design and analysis of seat valence using 3d experience

Journal of Multidisciplinary Engineering Science Studies (JMESS)

ISSN: 2458-925X

Vol. 7 Issue 4, April - 2021

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JMESSP13420739 3840

Design and Analysis of Seat Valence using 3D Experience

Arun Manohar Gurram, Associate professor

Centurion University of Technology & Management, Andhra Pradesh [email protected]

Sangram Shekhar Nayak, PG Scholar

,

Centurion University of Technology & Management, Parlakhemundi, Odisha. [email protected]

Raghuveer Dontikurti, Assistant professor

Aditya Institute of Technology & Management, Tekkali,

[email protected]

Abstract—The main objective of the project is to improve the quality & flow of plastic injection mold design. In this project, an attempt has been made to design & analyze the plastic part to have all required Engineering features so as to have a temporary attachment to reference metal parts and simultaneously also be manufacturable by doing proper Draft Analysis and considering all design rules to avoid plastic defects like sink marks, weld lines ,volume shrinkage, air traps etc. The intension of the project was to come up with a design process for plastic seat valance cover without inclusion of slider or lifter mechanism in mold design to reduce the mold making cost. The work started with concept generation of an automobile plastic component using brainstorming approach. Design concepts were developed using CATIA software and for initial plastic mold flow analysis a base material PP (polypropylene) was used using SIMULIA software, using Plastic Part Filling App and once design got optimized it was then analyzed with different plastic materials. The results revealed an optimized simple plastic design which is cost effective with minimum plastic defects within constraint of 70MPa injection pressure.

Keywords—Injection mold design, Engineering features, plastic defects, CATIA, CAE software, Flow analysis

I. INTRODUCTION

Plastic is an important part of our daily life nowadays.

Where its scope ranges from house hold items like

water bottles, lunch box, and dustbins to space

applications like plastic seating, helmets and visor etc.

one of those application comes under automotive

industries as interior and exterior parts like bumper,

dashboard, instrument panel, door trim etc. where its

lightweight yet rigid property helps in fulfilling its

functional requirement and reducing fuel usage. It is

estimated that every 10% reduction in vehicle weight

result in 5% to 7% reduction in fuel usage. In this

project we will use a plastic part whose model has

been prepared in CATIA software as a case study. It

is interior part of a standard four wheeler car used for

covering recliner mechanism called as seat valance

cover. Intention here is to design this plastic part in

around that metal recliner mechanism using CATIA

software keeping all design rules intact and validating

it with SIMULIA software by plastic part filling analysis

using different plastic materials. Where the final

design should have least possible mass, plastic

defects and should avoid unnecessary usage of slider

and lifter mechanism in mold design to make it cost

effective.

II. LITERATURE REVIEW

[1] C. T. Wong, S. Sulaiman, N. Ismail and A.M.S. Hamouda: “Design and simulation of plastic injection moulding process.” This paper presents all the necessary prerequisite information about plastic injection molding like simulation air tarps, weld lines, injection pressure, injection locations, and pressure of injection which were the foundational knowledge and assurance of success in our present research. [2] E. O’Neill, C. Wilson and D. Brown: “The benefit of solid modelling in plastics injection moulding industry.” This paper gives brief idea of solid modelling within plastic domain which need an extra time and analysis to understand and apply in real time. Which reduces the design time and ultimately helps in CAE of plastic product for higher quality. [3] MOLDFLOW DESIGN GUIDE by jay shoemaker: This book gives all relevant design rules for various engineering features and plastic flow analysis parameters and results. The design rules were followed and all parameters were used for getting appropriate results in plastic flow analysis. [4] Jagannath Rao MB, Dr Ramni: “Analysis of plastic flow in two plate multicavity injection mould for plastic component for pump seal.” This paper gives brief idea of plastic flow analysis considering gate types, size

