UNIVERSITI TEKNIKAL MALAYSIA MELAKA

CADCAM STUDY FOR AN INJECTION MOULD

Thesis submitted in accordance with the partial requirements of the Universiti Teknikal Malaysia Melaka for the Bachelor of Manufacturing Engineering (Manufacturing Design)

By

NOOR ASWANI BT SULAIMAN B050410089

Faculty of Manufacturing Engineering

ABSTRACT
The title for this project is CADCAM Study For An Injection Mould. The project aims the application of CADCAM in designing the name card box and the cavity mould as a product. The name card box is designed using Solidwork while the cavity mould is designed by CATIA. The project also identifies and design manufacturing process parameters for a standard mould such as sprue, runner and gate. For the cavity mould design, Boolean operation is used to remove the solid name card box from the part body. After the design process was completed, the rapid prototyping process is convert out. The design is transferred into the rapid prototyping machine and the printed process is done during 5-6 hours. Rapid prototyping is a process which is the raw materials is added layer by layer to produce the prototype. After the prototype making process, the measurement of surface roughness using surface roughness tester are done to identify the surface accuracy (Ra) of the prototype produced. The reading obtained are depends on the value of Ra. The objectives are accomplished due to the result obtained. By using the application of CADCAM, the name card box and cavity mould are designed. The cavity mould is produce as a product and the surface roughness of the product was measured.

ABSTRAK
Tajuk bagi projek ini adalah kajian tentang rekabentuk berbantu komputer dan pembuatan berbantu komputer dalam proses penyuntikan acuan (penyempritan). Projek ini tertumpu kepada pengunaan program komputer dalam mereka bentuk kotak untuk kad nama dan acuan berongga. Dengan menggunakan Solidwork, lukisan kotak untuk kad nama telah dihasilkan sementara acuan berongga pula dihasilkan menggunakan CATIA. Projek ini dilakukan untuk mengenalpasti parameter-parameter yang diperlukan dalam membuat acuan mengikut piawaian acuan.Acuan berongga yang dihasilkan adalah menggunakan operasi Boolean. Operasi ini memisahkan antara kotak kad nama dengan jasad utama.Setelah proses merekabentuk selesai, proses membuat prototaip dengan pantas dilakukan. Rekabentuk yang telah selesai dimasukkan ke dalam mesin pembuat prototaip pantas dan proses cetakan berlansung selama 5 6 jam. Proses membuat prototaip dengan pantas ini adalah satu proses di mana bahan kasar ditambah lapisan demi lapisan untuk mendapatkan prototaip. Setelah proses ini selesai, ukuran untuk mengenalpasti kerataan permukaan prototaip dilakukan menggunakan alat pengesan permukaan. Bacaan yang direkodkan dipengaruhi oleh kerataan permukaan. Semua objektif di dalam projek ini berjaya dilaksanakan. Dengan menggunakan aplikasi rekabentuk berbantu komputer dan pembuatan berbantu komputer, kotak kad nama dihasilkan. Acuan berongga dihasilkan sebagai produk. Dan bacaan permukaannya telah direkodkan.

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CHAPTER 1
INTRODUCTION

1.1

Background
Computer has a prominent often central role in engineering. As competitive pressures call for improvement in product performance and quality and for reduction in times scales, this role is becoming increasingly important. In the process of product design and manufacture, computers have found their most spectacular and advanced application. They assist engineers to improve the productivity with which they carry out their work through simulation. They allow the performance of a product to be evaluated before a prototype is made. They aid the organization of complex systems, and the communication of data within the engineering team. These applications may be termed CADCAM: Computer Aided Design and Computer Aided Manufacture. Conventionally, there are less people who are expertise and have experiences and knowledge in the mould making industry. To change the current situation, one way is to use a CADCAM system. Using CADCAM, it will help during mould design process. The mould flow of the design can be identified and any changes can be doing before the machining process is done.

