Use of a Holistic Design and Manufacturing Approach to Implement Optimized Additively Manufactured Mould Inserts for the Production of Injection-Moulded Thermoplastics
Abstract
:1. Introduction
2. Design and Manufacturing Chain of Mould Insert with Conformal Cooling Channels
2.1. Computer Aided Design (CAD) of Mould Insert and FE Process Model
2.2. Material Selection and Manufacuring Process Chain
2.3. Selective Laser Melting (SLM) Process and Finite Element Analysis (FEA) of Mould Insert Shape Accuracy
2.4. Heat Treatment, Mechanical Properties and Final Post-Processing of Mould Insert
3. Application of Developed Mould Insert for Injection-Moulding Process in Series Production
3.1. Injection-Moulding Process Setup
3.2. Results of Process and Injection-Moulded Product in Comparison to FE Process Model
3.2.1. Process Temperatures
3.2.2. Results of Injection-Moulded Product Quality Improvement and Process Cycle Reduction
- dimensional inspection with the aid of gauges;
- product assembly inspection;
- pull-out creep test under axial load of 1221 N for 1 h;
- hydrostatic pressure creep test at 40 bars for 1 h; and
- bending under a pressure of 28.8 bars for 1 h.
4. Discussion
5. Conclusions
Author Contributions
Funding
Conflicts of Interest
References
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Process Parameters | |
Filling Phase | Value/Units |
Filling time | 2 s |
Melt temperature | 230 °C |
Max. injection pressure | 80 MPa |
Screw speed | 21.5 mm/s |
Filing part mass | 60 g |
Cooling medium inlet temperature | 20 °C |
Packing Phase | Value/Units |
Packing time | 10 s |
Max. packing pressure | 60 MPa |
Cooling Phase | Value/Units |
Cooling time | 13 s |
Mould open time | 8 s |
Air temperature | 30 °C |
Mould temperature range | 10–40 °C |
Ejection temperature | 112 °C |
Material Properties | |
Polypropylene (BA160E-8229-01) | Value/Units |
Density | 900 kg/m3 |
Thermal conductivity | 0.22 W/mK |
Specific heat capacity | 1800 J/kgK |
Melt flow rate | 0.3 g/10 min |
Tensile modulus | 1300 MPa |
Shear Modulus | 481 MPa |
Poisson ratio | 0.392 |
Tensile strain at yield | 11% |
Yield stress | 30 MPa |
Maraging 300 steel (EN 1.2709) | Value/Units |
Density | 8000 kg/m3 |
Thermal conductivity | 25.3 W/mK |
Specific heat capacity | 3350 J/kgK |
Elastic modulus | 190 GPa |
Shear Modulus | 73 GPa |
Poisson ratio | 0.3 |
Elongation at break (%) | 5% |
Yield strength | 2040 MPa |
Aging Temperature (°C) | Aging Time (h) | Hardness | Yield Strength (MPa) | Ultimate Tensile Strength (MPa) | Elongation at Break (%) | |
---|---|---|---|---|---|---|
Vickers Number (HVN) | Rockewell C (HRC) | |||||
510 | 6 | 620–650 | 56–58 | 2040 | 1930 | 5 |
Al | C | Cr | Co | Cu | Mn | Mo | Ni | N | O | Si | Ti |
---|---|---|---|---|---|---|---|---|---|---|---|
0.05–0.15 | <0.03 | <0.5 | 8.5–9.5 | <0.5 | <0.1 | 4.5–5.2 | 17.0–19.0 | <0.1 | <0.1 | <0.1 | 0.6–0.8 |
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Papadakis, L.; Avraam, S.; Photiou, D.; Masurtschak, S.; Pereira Falcón, J.C. Use of a Holistic Design and Manufacturing Approach to Implement Optimized Additively Manufactured Mould Inserts for the Production of Injection-Moulded Thermoplastics. J. Manuf. Mater. Process. 2020, 4, 100. https://doi.org/10.3390/jmmp4040100
Papadakis L, Avraam S, Photiou D, Masurtschak S, Pereira Falcón JC. Use of a Holistic Design and Manufacturing Approach to Implement Optimized Additively Manufactured Mould Inserts for the Production of Injection-Moulded Thermoplastics. Journal of Manufacturing and Materials Processing. 2020; 4(4):100. https://doi.org/10.3390/jmmp4040100
Chicago/Turabian StylePapadakis, Loucas, Stelios Avraam, Demetris Photiou, Simona Masurtschak, and Juan Carlos Pereira Falcón. 2020. "Use of a Holistic Design and Manufacturing Approach to Implement Optimized Additively Manufactured Mould Inserts for the Production of Injection-Moulded Thermoplastics" Journal of Manufacturing and Materials Processing 4, no. 4: 100. https://doi.org/10.3390/jmmp4040100