A method to predict early-ejected plastic part air-cooling behavior towards quality mold design and less molding cycle time

Fu, Junyu; Ma, Yongsheng

doi:10.1016/j.rcim.2018.08.004

Cited by 21 publications

(13 citation statements)

References 26 publications

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“…Metallic powders, such as copper powder [ 50 ] or aluminum powder [ 51 ] can also be added in the manufacturing process to improve the physical properties of the fabricated filament. In addition, some reinforcing fillers, such as silicon carbide, aluminum oxide, molybdenum disulfide [ 52 , 53 , 54 ], zirconia [ 55 , 56 , 57 ], or silicon nitride [ 58 , 59 , 60 ] can also be mixed into the recycled PLA materials to develop filaments with high wear resistance [ 61 ] to enhance the life of direct soft tooling built with filaments [ 62 , 63 , 64 ].Therefore, the filament with both excellent mechanical and physical properties can be employed to fabricate rapid tooling [ 65 ] for thermoforming, blow molding [ 66 ], plastic injection molding [ 67 , 68 ], rotational molding, or transfer molding. These issues are currently being investigated and the results will be presented in a later study.…”

Section: Resultsmentioning

confidence: 99%

Optimization of Process Parameters for Fabricating Polylactic Acid Filaments Using Design of Experiments Approach

2021

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The amount of wasted polylactic acid (PLA) is increasing because 3D printing services are an increasingly popular offering in many fields. The PLA is widely employed in the fused deposition modeling (FDM) since it is an environmentally friendly polymer. However, failed prototypes or physical models can generate substantial waste. In this study, the feasibility of recycling PLA waste plastic and re-extruded it into new PLA filaments was investigated. An automatic PLA filament extruder was first developed for fabricating new PLA filaments. This paper also discusses the process, challenges, and benefits of recycling PLA waste plastic in an effort to fabricate new PLA filaments more sustainable. It was found that it was possible to fabricate PLA filament using recycled PLA waste plastic. The production cost is only 60% of the commercially available PLA filament. The tensile strength of the developed PLA filament is approximately 1.1 times that of the commercially available PLA filament. The design of experiments approach was employed to investigate the optimal process parameters for fabricating PLA filaments. The most important control factor affecting the diameter of PLA filament is the barrel temperature, followed by recycled material addition ratio, extrusion speed, and cooling distance. The optimal process parameters for fabricating PLA filament with a diameter of 1.7 mm include the barrel temperature of 184 °C, extrusion speed of 490 mm/min, cooling distance of 57.5 mm, and recycled material addition ratio of 40%.

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Section: Resultsmentioning

confidence: 99%

Optimization of Process Parameters for Fabricating Polylactic Acid Filaments Using Design of Experiments Approach

2021

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“…Melt temperature is the temperature required to melt the plastic material in a pellet formed in the screw barrel of the injection moulding machine before the injection stage to fill the mould cavities [ 84 , 85 ]. Some researchers reported that melt temperature is a significant processing parameter that causes warpage defects on the moulded parts produced.…”

Section: Injection Moulding Processmentioning

confidence: 99%

Potential of New Sustainable Green Geopolymer Metal Composite (GGMC) Material as Mould Insert for Rapid Tooling (RT) in Injection Moulding Process