This project contains background into the subject of Integrated CAD/CAM study. The task will be to study the progression of a component from computer solid modeling to finish product by CAD/CAM software. After the product is design in this software, the design is transfer into the rapid prototyping machine to produce the prototype. The surface roughness measurement is done to the prototype to analyze the accuracy of the surface produce.

1.2

Statement of the problem

The project is identify manufacturing process parameters for a standard mould. In designing a standard mould, the gating system is the most important parameter that needs to be considered. The gating system includes the sprue, runner, gate and etc. Usually, a standard mould is design by the designer that has experiences in mould making industry. Student difficult to understand the parameter for a standard mould especially in calculate the gating system compare to the mould designer. By using and explore the integrated CADCAM software such as CATIA and Solidwork, the design of mould can be produce in less time with high quality.

1.3

Objectives
a) To design name card box using CAD software.

b) To model a standard mould using CATIA CAD software. c) To produce the mould by using rapid prototyping machine. d) To analyze surface roughness using surface roughness tester.

1.4

Scope
a) To design the name card box. b) To design cavity mould with sprue, runner and gate. c) To learn the rapid prototyping processes. d) To identified the surface roughness of prototype by using surface roughness tester.

1.5 Importance of the project

The important of this project is the application of CAD software such as CATIA and Solidwork can be used to design the name card box. In designing the standard mould, the CAD software can be used to produce the mould in less time and high quality. The prototype of cavity mould can be produce by using the rapid prototyping process. Rapid prototyping transforms virtual design from computer added design (CAD) into cross sections which is still in virtual model and then creates each cross sectional in physical space, one after next until the prototype is finished.

CHAPTER 2
LITERATURE REVIEW

2.1

Introduction
One of the most common methods of converting plastics from the raw material form to an article of use is the process of injection moulding. This process is most typically used for thermoplastic materials which may be successively melted, reshaped and cooled. Injection moulded components are a feature of almost every functional manufactured article in the modern world, from automotive products through to food packaging. This versatile process allows us to produce high quality, simple or complex components on a fully automated basis at high speed with materials that have changed the face of manufacturing technology [1].

2.2

CAD/CAM
CAD/CAM is the integration of CAD and CAM. Products designed by CAD are input directly into the CAM system. The term CAD/CAM implies that an engineer can use the system both for designing a product and for controlling manufacturing processes. For example, once a design has been produced with the CAD component, the design itself can control the machines that construct the part [2].

2.2.1 CAD (Computer Aided Design)

CAD as an everyday term has grown to a broad range of capabilities and has applications in field ranging from education for school teaching to three dimensional mechanical designs. At the present time, most CAD system provides only the geometric modeling functions that facilitate the drafting operations of mould design [11]. CAD involves creating computer models defined by geometrical parameters. These models typically appear on a computer monitor as a three-dimensional representation of a part or a system of parts, which can be readily altered by changing relevant parameters. CAD systems enable designers to view objects under a wide variety of representations and to test these objects by simulating real-world conditions [3]. CAD is mainly used for detailed engineering of 3D models and/or 2D drawings of physical components, but it is also used throughout the engineering process from conceptual design and layout of products, through strength and dynamic analysis of assemblies to definition of manufacturing methods of components [2]. CAD has become an especially important technology, within the scope of Computer Aided technologies, with benefits such as lower product development costs and a greatly shortened design cycle. CAD enables designers to layout and develops work on screen, print it out and save it for future editing, saving time on their drawings [2].

2.2.2 CAM (Computer Aided Manufacturing)

Computer-aided manufacturing (CAM) is the use of a wide range of computerbased software tools that assist engineers and CNC machinists in the manufacture or prototyping of product components. CAM has been considered as

an NC programming tool wherein 3D models of components generated in CAD software are used to generate CNC code to drive numerical controlled machine tools [6].

