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Methods and Processes to Optimising Component Development for Injection Moulding

New tools and methods can be deployed in the development of moulded parts in order to improve and accelerate the lead time to product maturity. CAx systems throughout, from 3D component modelling, via prototyping, mould construction, the optimisation of the production process by means of simulation, through to component measuring and geometric feedback for mould corrections, can help to shorten development times in the product creation process, and to improve product quality and economy. Non-proprietary data formats and interfaces characterise efficient use. Generative rapid prototyping and rapid tooling approaches are available for fast evaluation of the functionality of new components. Support and expert systems provide repositories for state-of-art knowledge, draw consequences from this knowledge, and provide solutions or problem solving approaches in a dialogue with the user.

The dimensional and shape accuracy of precision parts is guaranteed by a combination of a precise injection moulding process and the suitability of the selected method for measuring key characteristics. Component developers define functional tolerances to ensure the functionality of a moulded part, and thus establish usability thresholds for the component under operating conditions. Permissible dimensional and shape deviations are defined by reference to permissible production tolerances. Increasingly, electro-mechanical drive axes are used on injection moulding machines for precision injection moulding, much like on machine tools. As an aid to failure recording and analysis in precision injection moulding, quality tools based on mathematical and statistical principles are deployed in precision injection moulding. The newly developed expansion injection moulding technology extends the injection moulding technology domain to extremely thin and small precision parts. This method stores the energy required for the filling process directly in the plastic melt by means of compression. Cavity filling occurs by the plastic melt in the accumulator expanding after the shut-off system is opened. This makes it possible to create extremely thin components with a good flow path to wall thickness ratio on the one hand, while on the other hand improving process reproducibility in manufacturing of precision parts.

Lesen Sie die deutsche Zusammenfassung auf

Georg Steinbichler
Lehrstuhl für Kunststofftechnik
Universität Erlangen-Nürnberg


Free keywords: Polymer Processing, Injection Moulding, Product Development Process, Component Design, 3-D-Modelling, Rapid Technologies, Knowledge-based Engineering, Precision Injection Moulding Process, Dimensional Accuracy, Manufacturing Tolerance, Expansion Injection Moulding Technology
Institute / chair: Technische Fakultät der Universität Erlangen-Nürnberg
Language: German
Technical consultant for expert services: Prof. Dr.-Ing. Dr. h.c. Gottfried W. Ehrenstein (Betreuer), Prof. Dr.-Ing. Johannes Wortberg, Prof. Dr.-Ing. Ernst Schmachtenberg
Publication year: 2008
Provider: Wissenschaftlicher Arbeitskreis Kunststofftechnik (WAK) /

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In cooperation with the Wissenschaftlicher Arbeitskreis Kunststofftechnik (WAK), we provide free access to current dissertations in the field of plastics technology.

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