ENG07032 2013 Polymer Tooling Design
Full Title
Polymer Tooling Design
Transcript Title
Polymer Tooling Design
Code
ENG07032
Attendance
75 %
Subject Area
ENG - Engineering
Department
MENG - Mech. and Electronic Eng.
Level
07 - NFQ Level 7
Credit
05 - 05 Credits
Duration
Semester
Fee
€
Start Term
2013 - Full Academic Year 2013-14
End Term
9999 - The End of Time
Author(s)
Sean Dalton
Programme Membership
SG_EPLYP_J07 201300 Bachelor of Engineering in Polymer Processing
SG_EPLYP_J07 201500 Bachelor of Engineering in Polymer Processing
SG_EPLYP_J07 201900 Bachelor of Engineering in Polymer Processing (Add-on)
SG_EPOLP_J07 202200 Bachelor of Engineering in Polymer Process Engineering (Add-on)
SG_EPOLZ_J07 202200 Bachelor of Engineering in Polymer Process Engineering (Add-on)
SG_EPOLY_J07 202400 Bachelor of Engineering in Polymer Processing (Add-on)
Description
This module familiarises the candidates with the mechanical considerations associated with the design and usage of plastic moulds. The module will be practically based and will consist of a combination of presentations on actual solutions to mould design problems followed by a CAD based mould design project.
Learning Outcomes
On completion of this module the learner will/should be able to;
1.
Demonstrate an understanding of the injection mould process/cycle.
2.
Demonstrate an understanding of the main features of mould construction
3.
Demonstrate an appreciation of the influence of part design on plastic flow
4.
Produce a mould design using an industry standard CAD system
5.
Work effectively in Design Teams.
Module Assessment Strategies
The subject will be assessed as follows.
- CAD element (40%)
- Mould design project (20%)
- Final written exam (40%)
Indicative Syllabus
MOULDING TOOL CONSTRUCTION AND THE MOULDING PROCESS
Injection mould design: Basic mould construction: core-cavity, two part moulds, multi-plate moulds, Use of core cavity inserts and local inserts for small detail.
Producing undercut detail: external slides, split moulds and collapsible cores, hydraulic vs. guide pin actuation, threaded components and unscrewing mechanisms.
Ejection systems: Ejector pins, sleeve ejector, stripper plate moulds. Hydraulic ejectors vs. tie rod actuated ejection, fixed half ejection.
Feed systems: Sprue, Runner and gate systems. Runner profiles and freeze characteristics, Gate types, size and choice of gating position. Surface vs submarine gates. Runner balancing. Hot runner / insulated runner systems.
Cooling channel design, size and layout. Heat transfer requirements.
Venting: Role of venting, choice of vent location, problems with poor venting.
Mould manufacture Manufacturing processes used in mould manufacture: Sources of mould bases and standard parts: DME, DMS, Hasco, Mold Masters etc.
The injection moulding process: Overview of injection moulding machine construction. The injection moulding cycle. Process parameters, role of melt temperature, injection and holding pressure and cooling temperature.
Part design: Design of plastic parts for mould-ability, influence of part design on plastic flow. Solving typical moulding problems, sink marks, weld lines etc.
COMPUTER AIDED MOULD DESIGN
This section will focus on the modelling of injection moulding tools for parts of varying complexity using an industry standard CAD system. Main aspect will be
- Revision of Part, Assembly and Draft tools.
- Automatic generation of core cavity and parting surfaces for simple moulds.
- Manual generation of core cavity and parting surface for complex moulds.
- Detection of shutout and creation of shutout detail.
- Detection of undercut detail and modelling of slides.
- Downloading mould base for part suppliers
- Analysis of plastic flow and interpreting results.
MOULD DESIGN PROJECT
In this element the student will design a mould required to produce a specified component. The student will sketch concepts for solutions drawing on past examples to select the best combination of mould elements necessary to mould the part in question. Detail drawings will then be produced of the finished design.
Coursework & Assessment Breakdown
Coursework & Continuous Assessment
60 %
End of Semester / Year Formal Exam
40 %
Coursework Assessment
| Title | Type | Form | Percent | Week | Learning Outcomes Assessed | |
|---|---|---|---|---|---|---|
| 1 | Continuous Assessment CAD assessment | Coursework Assessment | UNKNOWN | 40 % | OnGoing | 2,4,5 |
| 2 | Assignment Mould Design Project | Coursework Assessment | UNKNOWN | 20 % | OnGoing | 2,3,4,5 |
End of Semester / Year Assessment
| Title | Type | Form | Percent | Week | Learning Outcomes Assessed | |
|---|---|---|---|---|---|---|
| 1 | Final Exam Written Exam | Final Exam | UNKNOWN | 40 % | End of Term | 1,2,3 |
Part Time Mode Workload
| Type | Location | Description | Hours | Frequency | Avg Workload |
|---|---|---|---|---|---|
| Practical / Laboratory | Computer Laboratory | CAD tuition | 2 | Weekly | 2.00 |
| Off-Site Activity | Not Specified | Visit to moulding company | 7 | Once Per Semester | 0.47 |
| Independent Learning | UNKNOWN | Assignments | 2 | Weekly | 2.00 |
| Supervision | Flat Classroom | On site practical days | 8 | Monthly | 2.00 |
Total Part Time Average Weekly Learner Contact Time 4.47 Hours
Module Resources
Non ISBN Literary Resources
Injection Mould Design, RWG Pye, Longman Scientific
Injection Mold Design Engineering, David O Kasmer, Hanser
Other Resources
Solid works and Mould Design on line training material
Solid Professor (www.solidprofessor.com)
Igetit cad training (http://www.myigetit.com/)
Additional Information
None