2.2.3 CATIA
CATIA (Computer-Aided Three-Dimensional Interactive Application) has been devised and developed by Dassault Systems in France, is acclaimed throughout the world as the leading program for use in design. CATIA offers unequalled scope of functionality, together with total integration of all its functions, thereby ensuring that its users are able to address the most challenging design tasks, and then translate those into realistic, manufacturability products. Figure 2.1 shows the example of part that has been designed using CATIA software [9].

Figure 2.1: Example of part that been designed using CATIA [9].

This software gives a broad range of integrated solutions that cover all aspects of [9]:i. ii. iii.

Product design and manufacture. Driving enterprise competitiveness. Task productivity Process improvement.

CATIA provides easy to use solutions tailored to the needs of small and medium sized enterprises as well as large industrial corporations in all industries [9]:i. ii. iii. iv.

Consumer Goods. Fabrication & Assembly. Electrical & Electronics goods. Automotive, aerospace, shipbuilding and process plants.

2.2.4 Solidwork
SolidWork is a Parasolid-based solid modeler, and utilizes a parametric featurebased approach to creating models and assemblies. Parameters refer to constraints whose values determine the shape or geometry of the model or assembly. Parameters can be either numeric parameters, such as line lengths or circle diameters, or geometric parameters, such as tangent, parallel, concentric, horizontal or vertical, etc. Numeric parameters can be associated with each other through the use of relations, which can easily capture even the most complex design intent [7]. Features refer to the building blocks of the part. They are the shapes and operations that construct the part. Shape-based features would include slots, holes, bosses and the like that either add or remove material from the part. Shape-based features typically begin with either a 2D or 3D sketch. Operation-

based features generally do not have sketches. These types of features include operations like filleting, chamfering, shelling, or applying draft to a part [7]. Building a model in Solidwork usually starts with either a 2D or 3D sketch. The sketch consists of geometry such as lines, arcs, conics, and splines. Dimensions are added to the sketch to define the size and location of the geometry. Relations are used to define attributes such as tangency, parallelism, perpendicularity, concentricity, and such. The parametric nature of Solidwork means the dimensions and relations drive the geometry, not the other way around. The dimensions in the sketch can be controlled independently, or by relationships to other parameters outside the sketch [7]. Another aspect of the feature-based nature of Solidwork is you can roll back into the history of the part in order to make changes, add additional features, or change to sequence in which operations are performed. In an assembly, the analog to sketch relations are mates. Just as sketch relations define conditions such as tangency, parallelism, and concentricity with respect to sketch geometry, assembly mates define the same relations with respect to the individual parts or components. Beyond the simple mates are advanced mates that include gear and cam and follower mates [7].

2.3

Rapid prototyping
Rapid prototyping transforms virtual design from computer added design (CAD) or animation modeling software into cross sections which is still in virtual model and then creates each cross sectional in physical space, one after next until the model is finished. The process is correspondent almost identically for the virtual model and the physical model [14]. In additive fabrication, the machine reads in data from a CAD drawing and lays down successive layers of liquid or powdered material and in this way builds up the model from a series of cross sections. These layers, which correspond to the virtual cross section from the CAD model, are glued together or fused automatically to create the final shape. The primary advantage to additive construction is its ability to create almost any geometry. Table 2.1 below is shown prototyping technologies that already provided [14].

Table 2.1: Prototyping technologies and base materials [14].

Prototyping Technologies Selective laser sintering (SLS) Fused Deposition Modeling (FDM) Stereo lithography (SLA) Multi Jet Modeling (MJM) Laminated Object Manufacturing (LOM) Electron Beam Melting (EBM) 3D Printing (3DP)

Base Materials Thermoplastics metals, ceramic powders Thermoplastics, Eutectic metals Photopolymer Photopolymer Paper Titanium alloys Various materials

2.3.1 Rapid Prototyping Workflow

All RP systems have a common information workflow. The main stages in preparing and pre-processing data for automated fabrication of 3D objects are as Figure 2.2:

Data creation Data export Data validation and repair Part orientation and scaling

3D CAD package CAD interface to STL Specialised RP software

Specialised RP software

Support structures generation

Specialised RP software

Setting up of process parameters

Specialised RP software

2D slice data generation

Specialised RP software

Part build file

i.

