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Debes Bhattacharyya - One of the best experts on this subject based on the ideXlab platform.
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rotational Molding Cycle time reduction using a combination of physical techniques
Polymer Engineering and Science, 2009Co-Authors: Mohamad Zaki Abdullah, Simon Bickerton, Debes Bhattacharyya, R J Crawford, Eileen HarkinjonesAbstract:Rotational Molding is a process used to manufacture hollow plastic products, and has been heralded as a Molding method with great potential. Reduction of Cycle times is an important issue for the rotational Molding industry, addressing a significant disadvantage of the process. Previous attempts to reduce Cycle times have addressed surface enhanced molds, internal pressure, internal cooling, water spray cooling, and higher oven air flow rates within the existing process. This article explores the potential benefits of these Cycle time reduction techniques, and combinations of them. Recommendations on a best practice combination are made, based on experimental observations and resulting product quality. Applying the proposed Molding conditions (i.e., a combination of surface-enhanced molds, higher oven flow rates, internal mold pressure, and water spray cooling), Cycle time reductions of up to 70% were achieved. Such savings are very significant, inviting the rotoMolding community to incorporate these techniques efficiently in an industrial setting.
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rotational Molding Cycle time reduction through surface enhanced molds part a theoretical study
Polymer Engineering and Science, 2007Co-Authors: Mohamad Zaki Abdullah, Simon Bickerton, Debes BhattacharyyaAbstract:Rotational Molding has been regarded as a plastic Molding method with great potential. The process offers virtually stress-free products having no weld lines or material wastage, and utilizes relatively inexpensive molds. Yet its widespread growth is hindered due to long production Cycle times, which are limited by the time required to heat up and cool down the mold and the product. To address this issue, efforts have been made to enhance heat transfer to and from molds, ultimately reducing Cycle times. The application of extended and rough surfaces to molds is investigated here. The aim of this study is to predict reductions in Cycle time due to the enhancement of mold surfaces (i.e. roughness-enhanced and pin-enhanced molds). By utilizing a combination of heat transfer correlations, numerical analysis, and an existing rotational Molding process simulation, Cycle time predictions were made. The average predicted Cycle time reductions were ∼21 and 32% for the roughness-enhanced and pin-enhanced molds considered, under a variety of conditions. POLYM. ENG. SCI., 47:1406–1419, 2007. © 2007 Society of Plastics Engineers
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rotational Molding Cycle time reduction through surface enhanced molds part b experimental study
Polymer Engineering and Science, 2007Co-Authors: Mohamad Zaki Abdullah, Simon Bickerton, Debes BhattacharyyaAbstract:Rotational Molding is a process used to manufacture hollow plastic products, and has been heralded as a Molding method with great potential. Because of long production Cycle times, which are limited by the time required to heat-up and cool-down the mold and the product, its productivity is hampered. To address this issue, exterior mold modification techniques (i.e. the application of extended and rough surfaces) have been employed to enhance heat transfer to and from molds, ultimately reducing Cycle times. Extended surfaces have the potential to enhance heat transfer by increasing the surface area. Roughness elements are utilized in conjunction with turbulent flows, also producing significant increases in heat transfer rates. Experimental results presented here demonstrate very significant Cycle time reductions through the use of surface-enhanced molds. The experimental savings are in the order of 18 and 28%, whereas the predicted Cycle time reductions are around of 21 and 32% for roughness-enhanced and pin-enhanced molds, respectively. Although the prediction methods have been unable to forecast the exact experimental Cycle times very accurately, they have proved to be useful for predicting the approximate Cycle time reductions and the relative rankings of the plain and the surface-enhanced molds. POLYM. ENG. SCI., 47:1420–1429, 2007. © 2007 Society of Plastics Engineers
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Rotational Molding Cycle time reduction through surface‐enhanced molds, Part B: Experimental study
