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Optimization of core molds for injection molding
Stavárek, Václav ; Vaculka, Miroslav (oponent) ; Vosynek, Petr (vedoucí práce)
This thesis was written in cooperation with an industrial company that manufactures electric components for automotive industry. They have issues with frequent core breakage on some of their injection molds, mainly for connector housings. They own licences for injection molding simulation software Moldflow and Moldex3D and also for finite element method simulation software Ansys. After explaining the essential theoretical background to injection molding and its simulation, fluid-structure interaction problems and fatigue analysis, a complex process of determining fatigue lifetime of injection molding cores with the aid of softwares mentioned above is shown on a specific mold from the production of the company. The fatigue model that describes the current state of the mold the best is then chosen to analyze the influence of changing the core geometry and also injection molding process conditions. Changing other parameters that are not possible to involve in the simulation is also discussed and if possible, justified by using other sources. One of the recommendations is to add a radius to both of the cores, which could increase the more frequently breaking core’s fatigue lifetime from 30 days to more than 320 days. This could mean potential savings of 10 600 EUR every year. The other recommendations are changing the tool machining process and doing an additional heat treatment after the machining.
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Optimization of core molds for injection molding
Stavárek, Václav ; Vaculka, Miroslav (oponent) ; Vosynek, Petr (vedoucí práce)
This thesis was written in cooperation with an industrial company that manufactures electric components for automotive industry. They have issues with frequent core breakage on some of their injection molds, mainly for connector housings. They own licences for injection molding simulation software Moldflow and Moldex3D and also for finite element method simulation software Ansys. After explaining the essential theoretical background to injection molding and its simulation, fluid-structure interaction problems and fatigue analysis, a complex process of determining fatigue lifetime of injection molding cores with the aid of softwares mentioned above is shown on a specific mold from the production of the company. The fatigue model that describes the current state of the mold the best is then chosen to analyze the influence of changing the core geometry and also injection molding process conditions. Changing other parameters that are not possible to involve in the simulation is also discussed and if possible, justified by using other sources. One of the recommendations is to add a radius to both of the cores, which could increase the more frequently breaking core’s fatigue lifetime from 30 days to more than 320 days. This could mean potential savings of 10 600 EUR every year. The other recommendations are changing the tool machining process and doing an additional heat treatment after the machining.
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