ENG08021 2016 Injection Mould Design
The main purpose of this module is the give student the experience of designing and injection moulding tool similar base on real part requirements and constraints. The student will learn about latest trends in injection moulding and learn about the tool available to produce good quality part parts.
On completion of this module the learner will/should be able to;
Design low cavity moulds for complex parts
Design multi-cavity moulds for high volume parts
Apply plastic flow analysis to the mould design process
Understand the documentation requirements for various sectors: Medical, etc.
Complete a mould design project including all relevant documentation
Present and defend design solution to an audience of peers
Teaching and Learning Strategies
2 hour Lecture
6 hours practical
Module Assessment Strategies
100% continuous assessment
Advanced mould design: Design of low cavity moulds for complex parts including, two plate and three plate moulds, angle pin actuated slide, spring loaded slides, unscrewing/core pulling, collapsible cores, two shot moulding. Over-moulding metal inserts. Calculations associated with clamping, ejection and cooling time etc.
Multi-cavity mould design: Design of high cavity low complexity moulds, runner balancing, Hot runner moulds.
Part design for moulding: Design considerations in relation to standard features ribs, bosses, etc. Snap fit design. Design consideration for 2 shot moulding and other specialist moulding techniques.
Measurement and inspection: Defining inspection requirements, metrology principle, fixturing for inspection.
Optimising part design using Plastic flow analysis: Analysis of part design using plastic flow analysis. Understanding plastic flow, viscoelastic behaviour, shear stress, effect of moulding conditions, flow restrictors and flow leaders.
Standards and documentation: Awareness of relevant standards/ISO, FDA requirements etc. Validation.
Mould design project: For the mould design project the student will design a finished mould for a complex part and produce full documentation for the relevant sector. Generate electrodes of specific details. Plastic flow analysis will be used to ensure correct moulding parameters; runner and gate details are specified.
The student will document the decisions made in a report on the final design.
They will also present and defend design to a panel of peers.
Coursework & Assessment Breakdown
|Title||Type||Form||Percent||Week||Learning Outcomes Assessed|
|1||Mould Design project||Project||Individual Project||50 %||OnGoing||5,6|
|2||Injection Moulding theory||Continuous Assessment||Assessment||50 %||End of Semester||1,2,3,4|
Full Time Mode Workload
|Laboratory Practical||Computer Laboratory||Computer Aided Design||2||Weekly||2.00|
|Laboratory Practical||Computer Laboratory||Mould Design Project||4||Weekly||4.00|
Moldflow Design Guide, A resource for plastics engineerings, 1st Edition 2006
Pye, R.G.W. Injection Mould Design