at different trial and find that average percentage rejection is 6.25 of the casting product. Then we apply the Taguchi’s method and use of MINITAB 17 software to find out the optimum solution. These optimum solutions were applied on casting process and the calculated the percentage rejection 4.416 of the products. Thus we could improve 1.25% in casting defects.
The injection molding process itself is a complex mix of time, temperature and pressure
variables with a multitude of manufacturing defects that can occur without the right combination of
processing parameters and design components. Determining optimal initial process parameter
settings critically influences productivity, quality, and costs of production in the plastic injection
molding (PIM) industry. Up to now, most production engineers have used trial-and-error method to
determine initial settings for a number of parameters, including melt temperature, injection pressure,
injection velocity, injection time, packing pressure, packing time, cooling temperature, and cooling
time which depend on the engineers’ experience and intuition to determine initial process parameter
settings. However, the trial-and-error process is costly and time consuming.
Optimization of Material Removal Rate & Surface Roughness in Dry Turning of M...IJERA Editor
Optimization of machining parameters is valuable to maintain the accuracy of the components and to minimize
the cost of machining. Surface finish is an important measure for the quality of the machined parts. The present
work is an experimental investigation to study the effect of machining parameters on Material Removal Rate
and Surface Roughness in dry turning of medium carbon steel EN19. Taguchi’s single objective optimization
method was used to find the effect of input parameters on the responses. The experiments were conducted as per
Taguchi’s L9 Orthogonal Array on CNC lathe under dry conditions. Cutting parameters of speed, feed and
depth of cut were taken as inputs and machining was done by PVD TiAlN tool. Regression models for the
responses were prepared by using MINITAB-16 software. Analysis of variance (ANOVA) was used to find the
influence of machining parameters on the responses. From the ANOVA results, it is clear that speed has high
influence followed by feed and depth of cut has very low influence in achieving the optimum values for both
Material Removal Rate and Surface Roughness. Finally, experimental and Regression values of responses were
compared. From the results, it is found that both the values are close to each other hence, the regression models
prepared were more accurate and adequate. Percentage of errors between experimental and regression values
were calculated and they found in the range of ±0.20.
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
Piping Training course-How to be an Expert in Pipe & Fittings for Oil & Gas c...Varun Patel
Course Description
Piping a must know skill to work in Oil & Gas and similar Process Industries.
Oil and Gas industry is become a very competitive in the current time. Getting right mentor and right exposer within industry is difficult. With limited training budget spent by company on employee training, it is difficult to acquire the knowledge to success.
Knowing cross-functional skill give you an edge over others in your career success.
This course design based on years of field experience to ensure student will comprehend technical details easily and enjoy overall journey.
Learn in detail every aspect of Pipe & Pipe Fittings used in process industry
•Different types of Pipe, Pipe fittings (Elbow, Tee, reducers, Caps etc.), Flanges, Gaskets, Branch Connection, Bolting materials
•Materials (Metal-Carbon Steel, Stainless Steel, Alloy Steel etc. Non-Metal- PVC/VCM, HDPE, GRE-GRP etc.)
•Manufacturing methods
•Heat treatment requirements
•Inspection and Testing requirements (Non Destructive Testing, Mechanical & Chemical testing)
•Dimensions & Markings requirements
•Code & Standard used in piping
Content and Overview
With 2 hours of content including 30 lectures & 8 Quizzes, this course cover every aspect of Pipe, Pipe fittings, flanges, gaskets, branch connections and bolting material used in Process Piping.
This Course is divided in three parts.
1st part of the course covers fundamental of process industries. In this Part, you will learn about fundamental process piping. You will also learn about Code, Standard & Specification used in process industries.
2nd part cover various types of material used in process industries. In this part, you will learn about Metallic and Non-Metallic material used to manufacture pipe and other piping components.
3rd parts covers in detail about pipe and piping components used in Process piping. In this part we will learn about Industry terminology of Piping components, types of industrial material grade used in manufacturing and entire manufacturing process of these components. You will learn about different manufacturing methods, Heat treatment requirements, Destructive and Non-destructive testing, Visual & Dimensional inspection and Product marking requirements.
Upon completion, you will be able to use this knowledge direct on your Job and you can easily answer any interview question on pipe & fittings.
