International Journal of Research and Innovation (IJRI)
International Journal of Research and Innovation (IJRI) DESIGN OF MOULD TOOL & COOLING CHANNEL OPTIMIZATION OF REMOTE CONTROL TOP PANEL Peer Review- 1401-1402 V.Venkata Krishna Mohan, D.Gopichand Mother Theresa Institute of Technology(mist) Sanketika Nagar Sathupally Khammam,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 itself may have been made using a pattern or model of the final object. Cooling channels are used in mold tool to reduce the temperature of the object to help molten material to solidify quickly before the ejection. It is quite useful to increase the production rate. The aim of this project work is to design mold structure and optimize cooling channel system to reduce effect of warpage of remote control top panel. Literature survey and data collection will be done to understand working process of cooling channels, effects of warpage on plastic part’s, mold optimization. 3D model of remote control top panel will be prepared and die design calculations will be done to model the entire mold step. Assembly of complete mold will be prepared for further process. Analysis will be carried out on mold cooling channel’s for evaluation and Analysis will be done on different model’s to obtain optimum structure and cooling channel system. Conclusion will be mode according to the obtained results *Corresponding Author:
V.Venkata Krishna Mohan, Mother Theresa Institute of Technology(mist) Sanketika Nagar Sathupally Khammam,India
Published: Sep 22, 2014 Volume No: I Issue No. : III Citation:V.Venkata Krishna Mohan, D.Gopichand (2014) DESIGN OF MOULD TOOL & COOLING CHANNEL OPTIMIZATION OF REMOTE CONTROL TOP PANEL
Problem Description UN proper cooling effects on surface finish of the component and warpage may occur, due to that part dimensions may get deformed than generic/ modeld part. Generally different types of cooling channels are
used in the field of plastic part manufacturing, it directly effects on surface finish and warpage of the component, even material properties also effect on the same. Methodology The following methods are followed to rectify the above problem Plastic flow analysis will be done using various plastic materials. Thermal analysis will be done on different types of cooling channel systems, to suggest the optimum to ensure sufficient cooling and fill quality. Introduction To Cad Computer Aided Design (CAD) is a technique in which problem solving will be done in the combination of man and machine for high precision work flow. 1
International Journal of Research and Innovation (IJRI)
Computer Aided Design is an interactive process, where the exchange of information between the designer and the computer is made as simple and effective as possible. Computer aided design encompasses a wide variety of computer based methodologies and tools for engineering activity planning, analysis, detailing, drafting, construction, manufacturing, monitoring, management, process control and maintenance. CAD is more concerned with the use of computer-based tools to support the entire life cycle of engineering system. Introduction To Creo Parametric 2.0 (Creo 2.0) CREO PARAMETRIC is one of the most popular PLM software founded by Parametric Technology Corporation which consists of CAD/CAM/CAE. So that designer can easily check their part/product design compatibility with FEM and CAM segments and also they can check plastic flow for injection moldings parts to reduce production/component errors. CREO PARAMETRIC is completely feature based modeling tool with ribbon mode which is very easy to understand by the users. Summary of capabilities Like any software it is continually being developed to include new functionality. The details below aim to outline the scope of capabilities to give an over-
view rather than giving specific details on the individual functionality of the product. Engineering Design Creo parametric 2.0 offers a range of tools to enable the generation of a complete digital representation of the product being designed. In addition to the general geometry tools there is also the ability to generate geometry of other integrated design disciplines such as industrial and standard pipe work and complete wiring definitions. Tools are also available to support collaborative development. A number of concept design tools that provide upfront Industrial Design concepts can then be used in the downstream process of engineering the product. These range from conceptual Industrial design sketches, reverse engineering with point cloud data and comprehensive freeform surface tools. Manufacturing By using the fundamental abilities of the software with regards to the single data source principle, it provides a rich set of tools in the manufacturing environment in the form of tooling design and simulated CNC machining and output. Tooling options cover specialty tools for molding, die-casting and progressive tooling design.