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and gate location for smooth flow of plastic. Based on this some design modifications were done on design with different gate size, type and location for smoother flow of plastic. [5] Jitendra Dillip Ganeshkar; Prof R.B Patil, Swapnil S Kulkarni: “Design of plastic injection mold for an automotive component through ‘flow analysis’ (CAE) for design enhancement.” This paper researches from designer’s point of view for mold design considering dimensions, gate locations, gate size etc, to know the behavior of the melt during flow analysis and provide a mold design which will produce best quality product in terms of defect free output. Concept of Manufacturability analysis tool like draft analysis and idea of cost reduction by designing simple mold design is referred from this paper to design a manufacturable part with less cost. [6] K.kannakumar; jithin.k: “Plastic flow analysis & simulation of automobile brake light lens with optimum injection mold design.” This paper deals with design of injection mold for producing best quality and low cost mold, but instead of conventional method of sequential approach they have approached for concurrent process and so as we by considering plastic part defects, low cost of mold, selection of injection molding machine by constraining its injection pressure capacity to 70MPa to eliminate hit and trial method to reduce design cycle time. [7] Injection mould design by R.G.W.Pye : This book has been used as an introductory guide as it helps in understanding the basic considerations during plastic designs like feed system parting surface, Colling system and for specific design like splits , underfeed, hot runner etc. we got information’s for various concepts like injection locations, pressure of injections, air traps etc. [8] Z.Chun-Ying and W.Li.Tao:” Injection Mold Design Based on Plastic Advisor Analysis Software in Pro/E.”. Research of this paper include plastic advisor analysis method to optimize the injection position. The approach of this paper was taken as reference so as to optimize the design by reducing weld marks due to injection location and hence improving the quality of injection mold.

III. PROBLEM STATEMENT

Design and analysis of plastic parts in automotive industries is very much demanding as it comprises roughly around 50% by volume and 10% by weight of a car making these as an alternate for metals due to cheaper price and less mass making these contributor for better fuel efficiency. Design optimization of a plastic part to reduce cost and weight may not b be required for a luxury car but it would surely be helpful for less expensive car manufacturers all over the world. To achieve an optimal design of seat valence cover we need to focus on part design and mold flow with optimal fill time within a constraint of using injection pressure less than 70 MPa. [6]

IV. OBJECTIVES

Developing a design protocol for the tool to manufacture the component “seat valence cover”, with the following design objectives

To design required part around recliner mechanism.

Design for manufacturability i.e.:- to design part with proper draft analysis to have scratch free ejection from mold.

Design to minimize cost i.e., Design the tool as simple as possible with no proposal for the use of slider and lifter mechanism during mold design.

Analysis plastic flow in to the Mold.

Find best gate location.

Choose material for plastic part among PP, ABS, ASA, ASA+PC. [5]

V. DESIGN OF EXPERIMENT

FIG 1 DOE FLOW CHART

Note: 1

ST Plastic flow analysis:

It is the mold flow analysis of the plastic part design with only PP (Polypropylene). 2

nd Plastic flow analysis:

It is the mold flow analysis of the plastic part design with other materials like ABS, ASA, ASA+PC.

DRAFT

ANALYSIS

1ST FLOW

ANALYSIS

2ND FLOW

ANALYSIS

FINAL DESIGN

NO

ELSE

CAD MODEL

NO

Fig 5 complete smoothening of all edges.



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VI. CAD MODELLING BY DESIGN RULES

Fig 2 Design outline for part.

Fig 3 Remove of unwanted materials

Fig 4 Smoothening of outer edges of part

Fig 5 complete smoothening of all edges

Fig 6 clearance is provided for seat belt attachment

Fig 7 Feature for attachment with metal part

Fig 8 Ribs to increase rigidity of design

Fig 9. Complete Design 1

VII. VII DESIGN MODIFICATIONS

Old Design New Design

Fig 10. Depression for smooth flow and Ribs to strengthen the fastener

attachment.