Estimation Of Optimum Dilution In The GMAW Process Using Integrated ANN-SAIJRES Journal
To improve the corrosion resistant properties of carbon steel usually cladding process is used. It is a process of depositing a thick layer of corrosion resistant material over carbon steel plate. Most of the engineering applications require high strength and corrosion resistant materials for long term reliability and performance. By cladding these properties can be achieved with minimum cost. The main problem faced on cladding is the selection of optimum combinations of process parameters for achieving quality clad and hence good clad bead geometry. This paper highlights an experimental study to optimize various input process parameters (welding current, welding speed, gun angle, contact tip to work distance and pinch) to get optimum dilution in stainless steel cladding of low carbon structural steel plates using Gas Metal Arc Welding (GMAW). Experiments were conducted based on central composite rotatable design with full replication technique and mathematical models were developed using multiple regression method. The developed models have been checked for adequacy and significance. In this study, Artificial Neural Network (ANN) and Simulated Annealing Algorithm (SA) techniques were integrated labels as integrated ANN-SA to estimate optimal process parameters in GMAW to get optimum dilution.
Optimization of Weld Bead Parameters of Nickel Based Overlay Deposited by Pla...IJERA Editor
Plasma Transferred Arc surfacing is a kind of Plasma Transferred Arc Welding process. Plasma Transferred Arc surfacing (PTA) is increasingly used in applications where enhancement of wear, corrosion and heat resistance of materials surface is required. The shape of weld bead geometry affected by the PTA Welding process parameters is an indication of the quality of the weld. In this paper the analysis and optimization of weld bead parameters, during deposition of a Nickel based alloy Colmonoy on stainless steel plate by plasma transferred arc surfacing, are made and values of process parameters to produce optimal weld bead geometry are estimated. The experiments are conducted based on a five input process parameters and mathematical models are developed using multiple regression technique. The direct effects of input process parameters on weld bead geometry are discussed using graphs. Finally, optimization of the weld bead parameters, that is minimization of penetration and maximization of reinforcement and weld bead width, are made with a view to economize the input process parameters to achieve the desirable welding joint.
BlogWell Chicago Social Media Case Study: Honda, presented by Alicia JonesSocialMedia.org
In her BlogWell Chicago presentation, Honda's National Manager of Honda and Acura Social Marketing, Alicia Jones, talks about how they return the love to their loyal fans and amplify it through social media.
She goes into detail about their "Honda Loves You Back" campaign and shares several of the lessons they learned about engaging customers in social channels.
Optimization of Material Removal Rate & Surface Roughness in Dry Turning of M...IJERA Editor
Optimization of machining parameters is valuable to maintain the accuracy of the components and to minimize
the cost of machining. Surface finish is an important measure for the quality of the machined parts. The present
work is an experimental investigation to study the effect of machining parameters on Material Removal Rate
and Surface Roughness in dry turning of medium carbon steel EN19. Taguchi’s single objective optimization
method was used to find the effect of input parameters on the responses. The experiments were conducted as per
Taguchi’s L9 Orthogonal Array on CNC lathe under dry conditions. Cutting parameters of speed, feed and
depth of cut were taken as inputs and machining was done by PVD TiAlN tool. Regression models for the
responses were prepared by using MINITAB-16 software. Analysis of variance (ANOVA) was used to find the
influence of machining parameters on the responses. From the ANOVA results, it is clear that speed has high
influence followed by feed and depth of cut has very low influence in achieving the optimum values for both
Material Removal Rate and Surface Roughness. Finally, experimental and Regression values of responses were
compared. From the results, it is found that both the values are close to each other hence, the regression models
prepared were more accurate and adequate. Percentage of errors between experimental and regression values
were calculated and they found in the range of ±0.20.
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
Piping Training course-How to be an Expert in Pipe & Fittings for Oil & Gas c...Varun Patel
Course Description
Piping a must know skill to work in Oil & Gas and similar Process Industries.
Oil and Gas industry is become a very competitive in the current time. Getting right mentor and right exposer within industry is difficult. With limited training budget spent by company on employee training, it is difficult to acquire the knowledge to success.
Knowing cross-functional skill give you an edge over others in your career success.
This course design based on years of field experience to ensure student will comprehend technical details easily and enjoy overall journey.
Learn in detail every aspect of Pipe & Pipe Fittings used in process industry
•Different types of Pipe, Pipe fittings (Elbow, Tee, reducers, Caps etc.), Flanges, Gaskets, Branch Connection, Bolting materials
•Materials (Metal-Carbon Steel, Stainless Steel, Alloy Steel etc. Non-Metal- PVC/VCM, HDPE, GRE-GRP etc.)
•Manufacturing methods
•Heat treatment requirements
•Inspection and Testing requirements (Non Destructive Testing, Mechanical & Chemical testing)
•Dimensions & Markings requirements
•Code & Standard used in piping
Content and Overview
With 2 hours of content including 30 lectures & 8 Quizzes, this course cover every aspect of Pipe, Pipe fittings, flanges, gaskets, branch connections and bolting material used in Process Piping.
