International Journal of Research and Innovation (IJRI)
International Journal of Research and Innovation (IJRI) 1401-1402
DESING OF MOULD TOOL & COOLING CHANNEL OPTIMIZATION OF INDUSTRIAL HELMET
Bhonagiri Sudhir kumar1, Kandathil Abraham Mathew2, 1 Research Scholar, Department of Mechanical Engineering, Hyderabad Institute of Technology And Management, Hyderabad, India. 2 Professor, Department of Mechanical Engineering, Hyderabad Institute of Technology And Management, Hyderabad, India.
Abstract A Plastic Material Is Any of A Wide Range of Synthetic Or Semi-Synthetic Organic Solids That Are Moldable. Plastics Are Typically Organic Polymers Of High Molecular Mass, But They Often Contain Other Substances. They Are Usually Synthetic, Most Commonly Derived From Petrochemicals, But Many Are Partially Natural. Molding Is The Process of Manufacturing By Shaping Liquid Or Pliable Raw Material Using A Rigid Frame Called A Mold Or Matrix. This It 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 war page of industrial helmet. Literature survey and data collection will be done to understand working process of cooling channels, effects of war page on plastic part’s, mold optimization.3D model of industrial helmet will be prepared by reverse engineering process Assembly of complete mold will be prepared for further process. Analysis will be carried out on mold cooling channel’s for evaluation and Analysis will be done on different model’s to obtain optimum structure and cooling channel system. Conclusion will be mode according to the obtained results *Corresponding Author:
Materials
Bhonagiri Sudhir kumar, Research Scholar, Department of Mechanical Engineering, Hyderabad Institute of Technology And Management,Hyderabad,India.
Types of synthetic fiber used to make some helmets:
Published: October 29, 2015 Review Type: peer reviewed Volume: II, Issue : VI
In former times lightweight non-metallic protective materials and strong transparent materials for visors were not available. In Greece in ancient times helmets were sometimes strengthened by covering the surface with boars' tusks (= their canine teeth) laid flat.
Citation: Bhonagiri Sudhir kumar, Research Scholar (2015) DESING OF MOULD TOOL & COOLING CHANNEL OPTIMIZATION OF INDUSTRIAL HELMET.
INTRODUCTION TO HELMET A helmet is a form of protective gear worn on the head to protect it from injuries. Ceremonial or symbolic helmets (e.g., English policeman's helmet) without protective function are sometimes used. The oldest known use of helmets was by Assyrian soldiers in 900BC, who wore thick leather or bronze helmets to protect the head from blunt object and sword blows and arrow strikes in combat. Soldiers still wear helmets, now often made from lightweight plastic materials.
• Aramid • Twaron
INJECTION MOLD COOLING DESIGN The design of the injection mold cooling system is very important. The cooling time takes up 70% to 80% of injection molding cycle, a well-designed cooling system can shorten the molding time and improve the productivity magnificently. Poor design of cooling system will extend molding time, increase production cost, and the injection mold temperature has great influence to the mold shrinkage, dimensional stability, deformation, internal stress and surface quality.
In civilian life, helmets are used for recreational activities and sports (e.g., jockeys in horse racing, American football, ice hockey, cricket, and rock climbing); dangerous work activities (e.g., construction, mining, riot police); and transportation . 191
International Journal of Research and Innovation (IJRI)
Usually temperature of the sprue gate area are highest, so the cooling start from there would achieve the best cooling effective, see figure below.
So what are the factors that matter to the cooling effective? Plastic wall-thickness Part with thicker wall would need longer cooling time. Generally, the cooling time is approximately proportional to the square and the thickness of plastic parts. If possible, propose to the part designer to minimum the wall thickness. Cooling system design rules: • Ensure cooling efficiency, achieve shortest the cooling line meanwhile get quality parts. • Ensure uniform cooling to avoid deformation. • Ease of manufacturing. Some examples of injection mold cooling design, If possible, the number of cooling channels should be as many as possible, diameter of the cooling channel should be design as large as possible, cooling speed of A is faster than B as figure below. Diameter of cooling channel usually are 6-12mm.
Cooling channels layout must be reasonable. When the wall thickness of part is uniform, the distance of each channel to the surface of parts should be even, which means the layout of channels should follow the actual geometry of the part, see figure A. When the thickness of the part is un-uniform, then thicker wall area need more cooling, see figure B, the injection mold cooling channel can be closer to the part to enhance the cooling effect.
