HW04- InjectionMolding-Case Study-
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Drexel University *
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Subject
Mechanical Engineering
Date
Jan 9, 2024
Type
docx
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3
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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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