Modeling of remote
The above image shows the 2d sketch of remote using trimmed circles and arcs
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International Journal of Research and Innovation (IJRI)
The above image shows the fillets using round option
The above image shows the completed image of remote
The above image shows 2d drafting of remote
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International Journal of Research and Innovation (IJRI)
Injection Moulding In manufacturing processes Injection moulding plays a crucial role for producing plastic components by using thermo plastic and thermo setting. After completion of product design as per client requirement done by an engineer, molds are prepared by tool maker. For less number of components Aluminum is the better option. For large production better to use steel alloys to maintain good surface finish, dimensional stability. Maximum of components are made by thermo plastic which are recycled (or) reusable. plasticsMaterial is fed into a heated barrel, mixed, and forced into a mold cavity where it cools and hardens to the configuration of the mold cavity Commonly open top components are produced in injection molding which is having minimum thickness of 0.5mm, for good quality of product the wall thickness should be more than 2mm. For remote control panel better to use recycled polypropelene due to good impact resistence, low cost and eco-friendly and it has good structural stability. Process Characteristics • Utilizes a ram or screw-type plunger to force molten plastic material into a mold cavity • Produces a solid or open-ended shape which has conformed to the contour of the mold • Uses thermoplastic or thermoset materials • Produces a parting line, sprue, and gate marks • Ejector pin marks are usually present Injection molding is used to create many things such as wire spools, packaging, bottle caps, automotive dashboards, pocket combs, and most other plastic products available today. Injection molding is the most common method of part manufacturing. It is ideal for producing high volumes of the same object. Some advantages of injection molding are high production rates, repeatable high tolerances, and the ability to use a wide range of materials, low labour cost, minimal scrap losses, and little need to finish parts after molding. Some disadvantages of this process are expensive equipment investment, potentially high running costs, and the need to design moldable parts. Design Molds separate into two sides at a parting line, the A side, and the B side, to permit the part to be extracted. Plastic resin enters the mold through a sprue in the A plate, branches out between the two sides through channels called runners, and enters each part cavitythrough one or more specialized gates. Inside each cavity, the resin flows around cores and conforms to the cavity geometry to form the desired part. The amount of resin required to fill the sprue, runner and cavities
of a mold is a shot. When a core shuts offagainst an opposing mold cavity or core, a hole results in the part. Air in the cavities when the mold closes escapes through very slight gaps between the plates and pins, into shallow plenums called vents. To permit removal of the part, its features must not overhang one another in the direction that the mold opens, unless parts of the mold are designed to move from between such overhangs when the mold opens. Sides of the part that appear parallel with the direction of draw are typically draft with to ease release of the part from the mold, and examination of most plastic household objects will reveal this. Parts with bucket-like features tend to shrink onto the cores that form them while cooling, and cling to those cores when the cavity is pulled away. The mold is usually designed so that the molded part reliably remains on the ejector side of the mold when it opens, and draws the runner and the sprue out of the side along with the parts. The part then falls freely when ejected from the side. Tunnel gatestunnel sharply below the parting surface of the B side at the tip of each runner so that the gate is sheared off of the part when both are ejected. Ejector pins are the most popular method for removing the part from the side core, but air ejection, and stripper plates can also be used depending on the application. Most ejector plates are found on the moving half of the tool, but they can be placed on the fixed half if spring loaded. For thermoplastics, coolant, usually water with corrosion inhibitors, circulates throughpassageways bored through the main plates on both sides of the mold to enable temperature control and rapid part solidification. Plastic Advisor In Creo Parametric Problems found after tooling development are always expensive and frustrating. For plastic part design and manufacture, there is a better way. 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. CREO Plastic Advisor simulates mold filling for injection molded plastic parts. Advanced features provide valuable manufacturability insight - insight that can significantly reduce late-cycle design changes and mold reengineering costs. CREO Plastic Advisor simulates mold filling for injection molded plastic parts. Advanced features provide valuable manufacturability insight - insight that can significantly reduce late-cycle design changes and mold reengineering costs. Features & Benefits • Animates plastic injection fill process and automatically creates Web reports within Pro/ENGINEER browser 4