et al. 2023

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The investigation of mould inserts in the injection moulding process using metal epoxy composite (MEC) with pure metal filler particles is gaining popularity among researchers. Therefore, to attain zero emissions, the idea of recycling metal waste from industries and workshops must be investigated (waste free) because metal recycling conserves natural resources while requiring less energy to manufacture new products than virgin raw materials would. The utilisation of metal scrap for rapid tooling (RT) in the injection moulding industry is a fascinating and potentially viable approach. On the other hand, epoxy that can endure high temperatures (>220 °C) is challenging to find and expensive. Meanwhile, industrial scrap from coal-fired power plants can be a precursor to creating geopolymer materials with desired physical and mechanical qualities for RT applications. One intriguing attribute of geopolymer is its ability to endure temperatures up to 1000 °C. Nonetheless, geopolymer has a higher compressive strength of 60–80 MPa (8700–11,600 psi) than epoxy (68.95 MPa) (10,000 psi). Aside from its low cost, geopolymer offers superior resilience to harsh environments and high compressive and flexural strength. This research aims to investigate the possibility of generating a new sustainable material by integrating several types of metals in green geopolymer metal composite (GGMC) mould inserts for RT in the injection moulding process. It is necessary to examine and investigate the optimal formulation of GGMC as mould inserts for RT in the injection moulding process. With less expensive and more ecologically friendly components, the GGMC is expected to be a superior choice as a mould insert for RT. This research substantially impacts environmental preservation, cost reduction, and maintaining and sustaining the metal waste management system. As a result of the lower cost of recycled metals, sectors such as mould-making and machining will profit the most.

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“…Hwang and Kim [10] presented injection mould design of reverse engineering using injection moulding analysis and machine learning. Fu and Ma [11] proposed a method J. Eng., 2020, Vol.…”

Section: Introductionmentioning

confidence: 99%

“…Hwang and Kim [10] presented injection mould design of reverse engineering using injection moulding analysis and machine learning. Fu and Ma [11] proposed a method to predict early-ejected plastic part air-cooling behaviour towards quality mould design and less moulding cycle time, integrating Moldflow (TM) and Ansys (TM) by feeding Moldflow (TM) simulation results as the intermediate state dataset into Ansys (TM) for air-cooling effect simulation. Fomina and Stolboushkin [12] developed a novel mould design for manufacturing of hollow ceramic products from coal wastes, with investigations of granulometric, chemical, mineral compositions and technological properties of waste from coal argillites enrichment and clay raw materials.…”

Section: Introductionmentioning

confidence: 99%

Flexible gypsum mould applied in the mechanical system for blank of grouted ceramic handicrafts based on the radial movement of the sphere and connection by the principle of six‐point positioning

Huang

Song

et al. 2020

J. eng.

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In order to solve the problems of low production efficiency, poor quality of blanks, high labour intensity and inability to meet the market demand with the manual gypsum mould, a novel design of the gypsum mould to be applied into the automatic production of the planks was developed for ceramic handicrafts. This mould inherits the advantages of the manual mould with tenon-mortise connection and adopts six-piece combination. According to the spherical radial movement, the new mould opens and closes, mostly avoiding movement interference and significantly improving service life. The connection technique of 'sixpoint positioning principle' was proposed and adopted to embed the connection device of four side die pieces with manipulator, so as to realise the strength of gypsum die pieces and effectively connect with the manipulator. Based on the group technique, the standard eigenvector and norm for the grouping of geometric elements of target blanks were proposed to realise the grouping of many different kinds of blanks into a few number of groups with all the blanks. Within a group, the gypsum mould keeps the external geometric features and tenon-mortise connection unchanged, while the working cavity of different blanks only alters, for the flexibility of gypsum mould. Thus, the universality of the mould is gained, and the design and manufacturing efficiency is greatly improved, with the considerable reduction of the cost, and the digitisation of design, manufacturing and management processes is realised. The gypsum mould provides a new technological method and technical guarantee for changing the labour-intensive production mode of ceramic handicraft blank cast and forming, realising the intellectualisation and automation of the main production link of ceramic handicraft blank cast and efficiency automatic and intellectualised production of ceramic handicraft blank with high identity.

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A method to predict early-ejected plastic part air-cooling behavior towards quality mold design and less molding cycle time

Cited by 21 publications

References 26 publications

Optimization of Process Parameters for Fabricating Polylactic Acid Filaments Using Design of Experiments Approach

Optimization of Process Parameters for Fabricating Polylactic Acid Filaments Using Design of Experiments Approach

Potential of New Sustainable Green Geopolymer Metal Composite (GGMC) Material as Mould Insert for Rapid Tooling (RT) in Injection Moulding Process

Flexible gypsum mould applied in the mechanical system for blank of grouted ceramic handicrafts based on the radial movement of the sphere and connection by the principle of six‐point positioning

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