This Course is divided in three parts.
1st part of the course covers fundamental of process industries. In this Part, you will learn about fundamental process piping. You will also learn about Code, Standard & Specification used in process industries.
2nd part cover various types of material used in process industries. In this part, you will learn about Metallic and Non-Metallic material used to manufacture pipe and other piping components.
3rd parts covers in detail about pipe and piping components used in Process piping. In this part we will learn about Industry terminology of Piping components, types of industrial material grade used in manufacturing and entire manufacturing process of these components. You will learn about different manufacturing methods, Heat treatment requirements, Destructive and Non-destructive testing, Visual & Dimensional inspection and Product marking requirements.
Upon completion, you will be able to use this knowledge direct on your Job and you can easily answer any interview question on pipe & fittings.
Estimation Of Optimum Dilution In The GMAW Process Using Integrated ANN-SAIJRES Journal
To improve the corrosion resistant properties of carbon steel usually cladding process is used. It is a process of depositing a thick layer of corrosion resistant material over carbon steel plate. Most of the engineering applications require high strength and corrosion resistant materials for long term reliability and performance. By cladding these properties can be achieved with minimum cost. The main problem faced on cladding is the selection of optimum combinations of process parameters for achieving quality clad and hence good clad bead geometry. This paper highlights an experimental study to optimize various input process parameters (welding current, welding speed, gun angle, contact tip to work distance and pinch) to get optimum dilution in stainless steel cladding of low carbon structural steel plates using Gas Metal Arc Welding (GMAW). Experiments were conducted based on central composite rotatable design with full replication technique and mathematical models were developed using multiple regression method. The developed models have been checked for adequacy and significance. In this study, Artificial Neural Network (ANN) and Simulated Annealing Algorithm (SA) techniques were integrated labels as integrated ANN-SA to estimate optimal process parameters in GMAW to get optimum dilution.
Optimization of Weld Bead Parameters of Nickel Based Overlay Deposited by Pla...IJERA Editor
Plasma Transferred Arc surfacing is a kind of Plasma Transferred Arc Welding process. Plasma Transferred Arc surfacing (PTA) is increasingly used in applications where enhancement of wear, corrosion and heat resistance of materials surface is required. The shape of weld bead geometry affected by the PTA Welding process parameters is an indication of the quality of the weld. In this paper the analysis and optimization of weld bead parameters, during deposition of a Nickel based alloy Colmonoy on stainless steel plate by plasma transferred arc surfacing, are made and values of process parameters to produce optimal weld bead geometry are estimated. The experiments are conducted based on a five input process parameters and mathematical models are developed using multiple regression technique. The direct effects of input process parameters on weld bead geometry are discussed using graphs. Finally, optimization of the weld bead parameters, that is minimization of penetration and maximization of reinforcement and weld bead width, are made with a view to economize the input process parameters to achieve the desirable welding joint.
BlogWell Chicago Social Media Case Study: Honda, presented by Alicia JonesSocialMedia.org
In her BlogWell Chicago presentation, Honda's National Manager of Honda and Acura Social Marketing, Alicia Jones, talks about how they return the love to their loyal fans and amplify it through social media.
She goes into detail about their "Honda Loves You Back" campaign and shares several of the lessons they learned about engaging customers in social channels.
Vision of Ray Croc for McDonald's. McDonald's current position in international market. SWOT analysis for McDonald's. PESTEL analysis for McDonald's. Porter's Five forces of market. Conclusion. McDonald's customer satisfaction approach of business. King of international fast food chain.
Management 315: International Management, Professor In Hyeock Lee
Loyola University Chicago Spring 2013
This case study analyzes Honda's overall performance as a multinational enterprise using the company's revenue data, 4 distances, firm specific advantages, country specific advantages, foreign direct investment, and much more.
Broad analisis of the biggest company in the world. It includes WalMart history, internal and external analysis and a focus on WalMart's internationalization with some suggestions for the future.
Analysis of Wal-Mart using some Strategic Management tools:
*** Value Chain
*** Strategic Position And Action Evaluation (SPACE)
*** Resource & Capabilities analysis
***
This presentation will cover pipe support design, 3D modeling, Finite Element Analysis, special stress and thermal cases, along with the unique cases that brought on new pipe support designs. Increase your understanding of the value-added services that are offered by PT&P.
This presentation will cover pipe support design, 3D modeling, Finite Element Analysis, special stress and thermal cases, along with the unique cases that brought on new pipe support designs. Increase your understanding of the value-added services that are offered by PT&P, and rest assured that your Engineering and Design needs can be covered by our 24x7 web-based emergency services, providing field service, and quick-turn around time when you need it most. We look forward to having you join us for this complimentary presentation on Engineering and Design of Pipe Supports.