Polymer Engineering and Science, 2007Co-Authors: Mohamad Zaki Abdullah, Simon Bickerton, Debes BhattacharyyaAbstract:Rotational Molding is a process used to manufacture hollow plastic products, and has been heralded as a Molding method with great potential. Because of long production Cycle times, which are limited by the time required to heat-up and cool-down the mold and the product, its productivity is hampered. To address this issue, exterior mold modification techniques (i.e. the application of extended and rough surfaces) have been employed to enhance heat transfer to and from molds, ultimately reducing Cycle times. Extended surfaces have the potential to enhance heat transfer by increasing the surface area. Roughness elements are utilized in conjunction with turbulent flows, also producing significant increases in heat transfer rates. Experimental results presented here demonstrate very significant Cycle time reductions through the use of surface-enhanced molds. The experimental savings are in the order of 18 and 28%, whereas the predicted Cycle time reductions are around of 21 and 32% for roughness-enhanced and pin-enhanced molds, respectively. Although the prediction methods have been unable to forecast the exact experimental Cycle times very accurately, they have proved to be useful for predicting the approximate Cycle time reductions and the relative rankings of the plain and the surface-enhanced molds. POLYM. ENG. SCI., 47:1420–1429, 2007. © 2007 Society of Plastics Engineers
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Rotational Molding Cycle time reduction through surface enhanced molds: Part A—Theoretical study
Polymer Engineering and Science, 2007Co-Authors: Mohamad Zaki Abdullah, Simon Bickerton, Debes BhattacharyyaAbstract:Rotational Molding has been regarded as a plastic Molding method with great potential. The process offers virtually stress-free products having no weld lines or material wastage, and utilizes relatively inexpensive molds. Yet its widespread growth is hindered due to long production Cycle times, which are limited by the time required to heat up and cool down the mold and the product. To address this issue, efforts have been made to enhance heat transfer to and from molds, ultimately reducing Cycle times. The application of extended and rough surfaces to molds is investigated here. The aim of this study is to predict reductions in Cycle time due to the enhancement of mold surfaces (i.e. roughness-enhanced and pin-enhanced molds). By utilizing a combination of heat transfer correlations, numerical analysis, and an existing rotational Molding process simulation, Cycle time predictions were made. The average predicted Cycle time reductions were ∼21 and 32% for the roughness-enhanced and pin-enhanced molds considered, under a variety of conditions. POLYM. ENG. SCI., 47:1406–1419, 2007. © 2007 Society of Plastics Engineers
Janez Grum - One of the best experts on this subject based on the ideXlab platform.
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Wavelet Packet Decomposition to Characterize Injection Molding Tool Damage
Applied Sciences, 2016Co-Authors: Dragan Kusić, Janez GrumAbstract:This paper presents measurements of acoustic emission (AE) signals during the injection Molding of polypropylene with new and damaged mold. The damaged injection mold has cracks induced by laser surface heat treatment. Standard test specimens were injection molded, commonly used for examining the shrinkage behavior of various thermoplastic materials. The measured AE burst signals during injection Molding Cycle are presented. For injection Molding tool integrity prediction, different AE burst signals’ descriptors are defined. To lower computational complexity and increase performance, the feature selection method was implemented to define a feature subset in an appropriate multidimensional space to characterize the integrity of the injection Molding tool and the injection Molding process steps. The feature subset was used for neural network pattern recognition of AE signals during the full time of the injection Molding Cycle. The results confirm that acoustic emission measurement during injection Molding of polymer materials is a promising technique for characterizing the integrity of molds with respect to damage, even with resonant sensors.
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acoustic emission detection of macro cracks on engraving tool steel inserts during the injection Molding Cycle using pzt sensors
Sensors, 2013Co-Authors: Rajko Svecko, Dragan Kusic, Andrej Sarjas, Ales Hancic, Janez GrumAbstract:This paper presents an improved monitoring system for the failure detection of engraving tool steel inserts during the injection Molding Cycle. This system uses acoustic emission PZT sensors mounted through acoustic waveguides on the engraving insert. We were thus able to clearly distinguish the defect through measured AE signals. Two engraving tool steel inserts were tested during the production of standard test specimens, each under the same processing conditions. By closely comparing the captured AE signals on both engraving inserts during the filling and packing stages, we were able to detect the presence of macro-cracks on one engraving insert. Gabor wavelet analysis was used for closer examination of the captured AE signals' peak amplitudes during the filling and packing stages. The obtained results revealed that such a system could be used successfully as an improved tool for monitoring the integrity of an injection Molding process.
Mohamad Zaki Abdullah - One of the best experts on this subject based on the ideXlab platform.
