Sinan VARGELCİ, Atanur ACAR, Ayça KÜÇÜKOĞLU

5579

A Study for Detecting Flow Lines on The Aesthetic Plastic Parts During Design Phases as Using Material Flow Analysis Programs

In today’s competitive business environment the automotive industries aim to increase the usage of the plastic materials in automobile components in order to reduce weight of the vehicles. Although the plastic materials provide a considerable savings on vehicle weight, these materials have some problems to be solved. One of the difficult problems encountered in the production of plastics is the flow lines on plastics because of its unpredictable behavior. As a result, considered problem faced by automobile companies often spend plenty of time and money is an issue to resolve. In this study the source of plastic flow lines on automotive external aesthetical parts are investigated by using material flow analysis programs. According to conventional methodologies; weld lines, temperature differences, filling times, clamping forces, shrinkages parameters are examined deeply before tooling face especially to eliminate aesthetical problems. But in this case we observed an unordinary situation such as flow lines on front bumper visible surfaces after tooling phase and therefore we searched a new approach to simulate this flow lines on the material flow analysis program. Flow directions and flow velocity are comprehensively examined step by step during filling analysis. As a result of the analysis the geometric factors that affect the balance of flow and brings turbulence are detected. After the root cause analysis for plastic deformation the potential techniques are researched to find best solution.  Analysis are repeated in the same conditions that are considered to be made for all geometric changes.  The experiment results are comparatively analyzed and the solution approach that have the best flow balance is selected.
Keywords:

Automotive aesthetical plastic parts flow lines, mold flow, plastic injection,

PDF

___

  • Akbarzadeh A., Sadeghi M. (2011). Parameter Study in Plastic Injection Molding Process using Statistical Methods and IWO Algorithm. International Journal of Modeling and Optimization pp. 141.
  • Lopes, N., & Ribeiro, B. (1999). Part quality prediction in an injection moulding process using neural networks. proceedings of WMC, ISM.
  • Cheah, L. W. (2010). Cars on a diet: the material and energy impacts of passenger vehicle weight reduction in the US (Doctoral dissertation, Massachusetts Institute of Technology).
  • Taghizadeh, S., Özdemir, A., & Uluer, O. (2013). Warpage prediction in plastic injection molded part using artificial neural network. Iranian Journal of Science and Technology. Transactions of Mechanical Engineering, 37(M2), 149.
  • Guo, W., Hua, L., Mao, H., & Meng, Z. (2012). Prediction of warpage in plastic injection molding based on design of experiments. Journal of Mechanical Science and Technology, 26(4), 1133-1139.
  • Park, K., Sohn, D. H., & Cho, K. H. (2010). Eliminating weldlines of an injection-molded part with the aid of high-frequency induction heating. Journal of mechanical science and technology, 24(1), 149-152.
  • Rosato, D. V., & Rosato, M. G. (2012). Injection molding handbook. Springer Science & Business Media.
  • Harper, C. A. (2006). Handbook of plastic processes. John Wiley & Sons.
  • Frizelle W.G. (2016). Applied Plastic Engineering Handbook. 2nd ed. Part II. Chapter 10. pp. 191-203.
  • Fuh, J. Y., Fu, M. W., & Nee, A. Y. C. (2004). Computer-aided injection mold design and manufacture. CRC Press.
  • http://www.rpm-engineering.com/plastic.html
  • Rännar L.-E. (2008). An Optimization of Injection Molding Cooling. pp. 5-11.
  • Wang, J. (2012). PVT properties of polymers for injection molding. In Some Critical Issues for Injection Molding. IntechOpen. http://ayannaplastics.com
  • Dealy, J. M., & Wissbrun, K. F. (2012). Melt rheology and its role in plastics processing: theory and applications. Springer Science & Business Media.
  • Larson, E. R. (2015). Thermoplastic Material Selection: A Practical Guide. William Andrew.
  • Autodesk Moldflow Troubleshooting Guide. ‘https://knowledge.autodesk.com/support/moldflow-insight/learn-explore/caas/CloudHelp/cloudhelp/2017/ENU/MoldflowInsight/files/GUID-3E3EFE66-AE31-4E50-831E-5944C5820ED6-htm.html’.
  • https://knowledge.autodesk.com/support/moldflow-flex/learn-explore/caas/CloudHelp/cloudhelp/2014/ENU/MoldflowInsight360/files/GUID-8A317780-B538-40FB-9AD4-CB04B13FA82E-htm.html
  • http://www.moldex3d.com/en/newsletter/achieve-plastic-part-dimension-accuracy-through-3d-volume-shrinkage-compensation-method
  • https://knowledge.autodesk.com/support/moldflow-flex/learn-explore/caas/CloudHelp/cloudhelp/2015/ENU/MoldflowInsight360/files/GUID-099634AE-DB7A-41BA-B70C-5A23FB013B06-htm.html
  • https://knowledge.autodesk.com/support/moldflow-insight/learn-explore/caas/CloudHelp/cloudhelp/2017/ENU/MoldflowInsight/files/GUID-706D3A91-F6EE-4577-8186-9381D967E13A-htm.html
European Mechanical Science-Cover
  • Yayın Aralığı: 4
  • Başlangıç: 2017
  • Yayıncı: Ahmet Çalık
Arşiv
Sayıdaki Diğer Makaleler

Mümin YILMAZ, Onur SARAY, İmren ÖZTÜRK YILMAZ

Sinan VARGELCİ, Atanur ACAR, Ayça KÜÇÜKOĞLU

E. ŞİMŞEK, B. ŞAHİN, A. ÖZBEK, A. YAŞAR, M. BİLGİLİ

Eman M. KHALAF, Sameer A. AWAD

Caner ÇİL, Ahmet RODOPLU, Hatice ÖZBEK

Tamer AYDINER, Harun YENİ, Metehan BAYRAMOĞLU, Gürkan YILMAZOĞLU, Hafize ÇELİK, Erdem AYDOĞMUŞ, Levent AKSEL, İbrahim ÖZBAY

Mehmet BULUT