Figure 2.2: Rapid Prototyping information flow [14]. Data Creation:

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A 3D CAD package or 2D scanning device can be employed to create geometric data. In both cases, the data must be represented in a model whose surfaces define a closed 3D volume without any holes, surfaces with zero thickness or more than two surfaces meeting along common edge [14].

ii.

Data Export: The valid 3D model is exported from the CAD package in a neutral format which is most cases is STL format. Some CAD packages allow the size of the generated file to be controlled by increasing or reducing the model resolution [14].

iii.

Data Validation and Repair: The exported data is an approximation of the precise internal 3D model. During the approximation process the model surfaces are represented with simple geometrical entities in the form of triangles. Unfortunately, STL models created in this way can contain undesirable geometrical errors such as holes and overlapping areas along surface boundaries. Therefore, the generated files have to be validated before being further processed. Some RP package offer facilities for model repair, automatic and manual. These packages include software tools that evaluate the STL models and determine whether any triangles re missing. In case of errors, the gaps in he models are filled with new triangles [14].

iv.

Part Orientation and Scaling: RP systems build parts along the Z axis of their STL models. Through reorientation of the parts relative to the model coordinate systems, their accuracy, surface finish and build time can be optimized. Some RP systems allow several parts to be nested in the system chamber in order to be built simultaneously. In addition, the parts can be scaled to compensate for anticipated anomalies that

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might be introduced by downstream processes such as deformation, shrinkage, war page and curling [14].

v.

Support Structures Generation: Liquid-base RP processes require support structures to build overhanging areas of the parts. These structures are usually generated automatically employing specialized software tools. These areas requiring support structures can be minimized by appropriately selecting the part build direction [14].

vi.

Setting-up of Process Parameters: Process-related parameters are entered to specify the build style and desired system attributes. These parameters can be adjusted based on part requirements and the RP material being used [14].

vii.

2D Slice Data Generation: The STL file is sliced to produce successive cross sectional layers. In each cross section, poly lines are used to approximate the exterior and interior boundaries of the RP models. These poly line boundaries can be offset by a particular value to compensate for process errors. These slice data can be generated offline for the entire model or online, one cross section at a time during part building [14].

The process data generated following the stages outlined above is stored in a build file. This file contains all the information needed to guide material additive processes to build 3D objects [14].

2.3.2 Three-Dimensional Printing (3DP)

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Three Dimensional Printing is a process for the rapid and flexible production of prototype parts, end-use parts, and tools directly from a CAD model. Three Dimensional Printing has unprecedented flexibility. It can create parts of any geometry, and out of any material, including ceramics, metals, polymers and composites. Furthermore, it can exercise local control over the material composition, microstructure, and surface texture Figure 2.3 shows the process cycle for 3D printing [8].

Spread powder

Print layer Repeat cycle

Drop piston

Intermediate stage

Last layer printed

Finished part

Figure 2.3: Process cycle for 3D printing [8].

Process

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Three Dimensional Printing functions by building parts in layers. From a computer (CAD) model of the desired part, a slicing algorithm draws detailed information for every layer. Each layer begins with a thin distribution of powder spread over the surface of a powder bed. Using a technology similar to ink-jet printing, a binder material selectively joins particles where the object is to be formed. A piston that supports the powder bed and the part-in-progress lowers so that the next powder layer can be spread and selectively joined. This layer-bylayer process repeats until the part is completed. Following a heat treatment, unbound powder is removed, leaving the fabricated part. The sequence of operations is depicted as Figure 2.4 below [8].