International Journal of Research and Innovation (IJRI)
• Access library of common plastic materials and automatically select from typical injection-molding machine parameters • Identify optimal injection locations to reduce cycle time and improve product appearance • Identify potential mold-filling problems such as short shots, air traps, and weld lines • Improve design quality and reduces manufacturing cycle times and rework of molds
Materials Polypropylene (pp) Acrylonitrile Butadiene System (ABS) High Density Polyethylene (HDPE) Polyvinyl Chloride (PVC) Polybutylene terepthalate (PBT)
Plastic Flow analysis of remote control panel using polypropylene (pp)
The above image shows fill time
The above image shows confidence of fill
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International Journal of Research and Innovation (IJRI)
The above image shows injection pressure
The above image shows pressure drop
The above image shows flow front temp
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International Journal of Research and Innovation (IJRI)
The above image shows quality prediction
The above image shows surface temp variance Plastic Flow analysis of remote control panel using Acrylonitrile Butadiene System (ABS)
The above image shows fill time
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International Journal of Research and Innovation (IJRI)
The above image shows injection pressure
The above image shows pressure drop
The above image shows surface temp variance 8
International Journal of Research and Innovation (IJRI)
Plastic Flow analysis of remote control panel using High Density Polyethylene (HDPE)
The above image shows fill time
The above image shows injection pressure
The above image shows pressure drop
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International Journal of Research and Innovation (IJRI)
The above image shows surface temp variance Plastic Flow analysis of remote control panel using Polyvinyl Chloride (PVC)
The above image shows fill time
The above image shows injection pressure 10
International Journal of Research and Innovation (IJRI)
The above image shows pressure drop
The above image shows surface temp variance Plastic Flow analysis of remote control panel using polybutylene terepthalate (PBT)
The above image shows fill time
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International Journal of Research and Innovation (IJRI)
The above image shows injection pressure
The above image shows pressure drop
The above image shows surface temp variance
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International Journal of Research and Innovation (IJRI)
MOULD EXTRACTION A die is usually made in two halves and when closed it forms a cavity similar to the casting desired. One half of the die that remains stationary is known as cover die and the other movable half is called “ejector die�. The die casting method is used for castings of nonferrous metals of comparatively Low fusion tem-
perature. This process is cheaper and quicker than permanent or sand mould casting. Most of the automobile parts like fuel pump, carburetor bodies, Horn heater, wipers, brackets, steering wheels, hubs and crank cases are made with this process. Core: The core which is the male portion of the mold forms the internal shape of the molding. Cavity: The cavity which is the female portion of the mold, gives the molding its external form.
Parting Line Creation
The above image shows the parting surface Core and cavity preparation
The above image shows the work piece creation
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International Journal of Research and Innovation (IJRI)
The above image shows the cavity part
The above image shows the core part Mold Tool Design For Remote Control Top Panel
The above image shows cavity 14
International Journal of Research and Innovation (IJRI)
The above image shows core
The above image shows mould assembly
The above image shows exploded view
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2D Drafting For Mold Tool Design
BILL OF MATERIALS
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International Journal of Research and Innovation (IJRI)
Optimized Cooling Channels For Remote Control Top Panel
The above image shows linear
The above image shows horizontal
The above image shows vertical 17
International Journal of Research and Innovation (IJRI)
The above image shows spiral Introduction To Ansys ANSYS is general-purpose finite element analysis (FEA) software package. Finite Element Analysis is a numerical method of deconstructing a complex system into very small pieces (of user-designated size) called elements. The software implements equations that govern the behaviour of these 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. ANSYS is the standard FEA teaching tool within the Mechanical Engineering Department at many colleges. ANSYS is also used in Civil and Electrical Engineering, as well as the Physics and Chemistry departments.