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rotational Molding Cycle time reduction using a combination of physical techniques
Polymer Engineering and Science, 2009Co-Authors: Mohamad Zaki Abdullah, Simon Bickerton, Debes Bhattacharyya, R J Crawford, Eileen HarkinjonesAbstract:Rotational Molding is a process used to manufacture hollow plastic products, and has been heralded as a Molding method with great potential. Reduction of Cycle times is an important issue for the rotational Molding industry, addressing a significant disadvantage of the process. Previous attempts to reduce Cycle times have addressed surface enhanced molds, internal pressure, internal cooling, water spray cooling, and higher oven air flow rates within the existing process. This article explores the potential benefits of these Cycle time reduction techniques, and combinations of them. Recommendations on a best practice combination are made, based on experimental observations and resulting product quality. Applying the proposed Molding conditions (i.e., a combination of surface-enhanced molds, higher oven flow rates, internal mold pressure, and water spray cooling), Cycle time reductions of up to 70% were achieved. Such savings are very significant, inviting the rotoMolding community to incorporate these techniques efficiently in an industrial setting.
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rotational Molding Cycle time reduction through surface enhanced molds part a theoretical study
Polymer Engineering and Science, 2007Co-Authors: Mohamad Zaki Abdullah, Simon Bickerton, Debes BhattacharyyaAbstract:Rotational Molding has been regarded as a plastic Molding method with great potential. The process offers virtually stress-free products having no weld lines or material wastage, and utilizes relatively inexpensive molds. Yet its widespread growth is hindered due to long production Cycle times, which are limited by the time required to heat up and cool down the mold and the product. To address this issue, efforts have been made to enhance heat transfer to and from molds, ultimately reducing Cycle times. The application of extended and rough surfaces to molds is investigated here. The aim of this study is to predict reductions in Cycle time due to the enhancement of mold surfaces (i.e. roughness-enhanced and pin-enhanced molds). By utilizing a combination of heat transfer correlations, numerical analysis, and an existing rotational Molding process simulation, Cycle time predictions were made. The average predicted Cycle time reductions were ∼21 and 32% for the roughness-enhanced and pin-enhanced molds considered, under a variety of conditions. POLYM. ENG. SCI., 47:1406–1419, 2007. © 2007 Society of Plastics Engineers
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rotational Molding Cycle time reduction through surface enhanced molds part b experimental study
Polymer Engineering and Science, 2007Co-Authors: Mohamad Zaki Abdullah, Simon Bickerton, Debes BhattacharyyaAbstract:Rotational Molding is a process used to manufacture hollow plastic products, and has been heralded as a Molding method with great potential. Because of long production Cycle times, which are limited by the time required to heat-up and cool-down the mold and the product, its productivity is hampered. To address this issue, exterior mold modification techniques (i.e. the application of extended and rough surfaces) have been employed to enhance heat transfer to and from molds, ultimately reducing Cycle times. Extended surfaces have the potential to enhance heat transfer by increasing the surface area. Roughness elements are utilized in conjunction with turbulent flows, also producing significant increases in heat transfer rates. Experimental results presented here demonstrate very significant Cycle time reductions through the use of surface-enhanced molds. The experimental savings are in the order of 18 and 28%, whereas the predicted Cycle time reductions are around of 21 and 32% for roughness-enhanced and pin-enhanced molds, respectively. Although the prediction methods have been unable to forecast the exact experimental Cycle times very accurately, they have proved to be useful for predicting the approximate Cycle time reductions and the relative rankings of the plain and the surface-enhanced molds. POLYM. ENG. SCI., 47:1420–1429, 2007. © 2007 Society of Plastics Engineers
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Rotational Molding Cycle time reduction through surface‐enhanced molds, Part B: Experimental study
Polymer Engineering and Science, 2007Co-Authors: Mohamad Zaki Abdullah, Simon Bickerton, Debes BhattacharyyaAbstract:Rotational Molding is a process used to manufacture hollow plastic products, and has been heralded as a Molding method with great potential. Because of long production Cycle times, which are limited by the time required to heat-up and cool-down the mold and the product, its productivity is hampered. To address this issue, exterior mold modification techniques (i.e. the application of extended and rough surfaces) have been employed to enhance heat transfer to and from molds, ultimately reducing Cycle times. Extended surfaces have the potential to enhance heat transfer by increasing the surface area. Roughness elements are utilized in conjunction with turbulent flows, also producing significant increases in heat transfer rates. Experimental results presented here demonstrate very significant Cycle time reductions through the use of surface-enhanced molds. The experimental savings are in the order of 18 and 28%, whereas the predicted Cycle time reductions are around of 21 and 32% for roughness-enhanced and pin-enhanced molds, respectively. Although the prediction methods have been unable to forecast the exact experimental Cycle times very accurately, they have proved to be useful for predicting the approximate Cycle time reductions and the relative rankings of the plain and the surface-enhanced molds. POLYM. ENG. SCI., 47:1420–1429, 2007. © 2007 Society of Plastics Engineers
