Engineering Design and Manufacture - Assignment Example

MP2570 – Engineering Design and Manufacture Assignment: Design for manufacture and simulation of a manufacturing processes. Name: Date: 1.0 Finding of the error of the shape In the development of Tupperware container, there are some errors that occurs as a result of injection process. These errors needs to be correcting to help in producing the right quality product in the process. 1.1 Identifying errors in the first design. Figure 1. Poorly designed Tupperware container, available on Blackboard. There are many errors from the initial design from the blackboard. The edges are having some problems which needs to be fixed from the design of the Tupperware above. We will further give the new design without errors 1.2 Explain why each error identified above is bad for the injection moulding process. Kurowski (2013) states that the moulding process such deformation normally affect the quality of the injected product which will be produced. He states further that the kind of errors shown above are capable of rendering the disc impracticable more especially if it is a streaks or blistering.The errors may also cause impair to its cosmetic appearance that is cloud to the injection and it might also interrupt the production process. There are some instances when the fault interact with one another and in the process it makes it impossible to optimize the production process on the basis of a just a single fault (Claeys et al., 2015). There is need for correcting these errors so they do not occur during the moulding process. The moulding machines should be thoroughly checked to help in controlling such errors taking place as they are not good for injection. Injections can be described as process where plastic materials which are in the form of the granules which are melted till they soften then injected to form a mould (Claeys et al., 2015) The errors usually occur during the injection process (Kurowski, 2013). When errors occurs during the process, they form deformed products on the plastic. The errors are seen when the materials has cooled down, the sufficient hardening process is done and the injection mould normally opens releasing the part (Claeys et al., 2015). It is important to control these errors as it will result to perfect product during production process. The moulding process should be safeguarded and all the necessary states should be followed to help in ensuring that the right product is produced. The error result into wastage of materials and resources in the process hence need to reduce errors resulting from injection moulding process. 2.0 Improved Tupperware container from modelling The figure below shows the improved shape of the Tupperware container produced from the modelling process. It shows a complete process which produces containers without errors within them. ] 3.0 Manufacturing Simulations The next activity is to perform manufacturing simulation process using solid CAD software. The process will first explain all the procedures necessary in performing the simulation process and steps which are being followed in performing the activity. 3.1 First simulation In the process of using CAD solidworks, the initial step of creating a flow simulation, one would move to the main menu and click the flow simulation in the project wizard. From that click the create wizard inside the wizard and create new order. The next step involve clicking the next step and keep the default internal analysis type. Other physical features are excluded from this. The new flow channel ready for analysis. It should be noted that flow simulation is capable of analysing any flow type, choosing the type of flow channel will be analysed depending on the number of compressible flows for gases. Click next accepting this will help in creating wall condition and the photo of the same. This process will be able to produce the required mesh in the first step of simulation process using CAD. When we perform this practically, the shapes produced is shown below. Figure 2. Solid mesh of the cavity. The figures shows the produced mesh in the solidworks cavity which involve the flow pack warp in use. Use figures and notes to show important results of the simulation (Flow + Pack + Warp). When the result is imported the result are shown above. In developing the flow pack and warp, the following steps are important when using CAD solidworks. First import the model as shown in the figure 3 below indicating the simulation process in CAD In this step it is important to check the geometry to help in verifying the quality of the geometry you are intending to produce. In case the quality is poor, you can fixed it before moving to the next step. Click the CADdoctor t help in fixing the geometry. The geometry produces elements which are error free. The corrected image is shown in the figure below While using the CAD follow the auto fix steps to help in fixing the geometry. After that you can now export the geometry back to the designer and move to the next step when running the system. The next step is to build the runner system using the wizard in the system. The third system is to specify the cooling system. This is done using the cooling system wizard and it is done after creating the base of the mould and other parts like the cooling channels and the inlets and outlets (Lee, 2015). Ensure that you have clicked the cooling channel which will help in ensuring the layout of the cooling system you intend to use. This can be presented in the figure below. You can decide to either run fast cooling analysis or advanced cooling analysis depending with which one is wish to run. Ensure that you create cooling system solid mesh. When the cooling system is complete, a solid mesh of cavity and runner system will be formed based on cooling system which has just completed. The overall results is shown in the figure below:- 3.2 Cooling system design The cooling system which is proposed here is one in which the type with channels following the form of the product. The modern systems for quick prototyping that allow for the development of similar forms so as from the technological point of view and the real production of the injection and injection mold tools if that is possible. The position of the cooling system as per the available information given be presented in the figure below. The cross section surface of the cooling channels and their location in relation to the produced details are normally determined in accordance with the thickness of the details walls. From the simulation results this can be shown in the figure below; The figure above shows the cooling system simulated for mold Figure 3. Cooling circuit design It shows the fluid flow at low and high temperature and the material with both low and high conductivity. 3.3 Final optimisation The main aim of optimization is mainly to help in improving product performance. In this case we improve the moulding process using the CAD. From the optimization result above, note that the programmed refresh can deal with the structure part as well as the kind of changes which are required as appeared previously. Other alteration can likewise happen amid advancement prepare. These incorporate the bar lengths, the pillar turn point, strong change bodies and smother status. The SOLIDWORKS reenactment virtual products has helped with rearranging the basic advancement handle. There is need to produce product which are free from error and ensure that quality is maintained in the process of simulation. Reference Claeys, B., Vervaeck, A., Hillewaere, X. K., Possemiers, S., Hansen, L., De Beer, T., ... & Vervaet, C. (2015). Thermoplastic polyurethanes for the manufacturing of highly dosed oral sustained release matrices via hot melt extrusion and injection molding. European Journal of Pharmaceutics and Biopharmaceutics, 90, 44-52. Kurowski, P. (2013). Engineering Analysis with SolidWorks Simulation 2013. SDC publications. Lee, H. H. (2015). Mechanics of Materials Labs with SOLIDWORKS Simulation 2015. SDC Publications. Patil, N. R., Kulkarni, R. R., Mane, B. R., & Malve, S. H. (2014). Static analysis of Go-Kart Chassis frame by Analytical and SolidWorks Simulation. International Journal of Scientific Engineering and Technology. Read More