PE2007 Mould and Die Design

https://intranet.londonmet.ac.uk/prog-plan/module-catalogue/2/pe/pe2007.cfmPE2007 Mould and Die Design
Teaching Location
North
Teaching Semester
Spring
Module Level
I
Home Academic Department
LMPC
Module Leader
Peter Cracknell
Module Web Site
PE2007
Teaching Mode
day
Module Title
Mould and Die Design
Timeslot
City campusNorth campus
Credit Rating For Module
15
Module Summary
Module code: PE2007NModule title: Mould and Die DesignDescription: This module covers the principles essential to the design of moulds and dies with special emphasis on the processes used in manufacturing products from polymers.Semester: SpringPrerequisite: PE1004NAssessment: Coursework (60%) + Exam (40%)
Prerequisites And Corequisites
PE 1004N
Summary Description Of Assessment Items
(See Explanations and Definitions)
Assessment type
Description of item
% Weighting
Qual Mark
Qual Set
Tariff
Week due
CWK
Individual assignment
20
40%
1
-
7
PRA
Workshop practices reports
40
40%
1
-
11
EXU
2½ hours unseen examination
40
40%
-
-
15
Module Aims
• To develop in depth the principles of mould and die design with special emphasis on those used in the polymer industry. (A2, A3)• To enable students to design and evaluate moulds and dies of acceptable quality and performance for given specified polymer products. (A2, A3)The principal graduate attributes focused on in this module are A2 and A3.
Syllabus
• Tool Design criteria and analysisMould design types; 2-plate, multi-plate, undercut, runnerless and compression mould designs.• Die DesignRod, tube, sheet and profile die designs.• Special emphasisa) Flow behaviour and gating, calculations of feed system parameters.b) Ejection type and deployment.c) Cooling systems and deployment.d) Mould and die making materials, inc. criteria for selection.e) Standard mould and die parts (selection and design incorporation).f) Prototype tool designs and applications (RIM, rapid prototyping, etc).g) Flow behaviour in dies (pressure differential, land dimensions, output, etc.).h) Tool manufacturing and economic considerations.i) Case studies of good and bad design.• MoldFlow in Mould Design• Mould Design Workshop
Learning And Teaching
This module comprises 24 hours of lecture, 10 hours of MoldFlow computer simulation sessions, 4 hours of mould making workshop, 2 hours of tutorial and 4 hours of revision.• Lecture: The lecture will discuss the week’s topic by presenting the fundamental principles and main theoretical analysis accompanied by clarifying examples.• Tutorial: The tutorial will provide a forum where students will have the opportunity to work through exercise sheets and discuss issues related to the lectures and coursework elements of the module. The tutorial should be interpreted as a vehicle for discussion and debate.• MoldFlow computer simulation: Students will have access to the MoldFlow computer based simulation package to carry out a series of exercises. Upon completion, students should be able to model a part/runner system, optimise gate location, analyse and interpret fill, and recommend design changes.• Mould making workshop: Students will be guided through a comprehensive workshop practice as they work in-groups of two or three to design and make moulds. This activity will provide a valuable hands-on -experience of using mould-making tool design.• Student-centred learning: Students are expected to undertake directed independent study by reading through lecture notes, recommended chapters/sections from the module text and other recommended sources in order to complete coursework elements of the module.
Learning Outcomes
On successful completion of this module students should be able to:1. Construct an effective tooling specification fit for intended purposes. (A2)2. Design basic mould/die tooling in conformance to industrial practice. (A3)3. Discriminate between good and bad design practice. (A3)4. Effectively evaluate a given tool design with respect to cooling, feeding, ejection and integrity of construction. (A2, A3)5. Constructively criticise a given polymer product design regarding its mouldability in the context of the polymer used. (A3)6. Calculate manifold dimensions in sheet dies. (A2)
Assessment Strategy
This module is assessed by coursework and unseen examination. The assessment components are;• Individual assignment: This piece of coursework aims to develop and assess student understanding of the subject matter and his/her ability to produce solutions to specific mould design problems. Students are expected to write a critical appraisal on a mould, identifying its faults and recommend the necessary modifications required. This component contributes 20% to the overall mark of the module.• Workshop reports: Two reports each contributing 25% to the overall mark of the module must be submitted. The two reports are;(i) Moldflow simulation workshop report - The computational skills are developed and assessed through six sessions of using MoldFlow software package, each of approximately 2 hours duration. Students are required to submit an individual typewritten report discussing the computer simulation results and the conclusion that can be drawn from it.(ii) Mould making design workshop report: Student workshop skills are developed and assessed through 6 sessions of mould making activities each of approximately 1 hour duration. Students should submit a typewritten report which should include the drawings and the design analysis of various moulds.• Unseen examination: Students are required to sit end-of semester written examination of 2½ hours duration. Students will be instructed to answer four questions from six. Unseen examination contributes 40% to the overall mark of the module.
Bibliography
[1] P. Cracknell and R. W. Dyson, “Handbook of thermoplastic Injection Mould Design”., Blackies 1993.[2] RGW Pye, “Injection Mould Design for Plastics”, 4th Edition, Goodwin 1989.[3] H. Gastrow, “Injection Moulds”, 3rd Edition, Hanser 1983.[4] W. Michaeli, “Extrusion Dies for Plastic and Rubber”., Hanser 1992.[5] C. Rauwendaal, “Polymer Extrusion”., Hanser 1986.[6] D. Dunning and A. Whelan, “Extrusion Processors Handbook”., Dynisco 1988.[7] A. Whelan, “Injection Moulding Machines”., Elservier Applied Science 1984.[8] J. L. White., “Rubber Processing Technology”., Hanser 1995.[9] www.ticona.com download free design guide (00-332/3M/0402) (Designing with Plastics) 2000