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Rotational Molding Cycle time reduction through surface enhanced molds: Part A—Theoretical study
Polymer Engineering and Science, 2007Co-Authors: Mohamad Zaki Abdullah, Simon Bickerton, Debes BhattacharyyaAbstract:Rotational Molding has been regarded as a plastic Molding method with great potential. The process offers virtually stress-free products having no weld lines or material wastage, and utilizes relatively inexpensive molds. Yet its widespread growth is hindered due to long production Cycle times, which are limited by the time required to heat up and cool down the mold and the product. To address this issue, efforts have been made to enhance heat transfer to and from molds, ultimately reducing Cycle times. The application of extended and rough surfaces to molds is investigated here. The aim of this study is to predict reductions in Cycle time due to the enhancement of mold surfaces (i.e. roughness-enhanced and pin-enhanced molds). By utilizing a combination of heat transfer correlations, numerical analysis, and an existing rotational Molding process simulation, Cycle time predictions were made. The average predicted Cycle time reductions were ∼21 and 32% for the roughness-enhanced and pin-enhanced molds considered, under a variety of conditions. POLYM. ENG. SCI., 47:1406–1419, 2007. © 2007 Society of Plastics Engineers
Shamsuddin Sulaiman - One of the best experts on this subject based on the ideXlab platform.
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design and thermal analysis of plastic injection mould
Journal of Materials Processing Technology, 2006Co-Authors: Sai Hong Tang, Y M Kong, Razali Samin, S M Sapuan, Shamsuddin SulaimanAbstract:Abstract This paper presents the design of a plastic injection mould for producing warpage testing specimen and performing thermal analysis for the mould to access on the effect of thermal residual stress in the mould. The technique, theory, methods as well as consideration needed in designing of plastic injection mould are presented. Design of mould was carried out using commercial computer aided design software Unigraphics, Version 13.0. The model for thermal residual stress analysis due to uneven cooling of the specimen was developed and solved using a commercial finite element analysis software called LUSAS Analyst, Version 13.5. The software provides contour plot of temperature distribution for the model and also temperature variation through the plastic injection Molding Cycle by plotting time response curves. The results show that shrinkage is likely to occur in the region near the cooling channels as compared to other regions. This uneven cooling effect at different regions of mould contributed to warpage.
Satyandra K Gupta - One of the best experts on this subject based on the ideXlab platform.
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GMP - A step towards automated design of side actions in injection Molding of complex parts
Geometric Modeling and Processing - GMP 2006, 2006Co-Authors: Ashis Gopal Banerjee, Satyandra K GuptaAbstract:Side actions contribute to mold cost by resulting in an additional manufacturing and assembly cost as well as by increasing the Molding Cycle time. Therefore, generating shapes of side actions requires solving a complex geometric optimization problem. Different objective functions may be needed depending upon different Molding scenarios (e.g., prototyping versus large production runs). Manually designing side actions is a challenging task and requires considerable expertise. Automated design of side actions will significantly reduce mold design lead times. This paper describes algorithms for generating shapes of side actions to minimize a customizable Molding cost function.
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A Step Towards Automated Design of Side Actions in Injection Molding of Complex Parts
2006Co-Authors: Ashis Gopal Banerjee, Satyandra K GuptaAbstract:Side actions contribute to mold cost by resulting in an additional manufacturing and assembly cost as well as by increasing the Molding Cycle time. Therefore, generating shapes of side actions requires solving a complex geometric optimization problem. Different objective functions may be needed depending upon different Molding scenarios (e.g., prototyping versus large production runs). Manually designing side actions is a challenging task and requires considerable expertise. Automated design of side actions will significantly reduce mold design lead times. This paper describes algorithms for generating shapes of side actions to minimize a customizable Molding cost function.