Fig 11. Depression for smooth flow , Ribs to strengthen the locator boss

feature



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Fig 12. Depression for smooth flow and Ribs to strengthen the feature

Fig 13 Final Design2 with 2.5 mm nominal wall thickness

Fig 14 Through Hole

Fig 15 Sprue Gate in center to reduce weld lines and smooth flow. [4]

Fig 16 Back side draft analysis with 0.5 degree

Fig 17 TOP side draft analysis with 4.9 degree

VIII. SIMULIA SOFTWARE

Simulation-based Innovation, Design, and Manufacturing are driving the solution to important challenges facing society today—from electrification to sustainability to communications to livable cities. A holistic approach is needed including Electromagnetics, Material Science, Fluids, Structures, Multibody Simulation and other technologies. SIMULIA along with other Dassault Systèmes brands such as CATIA, DELMIA, and BIOVIA are working together to deliver new solutions united on the shared data from the 3DEXPERIENCE platform. One of the APP used here for mold flow analysis is PLASTIC PART FILLING. It helps in finite elemental analysis used in the design of plastic product, mold design and production of plastic components. The analysis is carried out using the PLASTIC PART FILLING APP of SIMULIA software which is a 3D Experience constituent

IX. PLASTIC PART FILLING ANALYSIS

SIMULATION

A Plastic Part Filling simulation predicts how molten polymer material fills the mold cavity. It accounts for heat transfer between the material and mold during filling, and predicts the changes to viscosity as the material begins to solidify. Results of the Filling simulation include distributions of pressure and temperature within the cavity, and detection of potential short shots and weld lines. You can use the Plastic Part Filling app to investigate the influences of the following:

The choice of material.

The position and number of injection locations.

The temperature settings of the molding machine.

The computational mesh refinement, which balances solution accuracy against simulation execution time

X. MOLD FLOW RESULT TERMS

Fill Time: The fill time analysis shows the profile of the plastic melt as it flows through the mold part cavity during the filling stage of the injection molding process. [4]

1. Blue region shows beginning of flow



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JMESSP13420739 3844

2. Red region shows end of fill Pressure at the End of fill: It shows how evenly the cavity has filled with uniform pressure. Injection location should be placed such that pressure distribution be even throughout the cavity. [6]

Sink marks: These are depressions on the surface of an injection molded plastic part. The uneven cooling due to non-uniform wall thickness is the fundamental cause. [9]

Weld lines: Weld lines are formed when two or more plastic flow front comes together. These are weaker areas and can cause cosmetic defects also. These weld lines can eliminated by avoiding multiple injection locations and non-uniform wall thickness. [3]

Air Traps: Air trap analysis shows non vented air in the mold cavity during the filling stage which will prevent plastic material from filling the volume where the air trap is located. [1] Volumetric Shrinkage: High rate of shrinkage will occur in thick section of a plastic part which do not undergo a sufficient packing stage during the molding process. Red and yellow shows high amount of volumetric shrinkage at the end of fill. [4]

Ease of fill: This shows whether cavity fills successfully or how much difficult it is to fill the cavity. 1) Green means it need less than 80% of maximum injection pressure. (Easy to fill with no quality issue) [1] 2) Yellow means it needs more than 80% of maximum injection pressure. (Bit difficult to fill or may have quality problem) [1] 3) Red means it needs maximum injection pressure to fill the cavity. (Very difficult to fill and may have quality problem)

XI. SIMULATION RESULTS

Simulation Results for PP (PolyPropylene)

Fig 18.Pressure at the end of fill.

Fig 19. Fill time.

Fig 20.Ease of fill

Fig 21.Weld lines

Fig 22. Air traps

Fig 23. Sink Marks

Simulation Results for ASA

(Acrylonitrile Styrene Acrylate)

Fig 24.Pressure at the end of fill



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JMESSP13420739 3845

Fig 25. Fill time

Fig 26.Ease of fill

Fig 27.Weld lines

Fig 28 Air traps

Fig 29. Sink Marks

Fig 30. volumetric shrinkage

Simulation Results For ASA+PC

(Acrylonitrile styrene acrylate+ Polycarbonate)

Fig 31. Pressure at the end of fill

Fig 32. .Fill time

Fig 33. Ease of fill

Fig 34 .Weld lines

Fig 35 Air traps

Fig 36 Sink marks

SIMULATION RESULTS FOR ABS (Acrylonitrile butadiene styrene) DESIGN 5



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Fig 37 Volumetric shrinkage

Simulation Results for ABS

(Acrylonitrile butadiene styrene)