Blending of traditional hot forging practice with the latest technologies in computational simulation,sensing and closed loop controls,to improve process efficiency.
This presentation will cover pipe support design, 3D modeling, Finite Element Analysis, special stress and thermal cases, along with the unique cases that brought on new pipe support designs. Increase your understanding of the value-added services that are offered by PT&P, and rest assured that your Engineering and Design needs can be covered by our 24x7 web-based emergency services, providing field service, and quick-turn around time when you need it most.
DESING OF MOULD TOOL & COOLING CHANNEL OPTIMIZATION OF INDUSTRIAL HELMETIjripublishers 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 It May Have Been Made Using A Pattern Or Model of The Final Object.
This presentation will cover pipe support design, 3D modeling, Finite Element Analysis, special stress and thermal cases, along with the unique cases that brought on new pipe support designs. Increase your understanding of the value-added services that are offered by PT&P, and rest assured that your Engineering and Design needs can be covered by our 24x7 web-based emergency services, providing field service, and quick-turn around time when you need it most.
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.
Detail proposal of project including activities such as Deliverables, Scope, Resources, Proposed Approach, Scheduling in Microsoft Project, Costs, Potential Problems, Critical Path Analysis, Linear Responsibility Chart, Evaluation Methods and Budget.
3. Product History
• The product is called as OPM Double & it is used in the assembly
of the water treatment system. First the component was developed
in metal. The product cost was too high.
• The part was made by assembling two parts to form one parts
• The component should withstand the continuous operating
pressure of 100 psi & it should pass all the product approval
procedures like leakage test, bursting test, etc
• It was a very challenging task to convert the thick walled
component (thickness around: - 8mm) into plastics & that to which
needs to be manufactured by injection molding process.
•After doing the product engineering we successfully injection
molded the component defect free.
4. Objective
• Metal to plastics substitution of the product & to make it feasible
to mold with the injection molding process.
• Product Re-Engineering using Moldflow & Structural Analysis
softwares.
• Plastic Product Design validation to match the customer’s
requirement.
• Process monitoring to ensure consistency in the quality of the
part.
5. Approach
• Studying the existing metal design & re-designing the component
considering plastic product design guidelines.
•Material selection considering customer’s requirement.
• Validation of product design & process parameters optimization
using Moldflow Software.
• Validating the design with structural point of view using FEA
Software.
• Mold-Design of the component.
• Mold-Trials to freeze the process parameters i.e. flow rate, cooling,
packing profile, mold temp, weight of component, etc.
• Process monitoring for achieving consistency in the quality of the
part.
• Part approval from the customer.
• Project Sign-off.
6. Component Application.
The image shows the assembly of the water treatment system.
The part is assembled in the area marked in the plot.
Filtration System
OPM (Part).
7. Material Selection Criteria
• The component should withstand the pressure of 100psi & it should
qualify for the bursting pressure as per the product requirements given by
the customer
• The component is used in water application hence the plastic material
should have lower water absorption.
• Good Dimensional Stability.
• The component will be in contact with water, so the material grade should
comply to the FDA & ROHS regulations (i.e. material grade should be NSF
approved & it restrict the use of lead,cadmium,mercury,etc).
• Component should be light in weight
8. Material Details
General Details
Physical Properties
Material Description
PA-12, 43% glass reinforced. NSF 61listing in several colors. FDA compliance. Low water absorption.
Hydrolytic stability. Dimensional stability. Suitable for fluid engineering applications including pump
housing, pump impellers & water meter components.
11. Challenges
Following were the challenges faced during the Product
Development: -
1. Being a thick walled component, molding the part defect free with the
injection molding process was a challenge. There was a problem of porosity
& sink marks in the thick areas which was affecting the quality of the part.
2. Longer Injection molding cycles due to higher cooling time.
3. As the length of the part was long, core-deflection was a major concern
4. High Level rejections of the product in production.
5. Optimization of the Process-parameters used for Injection molding of the
part.
12. Value Engineering
Old Metal Design
Modified Design in Plastics
12
Initially part was designed in metal by the client as shown in the top most image. Polysmart
studied the product application in details & designed the entire system in Plastics in two
parts without affecting the end application of the part.
13. Product Optimization
Further research was done on the part & finally the two plastic parts were combined together
to form one single part finally benefiting the client on the product cost without affecting the
end application.
