Design, Analysis and Fabrication of Plastic Injection Mould for Tensile Test Specimen

The a i m of this project is to design, analyse and produce the plastic injection mould for tensile test specimen. It is also concerned with presenting the technique, method, and theory for producing the plastic injection mould. This project is divided into three sections, namely design, analysis and fabrication. Each of the previous mentioned section is illustrated in proper order to ensure that the readers have a good understanding on how the process is done. The design of the mould is governed first by its intended function and is restricted by the specification limitation of the injection moulding process. Two other factors have to be considered such as material specification and mould condition. The total design method was used in this project to design, analyse and fabricate the mould. This concept allows us to produce the best conceptual design. The techniques in Total Design Method used were Product Design Specification, Quality Function Deployment and Matrix Evaluation System. In the design section, Unigraphics CAD/CAM system is used to produce the detail design and the numerical control codes that are needed to assist machining mould components. Careful consideration has to be taken during selection of various machines that can be used to manufacture the mould. In this project a Computer Numerical Control (CNC), milling, drilling, grinding and Electrode Discharge Machining (EDM) machines were used to machine the mould components. The rework cost is a major problem to the mould making industries, therefore by integrating the Moldflow analysis software (part advisor version 4) into the mould fabrication process this problem can be avoided. This software simulates how the molten plastic enters the mould during the injection process and also the possible defects that might occur. This step will eliminate the rework cost and time as all the possible errors are eliminated before it actually occur in the actual production process. The quality of the mould and injected product depend on the processing conditions such as melt temperature, mould temperature and injection pressure as we" as the machines used to fabricate the mould. As a conclusion the aim of the project to create a mould for tensile test specimen has been achieved

Finite element analysis of sheet metal formability effect on automotive part

An increasing demand for lower price and better quality vehicle has increase complexity of tool development process. This includes concept evaluation, design phase, prototype phase and pre production phase. Experience show that R&D spends most of the time and cost for tool development process, which includes assembly tooling, product tooling for automobile sheet metal component or part requires the highest cost in tool development process as most metal stamping part requires more than one tool to produce finished stamping part. For these reason, sheet metal forming simulation and analysis at early stage of tool development process is very important to shorten the tool development cycle time and cost. In other word by applying sheet metal forming simulation and analysis at early stage it can reduce the die manufacturing cycle time and cost

Performance optimization of simultaneous machine and automated guided vehicle scheduling using fuzzy logic controller based genetic algorithm.

The current trend in manufacturing technology is considered by two main items automation andflexibility. Flexible manufacturing system (FMS) is one of the most identified systems that include bothautomation and flexibility criteria. It comprises three principle elements: computer controlled machinetools, an automated material handling system and a computer control system. One of the automatedmaterials handling equipment in FMS is automated guided vehicles (AGVs). Integrated scheduling ofAGVs and machines is an essential factor contributing to the efficiency of the manufacturing system inFMS environment. Previously, genetic algorithm (GA) is considered as a heuristic method to solve AGVscheduling problem. GA may not be able to achieve the global optimum due to premature convergencebecause of control’s lack on its operators parameters. Fuzzy logic controller (FLC) is proposed tocontrol the behavior of GA during solving the scheduling problem of AGVs. This paper presents a job-based GA that is based on job sequencing. Through the optimization, the FLC is used to control the GAoperators (crossover and mutation rate) simultaneous to solve the AGV scheduling proble

Integrated TRIZ-AHP support system for conceptual design

Amid the fierce rising competition in the market, accelerating the problem solving and decision making process have become major issues in product design especially in conceptual design stage. For years, Theory of Inventive Problem Solving (TRIZ) has been extensively applied in problem solving. In this paper, Analytical Hierarchy Process (AHP) was proposed to strengthen three major steps in TRIZ methodology namely as problem definition, root cause identification and solution generation. The integration was then structured in the form of computer-based system. The integration, application and software in AHP and TRIZ method have been discussed in this paper. This proposed support system not only provided evidence that TRIZ methodologies improved by the support of AHP and also aided the designers in early design phase such as concept, process and material selection