Fig 38 Fill time

Fig 39 Pressure at the end of fill

Fig 40. Ease of fill

Fig 41 Weld lines

Fig 42.Air traps

Fig 43.Sink marks

Fig 44 Volumetric shrinkage

TABLE I. COMPARISION BETWEEN DIFFERENT MATERIALS

Results PP ABS ASA ASA+PC

Injection

pressure

18.5

MPa

88.3

MPa

63.4

MPa

75.4MPa

Fill time 2.53 2.83 2.78 4.34 sec

Ease of fill All

green

Red All

green

yellow

Weld lines Very

less

Very

less

Very

less

Very less

Air traps 4

location

7

location

3

location

3

location

Sink marks .04mm

in

visible

areas

.08mm

in

visible

areas

.03 to

.04mm

in

visible

areas

.08 to

.09mm in

visible

areas

Volumetric

shrinkage

18.3% 10.1% 10.9% 10.1%



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The above comparison shows ASA material is better

suited for this plastic part design as compared to other

materials like PP, ABS, ASA+PC as Results like Ease

of fill, air traps, sink marks, weld lines are much better

whereas injection pressure ,fill time and volumetric

shrinkage are also satisfactory.

XII. CONCLUSIONS

Plastic part was so designed and optimized using CATIA v5, that the requirement of slider or lifter mechanism during mold making process is excluded. Mold flow analysis was performed using PLASTIC PART FILLING APP of SIMULIA software in 3DEXPERIENCE PLATFORM, with all required results like injection pressure, fill time, air traps, weld lines, air traps, sink marks, volumetric shrinkage. Results shows that sprue gate with a central location of the part produces much better results as it removes lots of weld lines and gives smooth flow of plastic to every corner of plastic part, but with an additional operation of drill hole to make space for fastener to hold plastic part in place with recliner metal reference part. During mold flow analysis with different materials like PP (polypropylene), ABS (Acrylonitrile butadiene styrene), ASA (Acrylonitrile styrene acrylate) and ASA+PC (Acrylonitrile styrene acrylate+ Polycarbonate) it revealed that ASA material is better among all of the above listed plastic material as it produced plastic part with less plastic defects and with satisfactory fill time and injection pressure of 63.4 MPa.

REFERENCES

[1] C.T.Wong,Shamsuddin-Sulaiman, Napsiah

Ismail & A.M.S. Hamouda, “Design and

Simulation of Plastic Injection Molding Process“

Pertanika J. Sci. & Techno. Volume12, Issue 2,

2004

[2] E O’Neill, C. Wilson and D. Brown, “The benefits

of solid modelling in the plastics injection

molding industry”, IEEE April 1997 [99-107].

[3] MOLDFLOW DESIGN GUIDE by jay shoemaker.

First Edition (2006).

[4] Jagannath Rao MB, Dr Ramni,” Analysis of

plastic flow in two plate multicavity injection

mould for plastic component for pump seal”

IJSRP, Volume 3, Issue 8, August 2013.

[5] Jitendra Dillip Ganeshkar; Prof R.B Patil,

Swapnil S Kulkarni,” Design of plastic injection

mold for an automotive component through ‘flow

analysis’ (CAE) for design enhancement”

IJAERS, Volume3, Issue 2, March 2014.

[6] K.kannakumar; jithin.k, “Plastic flow analysis &

simulation of automobile brake light lens with

optimum injection mold design” IRJET, Volume

4, Issue 5, May 2017.

[7] Injection Mould Design: A Design Manual for

Thermoplastic Industry by R.G.W.Pye. G.

Godwin, 1983.

[8] Zhou Chun-ying, Wang Li-tao,“ Injection Mold

Design based on Plastic Advisor Analysis

Software in Pro/E,“ IEEE 2011 [ 205-208 ].

[9] M.B.Pagar, V.Wakchaure “Review on Tool

Design and Analysis of Injection Moulding”

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