DSGN08054 2016 Mould, Tool & Product Design

Demonstrate a comprehensive knowledge of the issues involved in the design of plastic products for high volume manufacturing.

Use a CAD system to preform advanced 3D solid and surface modelling and animation of mould, tool & product design.

Contribute to the design of special purpose machinery involving production aids, automation equipment, inspection, metrology, packaging and assembly.

Design a progression press tool involving piercing, blanking, cropping and forming operations.

Design single cavity injection mould of reasonable complexity and produce all the relevant models, drawings and documentation necessary for its specification.

Yes

Continuous assessment will involve the assessment of a all assignments undertaken in class, design projects, activity completed independently and an end of term in-house assessment test.

CA

Product Development: Plastic product design and development, stages in the design process, design brief, documentation, validation implications, precision tolerances and fits, shrinkage, warpage, flash, weld and meld lines, product defects, part wall thickness, ribs, stress, cycle times, material selection.

CAD: Design principle, computer modelling tools, amination, draft, advanced modelling, cores and cavities, polymer flow behaviour in injection moulds, filling pattern, shrinkage, moulding conditions and injection pressure, part and runner volumes, runner optimisation, cooling system design.

Machine Design: Jig & fixturedesign: Introduction, planning and the design procedure, supporting and locating principles, loading/unloading, clamping, cutter guides, drill bushes, standard and commercial fixture components, fixture bodies, swarf removal, design for varying production runs, carousels, gauge design, dimensioning and tolerances, various jig and fixture types, sensors.

Press Tool Design: blanking, bending, forming and drawing operations and the necessary calculations for these, blank sizes and development of blanks, strip widths, progression feeds and stops, shut height, strippers and component ejection, cams, pressure pads, die draft, punches, embedded sensors.

Mould Design: Moulding machine selection and considerations, clamping force, component draft, split lines, cams, undercuts and angular ejectors, material selection, heat treatment considerations, use of standard mould bases, tool type and manufacture considerations, runner system types / design and gate types / design, shrinkage and warpage, part defects: air traps, venting.