WARPAGE INTRODUCTION Part warpage, either soon after molding or at some time in-service, is a problem frequently experienced by injection molders and, at times, also by extruders. Similar to mold shrinkage, the causes and control of warpage are closely related to inherent material characteristics and the laws of heat transfer. In this Technical Tip, we explain the causes and general guidelines to minimize warpage. It should be noted that warpage, like mold shrinkage, is a very complex mechanism and many factors, other than those mentioned here, have an effect on warpage. In some cases, a specific variable may have a different effect depending on other factors present. WHAT CAUSES WARPAGE? Warpage of thermoplastic parts can be caused by two mechanisms: the contraction of the polymer during cooling and the tendency of high-molecular-weight molecules to "relax' if they are under stress. The first is easy to understand, as it is a common property of all solids. The second may be compared to stretching a rubber band. As the stress is reduced, the band returns to its original size at a speed related to the rate of stress reduction. However, if the band is “frozen” while stretched, it retains its shape until the temperature increases sufficiently to allow it to “relax” and return to its normal state. CONTROL OF WARPAGE As noted, there are certain polymer material characteristics such as high molecular weight, low heat transfer coefficients, crystallinity, contraction during cooling, etc., which are inherent and cannot be changed. The primary keys to achieving low or minimal warpage are in the design of the part and mold. A thorough review of the factors that cause warpage, conducted at the design stage, can circumvent many problems after the mold has been constructed. INTRODUCTION TO CAD Computer-aided design (CAD), also known as computer-aided design and drafting (CADD), is the use of computer technology for the process of design and designdocumentation. Computer Aided Drafting describes the process of drafting with a computer. CADD software, or environments, provide the user with input-tools for the purpose of streamlining design processes; drafting, docu192
International Journal of Research and Innovation (IJRI)
mentation, and manufacturing processes. CADD output is often in the form of electronic files for print or machining operations. The development of CADD-based software is in direct correlation with the processes it seeks to economize; industry-based software (construction, manufacturing, etc.) typically uses vector-based (linear) environments whereas graphic-based software utilizes rasterbased (pixilated) environments.
Mould flow analysis gives you the ability to maintain the integrity of your product designs. It provides you the tools to quickly optimize part designs and check the impact of critical design decisions on the manufacturability and quality of the product early in the design process.
MODEL OF INDUSTRIAL HELMET
Plastic flow analysis
PLASTIC FLOW ANALYSIS OF INDUSTRIAL HELMET USING MATERIAL POLYPROPYLENE (PP)
The Flow Analysis summary page gives an overview of the model's analysis, including information about actual injection time and pressure and whether weld lines and air traps are present. In addition, the dialog uses the Confidence of Fill result to assess the mould ability of the part.
The above image shows sketcher
The above image shows Plastic flow analysis
Fill Time
The above image shows adding ribs
This result shows the flow path of the plastic through the part by plotting contours which join regions filling at the same time. These contours are displayed in a range of colors from red, to indicate the first region to fill, through to blue to indicate the last region to fill. A short shot is a part of the model that did not fill, and will be displayed as translucent. By plotting these contours in time sequence, the impression is given of plastic actually flowing into the mould.
The above image shows final model of industrial helmet
MOULD FLOW ANALYSIS Mould flow, 3D solids-based plastics flow simulation that allows plastics part designers to determine the manufacturability of their parts during the preliminary design stages and avoid potential downstream problems, which can lead to delays and cost overruns. Following are the benefits: • Optimize the part wall thickness to achieve uniform filling patterns, minimum cycle time and lowest part cost Identify and eliminate cosmetic issues such as sink marks, weld lines and air traps. • Determine the best injection locations for a given part design
The above image shows Fill time
Confidence of Fill The confidence of fill result displays the probability of a region within the cavity filling with plastic at conventional injection molding conditions. This result is derived from the pressure and temperature results.
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International Journal of Research and Innovation (IJRI)
PLASTIC FLOW ANALYSIS OF INDUSTRIAL HELMET USING MATERIAL HIGH-DENSITY POLYETHYLENE (HDPE)
The above image shows Confidence of fill
The above image shows Flow front temperature
The above image shows Fill time The above image shows Quality indication
The above image shows Confidence of fill
PP
ABS
HDPE
Injection Time:
2.73 sec
3.18 sec
4.05 sec
Injection Pressure:
61.91 MPa
98.57 MPa
106.90 MPa
Surface Temperature Variance Range
-14.45 deg.C to 19.34 deg.C
-21.44 deg.C to 21.29 deg.C
-21.44 deg.C to 21.29 deg.C
Freeze Time Variance Range
-2.38 sec to 4.33 sec
-2.41 sec to 4.53 sec
-2.41 sec to 4.53 sec
Cycle Time:
18.34 sec
21.65 sec
15.58 sec
MOULD EXTRACTION
The above image shows cooling quality
The above image shows parting surface
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International Journal of Research and Innovation (IJRI)
The above image shows core
The above image shows meshed model
The above image shows cavity
INTRODUCTION TO ANSYS ANSYS is general-purpose finite element analysis (FEA) software package. Finite Element Analysis is a numerical method of deconstructing a complex system into very small pieces (of user-designated size) called elements. The software implements equations that govern the behaviour of these elements and solves them all; creating a comprehensive explanation of how the system acts as a whole. These results then can be presented in tabulated, or graphical forms. This type of analysis is typically used for the design and optimization of a system far too complex to analyze by hand. Systems that may fit into this category are too complex due to their geometry, scale, or governing equations.