CAD Model

3DP machine

Any geometry Any material Controlled material composition Controlled microstructure Controlled surface texture

Figure 2.4: Process sequence [8].

Process Capabilities
The 3D Printer process combines powders and binders with unprecedented geometric flexibility. The support gained from the powder bed means that overhangs, undercuts and internal volumes can be created (as long as there is a hole for the loose powder to escape). 3D Printing can form any material that can be obtained as a powder - which is just about any material. Further, because different materials can be dispensed by different print heads, 3D Printing can exercise control over local material composition. Material can be in a liquid

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carrier, or it can be applied as molten matter. The proper placement of droplets can be used to create surfaces of controlled texture and to control the internal microstructure of the printed part [8]. The 3D Printer process surpasses conventional powder processing because while the 3D Printer components rival the performance of those made by conventional methods, there are no tooling or geometric limitations with Three Dimensional Printing. Because of its great flexibility in handling a wide range of materials and because of the unique ability to locally tailor the material composition, Three Dimensional Printing offers potential for the direct manufacture of structural components with unique microstructures and capabilities. Three Dimensional Printing is also readily scaled in production rate through the use of multiple nozzle technology which has been commercially developed for printing images on paper [8].

Injection mould

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Injection mouldings are manufacturing techniques for making parts from both thermoplastic and thermosetting plastic materials in production. Molten plastic is injected at high pressure into a mould, which is the inverse of the product's shape. After a product is designed by an Industrial Designer or an Engineer, moulds are made by a mould maker (or toolmaker) from metal, usually either steel or aluminum, and precision-machined to form the features of the desired part. Injection moulding is widely used for manufacturing a variety of parts, from the smallest component to entire body panels of cars [13]. The plastic injection molding process is a cyclic process. There are four significant stages in the process. These stages are filling, packing, cooling and ejection. The plastic injection molding process begins with feeding the resin and the appropriate additives from the hopper to the heating/injection system of the injection plastic injection molding machine. This is the filling stage in which the mould cavity is filled with hot polymer melt at injection temperature. After the cavity is filled, in the packing stage, additional polymer melt is packed into the cavity at a higher pressure to compensate the expected shrinkage as the polymer solidifies. This is followed by cooling stage where the mould is cooled until the part is sufficiently rigid to be ejected. The last step is the ejection stage in which the mould is opened and the part is ejected, after which the mould is closed again to begin the next cycle [12].

2.4.1 Types of mould

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There are two main types of injection moulds: cold runner (two plate and three plate designs) and hot runner. The significant difference is the presence of a sprue and runner with every moulded part in the cold runner type. This extra moulded component must be separated from the desired moulded part [4].

2.4.1.1 Cold runner moulds The cold runner mould type is very simple and much cheaper than a hot runner system. The mold requires less maintenance and less skill to set up and operate. Color changes are very easy since all the plastic in the mould is ejected with each cycle [4]. The two plate and the three plate designs are the two major types of cold runner molds. The two plates is the simplest type of mould. It has one parting line and hence two sections or halves. The runner system must be located on this parting line and the part must be gated on its perimeter. The runner is ejected together with the part. Figure 2.5 shows two plate mould in closed (a) and open (b) positions [4].

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Stationary Platen

Water channel Support plate Movable platen Ejector housing

Cavity Runner Sprue Gate

Ejector plate

Ejector pin

plate

Parting line

Ejector pins

(a)

Ejector pins

Sprue puller

Sprue bushing

(b) Figure 2.5: Two Plate Mould in Closed (a) and Open (b) Positions [4].

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The three plates have two parting lines and therefore three sections. The runner system can be located on one parting line and the part on the other parting line. Three plate designs are used because of their flexibility in gating location. A part can be gated virtually anywhere along its surface. In a two plate design, the part must be suitable for edge gating. With a three plate mould design, the parts must be suitable for center gating. This will allow for uniform part filling without partweakening weld lines [4].

