Process planning for rapid manufacturing of plastic injection mold for short run production

نویسندگان

  • Rajesh Kumar Karthikeyan
  • Frank Peters
  • Scott Chumbley
چکیده

This thesis presents a process planning methodology for a rapid injection mold tool manufacturing system that involves additive and subtractive techniques, whereby slabs are sequentially bonded and milled using layered tool paths. Mold tools are grown in a bottom up fashion, eliminating the need for multi-axis machining operations (beyond three axes) and allowing small features in deep cavities. In this research, a new layer bonding method using friction stir welding of aluminum plates is presented. In this manner, one can create seam-free laminated aluminum injection mold tooling using a unique combination of industrial adhesives and friction stir spot welding to initially secure the slab, then continuous friction stir welding of layer perimeters that are sequentially machined in a layer wise process. The original research is presented as a journal article. This research includes three areas of interest that will enable highly automated process planning. The first research area focuses on determining the process plan for applying adhesives on the laminated plates that will be sufficient to resist the forces acting on the plate due to subsequent friction stir spot welding. The use of fixtures and clamps for machining in rapid manufacturing create a potential problem for collision of the tool/spindle and the workpiece setup. Therefore, the process proposed in this thesis uses a combination of industrial adhesives and friction stir spot welding to secure the aluminum plates for machining. The second area focuses on determining the number, location and sequence of friction stir spot welds sufficient to secure the plate prior to continuous friction stir welding. The use of

برای دانلود متن کامل این مقاله و بیش از 32 میلیون مقاله دیگر ابتدا ثبت نام کنید

ثبت نام

اگر عضو سایت هستید لطفا وارد حساب کاربری خود شوید

منابع مشابه

Finding efficient frontier of process parameters for plastic injection molding

Product quality for plastic injection molding process is highly related with the settings for its process parameters. Additionally, the product quality is not simply based on a single quality index, but multiple interrelated quality indices. To find the settings for the process parameters such that the multiple quality indices can be simultaneously optimized is becoming a research issue and ...

متن کامل

Experimental Study of Packing Time and Melt Temperature Effects on Shrinkage of a Thin Sheet Made of Wood-HDPE Composite

Injection molding is one of the most common processes which are used for manufacturing different plastic parts. This method includes 3 continuous steps: filling of the mold, cooling and driving the part out. A wide range of plastic and Non-Plastic materials can be used as raw material in this process. One of the most important advantages of this way of production is that it is very economic. In...

متن کامل

Experimental Study of Packing Time and Melt Temperature Effects on Shrinkage of a Thin Sheet Made of Wood-HDPE Composite

Injection molding is one of the most common processes which are used for manufacturing different plastic parts. This method includes 3 continuous steps: filling of the mold, cooling and driving the part out. A wide range of plastic and Non-Plastic materials can be used as raw material in this process. One of the most important advantages of this way of production is that it is very economic. In...

متن کامل

Geometric Tailoring: A Design for Manufacturing Method for Rapid Prototyping and Rapid Tooling

The goal of fabricating functional prototypes quickly is hindered by a mismatch of material properties between production materials and those used in rapid prototyping (RP) machines, such as stereolithography. Even when rapid tooling (RT) technologies are utilized for injection molded parts, differences in mold materials cause differences in molded part properties. To compensate for these mater...

متن کامل

Optimization of the injection molding process of Derlin 500 composite using ANOVA and grey relational analysis

Warpage and shrinkage control are important factors in proving the quality of thin-wall parts in injection modeling process. In the present paper, grey relational analysis was used in order to optimize these two parameters in manufacturing plastic bush of articulated garden tractor. The material used in the plastic bush is Derlin 500. The input parameters in the process were selected according ...

متن کامل

ذخیره در منابع من


  با ذخیره ی این منبع در منابع من، دسترسی به آن را برای استفاده های بعدی آسان تر کنید

برای دانلود متن کامل این مقاله و بیش از 32 میلیون مقاله دیگر ابتدا ثبت نام کنید

ثبت نام

اگر عضو سایت هستید لطفا وارد حساب کاربری خود شوید

عنوان ژورنال:

دوره   شماره 

صفحات  -

تاریخ انتشار 2015