The above image shows load applied
ANSYS is the standard FEA teaching tool within the Mechanical Engineering Department at many colleges. ANSYS is also used in Civil and Electrical Engineering, as well as the Physics and Chemistry departments. THERMAL ANALYSIS ON INDUSTRIAL HELMET WITH STRAIGHT COOLING CHANNELS WITH WATER AS COOLANT
The above image shows imported model
The above image shows temperature
The above image shows total heat flux
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International Journal of Research and Innovation (IJRI)
THERMAL ANALYSIS ON INDUSTRIAL HELMET WITH ZIGZAG COOLING CHANNELS WITH WATER AS COOLANT
water
glycol
Straight
Zigzag
spiral
Straight
Zigzag
Spiral
temperature
200
200
200
200
200
200
total heat flux
5.9198e14
6.8771e15
4.7871e14
1.3172e14
6.8771e15
6.9655e15
Directional heat flux in X
5.0854e14
4.9278e15
4.6474e14
7.3145e15
4.9278e15
5.8607e15
Directional heat flux in Y
8.2583e15
3.9391e15
4.6989e14
3.0377e15
3.9391e15
5.1032e15
Directional heat flux in Z
2.9329e14
4.2854e15
2.0568e14
3.5655e15
4.2854e15
5.0786e15
GRAPHS FOR ANALYSIS RESULTS The above image shows temperature
The above image shows total heat flux
THERMAL ANALYSIS ON INDUSTRIAL HELMET WITH SPIRAL COOLING CHANNELS WITH WATER AS COOLANT
The above image shows temperature
The above image shows total heat flux
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International Journal of Research and Innovation (IJRI)
3)Design and Analysis of Industrial Safety Helmet using Natural Fibers Rajasekar.K PG Student, Department of Mechanical Engineering, Narayanan.L Assistant Professor, Department of Mechanical Engineering 4)The Damping of Off-Central Impact for Selected Industrial Safety Helmets Used in Poland Ryszard Korycki, Department of Technical Mechanics, Technical University of £o´dz´, Poland 5)INTERNATIONAL JOURNAL OF OCCUPATIONAL SAFETY AND ERGONOMICS 6) Improving Thermal Comfort in Industrial Safety Helmet using Phase Change Material
CONCLUSION • In this project, we have designed an Industrial Helmet as per the parameters. • Core and Cavity is extracted for the Helmet. • Die design is prepared for the same. • The modeling, core-cavity extraction and die design is done in PRO/ENGINEER. • Mould Flow Analysis is done on Helmet, We are using mould flow analysis for finding the material filling, pressure distribution during injection molding process.
7) GOWTHAM VIGNESWARAN1, L. ARULMURUGAN2 K.S.Rangasamy College of Technology, 8)Design and Analysis of Multi-Funtional Helmet for the Industries A.V. PRADEEP *, R. SURYA KIRAN ** *(Department of Mechanical Engineering, Sankethika Vidya Parishad, Visakhapatnam-45,India) 9)Fabrication of Industrial Safety Helmet by using Hybrid Composite Materials B.Murali, D.Chandramohan, S.K.Nagoor Vali and B.Mohan,Department of Mechanical Engineering,Veltech ,Avadi,Chennai, India
Author
• Mould Flow Analysis is done using “Plastic Advisor” which is a module in Pro/Engineer. • By simulating the plastic-filling process for injectionmolded parts, Pro/ENGINEER Plastic Advisor enables engineers to design for manufacturability, uncover problems, and propose remedies, reducing development time and expense. • ASPER THE ANALYSIS GLYCOL SPIRAL WILL PROVIDE GOOD THERMAL TRANSPORTATION WHICH REDUCES WARPAGE TO THE COMPONENT WHILE DOING MANUFACTURING.
Bhonagiri Sudhir kumar, Research Scholar, Department of Mechanical Engineering, Hyderabad Institute of Technology And Management, Hyderabad,India.
• ASPER THE MOULD FLOW ANALYSIS RESULTS PP MATERIAL IS BETTER WHILE CONSIDERING MANUFACTURING PARAMETERS LIKE PRESSURE, FLOW QUALITY AND FILL TIME. • By using this process manufacture of Helmet can be done without any failures…. REFERENCES 1)Improving thermal properties of industrial safety helmets Yeh-Liang Hsu*, Chi-Yu Tai, Ting-Chin Chen Department of Mechanical Engineering, Yuan Ze University, Chung Li 320, Taoyuan, Taiwan, ROC
Kandathil Abraham Mathew, Professor , Department of Mechanical Engineering, Hyderabad Institute of Technology And Management, Hyderabad,India.
2) Design and Analysis of Industrial Helmet 1Anil Kumar. K, 2Y. Suresh babu M.Tech 1,2Department of Mechanical Engineering, Rajiv Gandhi Memorial College of Engineering & Technology, Affiliated to J.N.T.University Anantapur, Nandyal,
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