HW04- InjectionMolding-Case Study-

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Drexel University *

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Jan 9, 2024

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Nathaniel Haye Pitchapa Inroon Groover/Introduction to Manufacturing Processes Injection Molding Case Study : Awesome Amps and its Amplifier O-Frame Awesome Amps, Inc., is a small start-up company that has designed a portable amplifier for digital music players and musical instruments. The product design includes an important component, the O-frame, that provides structure to the amplifier and compartmentalizes the various electrical circuits and subassemblies. The O-frame geometry is fairly complex, but it is small enough to fit in the palm of a hand. An initial production run is anticipated for 5,000 units, with possibly larger runs to be completed later. The engineer in charge needs to design a production process for the O-frame that is economical and environmentally responsible and that leads to a consistent, high-quality part. Since the structural load on the part is modest and the required dimensional tolerances are fairly loose, a polymer is suggested for the O-frame material and a plastic molding process considered for production. Since high-density polyethylene (HDPE) is inexpensive and easily molded, it is chosen for the part. Ultimately, injection molding is selected for the part. A horizontal machine with a reciprocating- screw injector is acquired and a two-plate mold is constructed for the part. The process is run according to the recommended machine settings found on the website of the HDPE supplier, with two exceptions. First, in order to eliminate weld lines on the part, a higher injection temperature is specified. And second, to correct a problem of incomplete parts, a higher injection pressure is applied. Although the parts are successfully produced, it is eventually discovered that the parts from the initial run are considerably larger than designed. The outer diameter is specified to be 112.5 +/- .25 mm, but most parts measure between 112.9 and 113.0 mm. The engineer is troubled and perplexed by the problem. WATCH THE VIDEO: SME -Plastic Injection Molding (Week 7- Plastics Videos) 1. Which material type is more commonly injection molded, thermoplastics or thermosets? Thermoplastics are more commonly injection molded. This is because they are easy to use and remelted easily into liquids. 2. What machine settings have important effects on the part properties in injection molding? The most important parameters affecting are surface waviness, melt temperature, followed by mold temperature, injection pressure and packing pressure. 3. What two mechanisms provide heat to melt the polymer in the molding machine barrel? Drag flow and external heating bands provide additional heat to melt the polymer in the machine barrel. Drag flow causes the polymer molecules to slide over each other creating frictional heat which melts the material. External heating bands provide additional heat to the injection barrel, the heating bands brings the material to its final temperature and compensate for heat loss.
4. Most industrial machines for injection molding are structured horizontally. What types of molded parts are typically produced on a vertical machine? Molded parts are widely used daily for car parts and hydraulic systems. 5. A three-plate mold for injection molding is more complex and expensive than a two- plate mold. What advantage of the three-plate system allows this extra investment to be justified? Three plate mold is relatively cheaper to build and very less likely to break down. It has a gate located at the middle of the plastic part and allows pin-point gates. GO TO THE TEXT: Chapters 2 and 8 6. Some types of plastics are readily recycled, if they can be repeatedly heated (melted) and cooled with little material degradation. Will the choice of HDPE for the O-frame allow for the part to be recyclable? See Section 2.3. HDPE is a recyclable material, so it is a good choice for 0 frame for reusing and recycling again.
7. Why is the O-frame part appropriate for the process of injection molding? See Section 8.6. 8. How could the use of a three-plate mold possibly correct the problem of the weld lines on the part without needing to increase temperature? See Section 8.6. 9. Why did the parts come out too large from the initial run? See Section 8.6. SOLVE 10.Use the shrinkage values in Table 8.1 to determine the correct size of the outer diameter in the mold cavity. 11.If the actual shrinkage rate is just one-half of the rate in the table, what would be the correct diameter for the mold cavity. 12.What can be done if the mold has already been made and purchased with the wrong diameter? 13. (3 points) Estimate the die-clamping force required for injection molding of 12 identical 50x50 mm 2 square soldiers in one die. Include the runners of appropriate length and diameter. Runners need a 7mm diameter. The main runner will be given a 10 mm diameter so that it has roughly twice the cross section of the part runner. Assume the injection pressure is 100 MPa.
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