Integrated AHP-TRIZ innovation method for automotive door panel design

This research is intended to improve the ‘Theory of Inventive Problem Solving’ TRIZ methodology by integrating with the Multi Criteria Decision Making (MCDM) tool; Analytical Hierarchy Process (AHP). This integration works as a support tool to assist the TRIZ practitioners or design engineers. AHP is employed to rank ideas generated by TRIZ in order to select the most ideal idea further to next stages. This integration was analyzed and validated by a study case of door panel of a sedan car. Both front and rear door panels are covered in this study. A survey of interior’s problems and customer’s preferences had been conducted in order to identify the criteria and weights for AHP evaluation processes. Basically, there were 10 ideas triggered by TRIZ contradiction and principle approach. The ideas were refined and ranked through AHP’s Expert Choice software. Several ideas had been combined and finalized as one ideal improved design. Applying AHP into problem solving method of TRIZ results in avoiding cost waste and increasing the design efficiency during the product design and development processes

Review of Earned Value Management (EVM) tool for project management

This paper presents a review of an Earned Value Management System (EVM) for assessing project performance compared to others methodology. This study attempts to solve problem to the project manager and project stake holder in handling complicated, dynamic and massive project information especially when changes to the project baseline which is unavoidable. Through feasibility review study, it has been shown that the EVM provide an objective measures of the work that project manager can access project achievement by converting the project data into manageable information clusters and in parallel promoting the earned value management method as an effective tool to monitor and control project constraints which are cost, timeline and scope

Surface quality and chip formation in turning of LM6 aluminium alloy and particulate reinforced metal matrix composite

Majority of the components of aerospace and automotive vehicles need different machining operations, mainly for the assembly requirements. The components have to present both high dimensional precision and surface quality. This present work is concerned with the effect of cutting parameters (cutting speed, feed rate and depth of cut) on the surface roughness and the chip formation in turning process. The machining results are compared with LM6 aluminium alloy and TiC reinforced metal matrix composite under the same cutting conditions and tool geometry. The cutting condition models designed based on the Design of Experiments Response Surface Methodology. The objective of this research is to obtaining the optimum cutting parameters to get a better surface quality and also the chip formation and furthermore does not hazardous to the worker and the machined products quality. Results shows that Surface roughness values of LM6-TiC composite are higher as compared LM6 alloy at similar cutting condition. With increasing in cutting speed improves the surface quality. The surface quality increases with decrease of the feed rate and the depth of cut. There are difference chip forms for LM6 aluminium alloy and Al-TiC composite for a similar of cutting condition. Generally, chip formations of both materials are acceptable and favourable for the worker as well as the products and the tools

Design improvement of automatic transmission system for remote controlled car

Remote controlled cars currently in the market only offer one transmission mode. They are less efficient in acceleration while the torque cannot be increase during the low speed. Although improvement has been made by upgrading to two speed transmissions, but the gearing system is still not sufficient to maximize the speed of nitro engine. With a third gear, the car has the potential to increase its velocity and fully utilize its engine power. This paper focus on the transmission system model for 1/10th scale nitro engine which can produce up to 30,000 rpm. The third gears has shown significant improvement of the car theoretical speed up to 210 km/h

Influence of cutting parameters on surface roughness for wet and dry turning process.

This paper presents a study of the quality of a surface roughness model for mild steel with coated carbide cutting tool on turning process. The experiments were carried out under wet and dry cutting conditions. The model is developed based on cutting speed, feed and depth of cut as the parameters of cutting process. This research applies the fractional factorial design of experiment approach to studied the influence of cutting parameters on surface roughness. The measured results were collected and analyzed using commercial software package called Minitab. Analysis of variances is used to examine the influence of turning factors and factor interactions on surface roughness. The result indicated that, there are inherent differences in surface roughness between wet and dry cutting process with the same parameters process model. Analysis of variance was found that feed parameter is the most significant cutting parameter, which influences the surface roughness. The most significant interactions were found between cutting speed and feed parameters for dry turning process. Therefore is a significant effect of using combination of the fluid for cooling the cutting operation

A review on fuzzy control charts for monitoring attribute data

Up to now, several methods have been proposed for monitoring processes with attribute data. These methods can be categorized into two major group; statistical methods and fuzzy methods. In this paper current fuzzy methods are introduced and the performance of fuzzy methods and statistical methods are compared together based on the Average Run Length (ARL). The comparison shows that the statistical method has the best performance. We show the necessity of using fuzzy method in case of attribute data. Then the critiques towards fuzzy methods are reviewed which show the usage of fuzzy set theory in these methods have some restriction. As a result we indicate a study gap about the usage of fuzzy set theory for monitoring processes with attribute data and at the end some guideline for the next study are proposed