2.4.1.2 Hot runner mould The hot runner mould is essentially a two plate mould with a heated runner system inside one half of the mould. The runner system through the manifold and the drops convey the heated plastic to the part. This system allows greater control over melt temperatures and other processing conditions. A hot runner system is considered where production volumes are high and a shorter cycle time is a requirement [4].

2.4.2 Mould parts

A mould of good quality should have the following features: cavity and core, sprue, runners and gates cooling system, and ejection system.

2.4.2.1 Cavity and core Simply described, a mould is made of two halves where the cavity is depressed into the one half, and the core sticks out from the other. The space formed between them is filled with heated plastic that is cooled before leaving the mould. Figure 2.6 below shows core, cavity and simple plastic product [5].

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Figure 2.6: Core, cavity and simple plastic product [5]. Since the mould must be opened before the product is released, it is provided with a movable section and a fixed section, one attached to the movable pressure plate and the other to the fixed plate. In order to make the core fit the cavity guide pins are fitted into corresponding holes in the cavity half of the mould [5].

2.4.2.2Sprue
The sprue connects the injection head of the cylinder with the mould (Figure 2.7), and it is through the sprue that the plastic is injected to the mould. Often the sprue passage is a conical channel inside a sprue washer. Sprues may also be formed directly in the fixed mould without a washer. This type of design makes for more expensive repairs when the sprue has been damaged. Figure 2.8 below show the injector head and washer [5].

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Figure 2.7: Sprue [5].

(a)

(b) Figure 2.8: Injector head and washer [5].

(c)

a) Injector head shape accords well to sprue washer. b) Sprue washer radius too small compared to injector head making the sprue less tight. c) Injector head sprue radius larger than washer, resulting in leakage. d).When the tip of the injector head is flat good tightness is hard to obtain, leaving plastic between head and washer making it difficult to release the product.

2.4.2.3Runner and gate

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The plastic is injected from the injecting head directly into mould chamber only when the mould is made of one chamber. When it comes to multi-chamber moulds, runners must be used to lead the plastic to all chambers. Runners and mould chambers connect to each other by a narrow channel called gate. Figure 2.9 shows the gate design [5].

Figure 2.9: Gate [5].

2.4.3 Mould design

In injection moulding, the design of a mould is of critical importance for product quality and efficient processing. In most cases, quality of mould is responsible for the economics of the entire process. Injection mould design involves extensive empirical knowledge about the structure and functions of the components of the mould. Nowadays, mould design faces with increasing deadline pressures and the design itself is predominantly based upon experience of the mould designer. Mould designers are required to possess thorough and broad experience, because detailed decisions require the knowledge of the interaction among various parameters. Unfortunately, it is presently impossible to cover the growing demand for such experienced designers. Therefore,

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intelligent CAD tools that can assist in the various tasks of the mould design process are very important to the productivity of the mould-making industry. The basic features of an injection mould consist of cavity number and layout, feed system, cooling system, ejection system and mould construction. Figure 2.10 shows the general procedure of mould design [11]. This is followed by consideration of the arrangements of the cavities in the mould frame, which might directly include thoughts on the ease of ejection and subsequently, the connection between mouldings and runners and part quality (number, position and shape of gates). The feed system accommodates the molten plastic material coming from the injection nozzle of the moulding machine and distributes it into each cavity. To remove the heat from the moulding, it is necessary to provide the mould with a cooling system. After the moulding has solidified and cooled down, it has to be removed from the mould by the ejection system [11].

Details of order
General items: size of order, costs, delivery dates Part: geometry, material, appearance tolerances, strength and other properties Machine data

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Number of cavities

Cavity layout

No of parting line

Dimension of cavity

Sprue, runner

Gates

Cooling system

Mechanical design

Exact cavity dimensions

Ejector system

Leader & alignment

system
Venting

Mounting options

Figure 2.10: The general procedure for mould design [11].

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