Warpage Analysis Of Remote Control Top Panel Using Coupled Field Analysis Linear type cooling system
The above image shows imported model of remote control top panel with linear cooling system
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International Journal of Research and Innovation (IJRI)
The above image shows meshed model
The above image shows total deformation
The above image shows temperature
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International Journal of Research and Innovation (IJRI)
The above image shows total heat flux
The above image shows thermal error Spiral type cooling system
The above image shows total deformation 20
International Journal of Research and Innovation (IJRI)
The above image shows temperature
The above image shows total heat flux
The above image shows thermal error
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International Journal of Research and Innovation (IJRI)
Zigzag horizontal type cooling system
The above image shows total deformation
The above image shows temperature
The above image shows total heat flux
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International Journal of Research and Innovation (IJRI)
The above image shows thermal error Zigzag vertical type cooling system
The above image shows total deformation
The above image shows temperature
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International Journal of Research and Innovation (IJRI)
The above image shows total heat flux
The above image shows thermal error Results Result table for plastic flow analysis PP
ABS
HDPE
PVC
PbT
Fill time
0.96
1.38
1.19
2.57
1.50
Injection pressure
19.30
36.31
34.31
65.43
61.24
Pressure drop
19.30
36.31
34.31
65.43
61.24
Flow front temperature
240.01
230.04
210.07
170.15
247.18
Surface temperature variance
4.98
4.98
4.98
4.98
4.98
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International Journal of Research and Innovation (IJRI)
Result table for optimized cooling channels Linear
Spiral
Zigzag horizontal
Zigzag vertical
Total deforma- 0.019266 tion
0.0096524
0.019223
0.019331
Temperature
200
200
200
200
Total heat flux
8.2928e-12
8.3161e-12
9.6433e-12
9.7462e-12
Thermal error
1.3267e-18
1.3616e-18
3.7358e-18
3.7255e-18
Conclusion This project work deals with design of mold tool and cooling channel optimization of remote control top panel to suggest optimum material and cooling channel system to reduce warpage of the product. Initially literature survey and data collection was done to understand the methodology and material selection. Remote control top panel was modeled and designed mold tool for the same using parametric software creo-2.0 (pro-engineer). Mold flow analysis was conducted on part by varying plastic materials.
tronic version) ISSN 1503-8181 Doctoral theses at NTNU, 2008:113 4]. B. Sidda Reddy 1,*, J. Suresh Kumar2, Vijaya Kumar Reddy2 and G. Padmanabhan3 1 Department of Mechanical Engineering, R. G. M. College of Engineering & Technology, Nandyal, Kurnool (Dt), A.P-518 501, India. 2 Mechanical Engineering, J.N.T University, Hyderabad, India. 3 Mechanical Engineering, S.V. University College of Engineering, S.V. University, Tirupati, A.P. India 5]. Omar A. Mohamed, S.H. Masood, AbulSaifullah Faculty of Engineering and Industrial Science, Swinburne University of Technology, Hawthorn, Melbourne, Australia Corresponding Email: smasood@ swin.edu.au
As per flow analysis P.P (polypropylene) is showing good characteristics in confidence of fill and quality with in low pressure and less drop, but it requires little bit high temperature than other materials.
6]. Mohammad Aashiq M1, Arun A.P1, Parthiban M2 1 PGD IN TOOL & DIE DESIGN ENGINEERINGPSG IAS 2 ASST.PROFESSOR DEPARTMENT OF MECHANICAL ENGINEERING-PSG CT Coimbatore – 641004, India
Thermal analysis is done in ansys work bench by varying cooling channel systems to analyze thermal behavior.
7]. JiajunShen An Engineering Project Submitted to the Graduate Faculty of Rensselaer Polytechnic Institute
As per thermal analysis spiral system is showing good quality in providing sufficient cooling effect to the part.
Authors
As per above analysis results this project work concludes that remote control with P.P (polypropylene) material along with spiral cooling channel system gives good quality product due to its quality of filling and sufficient cooling effect. References 1]. P. Postawa*, D. Kwiatkowski, E. Bociaga Institute of Polymer Processing and Production Management, Czestochowa University of Technology, al. ArmiiKrajowej 19c, 42-200 Czêstochowa, PolandCorresponding author: E-mail address: postawa@ kpts.pcz.czest.pl 2]. Hong-Seok Park and Xuan-Phuong Dang University of Ulsan South Korea Z. Shayfull*1, M.F. Ghazali1, M. Azaman1, S.M. Nasir1, N.A. Faris2 1School of Manufacturing Engineering, Universiti Malaysia Perlis, Malaysia 2Politeknik Sultan Abdul HalimMu’adzam Shah (POLIMAS), Malaysia shayfull@unimap.edu.my 3].Lars-Erik Rännar ISBN 978-82-471-8270-3 (printed version) ISBN 978-82-471-8284-0 (elec-
vadlamannati venkata krishna mohan 25 Year’s Teching Experience In Govt Polytechnic College
D.Gopichand Qualification: m.tech Designation: assistant profressor Experience :4 yr in teaching & 2 yr experience in InfoTech as design engineer 25