Sr.no Description Metal
Design
Plastic
Design
1. Part Weight
(gms)
2175 344
2 Part Cost
(INR)
Above
800/-
Approx
443/-
3. Manufacturing
operations
3-4 1
4. Assembled
Parts
3-4 1
14. DFM Study
After optimizing the product design, the part was studied in detailed with respect to mold
construction & ease of manufacturing. The part was simplified & tool was manufactured
resulting in drastic reduction in the tool cost.
15. Moldflow
Gate Selection Criteria : -
1.Balance Filling at both the extreme ends
2.As there were longer core in the slides, uniform distribution of the injection pressure
is main requirement to control core deflection.
3.As it is a thick walled part, gate was placed in such a way that there should be
sufficient packing provided in the thicker region to overcome the problem of porosity
& sink marks.
16. Core Deflection Analysis
In the core deflection Analysis the constraints were assigned to the core As the side
cores were cantilever & longer in length the main concern was of core deflection
due to injection pressure. The process-parameters were optimized by Moldflow & the
part rejection due to wall thickness variation was reduced drastically.
Core Constraints
Uniform wall thickness observed
in the molded part after optimizing
the results using Core-Deflection
Analysis in Moldflow.
Core Deflection results with
different gating options.
OK Part
17. FEA Analysis
The product was Analyse for thermal loads & as well as structurally to comply to the rule &
regulation specified by the client
21. Causes of Porosity & Sink
Marks
Major aspects considered for Porosity & Sink mark Issues
• MATERIAL
-Discharge gases while molding
- High Moisture Content
- High Shrinkage
- Glass Fiber
Vital & Trivial
Variables
affecting
porosity & sink
marks
• PROCESS
- Shrinkage after Molding
- Material Too Hot
- Injection rate too fast
- Insufficient packing pressure
- Mold temp too high
• DESIGN
• PART • Tool
- Thick Wall Section
- Geometry variations
causes low probability
of the fiber alignment causing
porosity.
- Gate Design
- Gate Location
- Mold Temp
- Mold cooling
- Air Vents.
22. On line Sampling NSF/nonNSF grade Competency
Predrying of material Grinding %age Training
preventive maint of mold & machine Type of grinding
Product Design (*) Percentage of Glass
Annealing Mold Design (*)
Purging
Fiber orientation
Shot weight
Functional Testing Injection rate
dust/dirt Tonnage
ambient temperature Measurement system Barrel temperature
ambient humidity Hold on pressure
Gate type
Mold temperature
MOTHER NATURE Cooling efficiency
Screw-barrel gap
(*)- constraint
Variables in red above are significantly affecting porosity
METHOD
MEASURMENT
Porosity
& Sink
Marks
MACHINE
MATERIAL MAN
CAUSE AND EFFECT DIAGRAM FOR
POROSITY
23. DOE on Shop floor
DOE was done on the shop floor & the finally the optimised process-parameters were
identified by which we were getting the parts defect free.
By conducting DOE
We were able to
optimize the injection
Pressure which was the
main factor for
Core deflection.
24. Process Capability Study
(SPC)
11.511.010.510.09.59.0
USLLSL
Process Capability Analysis for CTQ
PPM Total
PPM > USL
PPM < LSL
PPM Total
PPM > USL
PPM < LSL
PPM Total
PPM > USL
PPM < LSL
Ppk
PPL
PPU
Pp
Cpm
Cpk
CPL
CPU
Cp
StDev (LT)
StDev (ST)
Sample N
Mean
LSL
Target
USL
1.23
0.94
0.29
1.23
0.94
0.29
0.00
0.00
0.00
1.59
1.67
1.59
1.63
1.56
1.59
1.67
1.59
1.63
0.255996
0.255996
30
10.28
9.00
10.20
11.50
Expected LT PerformanceExpected ST PerformanceObserved PerformanceOverall (LT) Capability
Potential (ST) Capability
Process Data
ST
LT
Variation (Before) Variation (After)
After doing the DOE on the shop
floor & deriving the optimised
process setting, Process Capability
Study was used to monitor the
consistency in the Quality of the
part.
27. Conclusion.
Product was re-engineered with respect to plastic product design
guidelines.
Product Design was optimised by combining two different parts to
form one single part, leading to cost saving in Material,
Manufacturing cost & Assembly processes without affecting the end
application.
The longer cycle time was addressed by cooling the 90% of the
part in mould & remaining outside the mould by putting part in water
bath to save on the cycle time & increase productivity.
By applying various methodology of Six Sigma, FEA & Moldflow
we were able to solve the chronic issue of porosity & sink marks
which was affecting the quality of the part.
Process Capability Study was used to precisely monitor the
consistency in the quality of the part.