v
TABLE OF CONTENTS
Abstrak i
Abstract ii
Dedication iii
Acknowledgement iv
Table of Contents v
List of Tables x
List of Figures xii
List of Abbreviations, Symbols and Nomenclatures xiv
CHAPTER 1: INTRODUCTION 1
1.1 Background
1 1.2
Problem Statement 2
1.3 Objective
3 1.4
Scope of Project 3
CHAPTER 2: LITERATURE REVIEW 4
2.1 Introduction
4 2.2
Injection Molding Machine 6
2.2.1 Injection system 7
2.2.2 Hydraulic system 9
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2.2.3 Mold system 9
2.2.4 Clamping system 11
2.2.5 Control system 11
2.3 Process of Injection Molding
11 2.3.1 Total Design Stage
14 2.4
Gate 15
2.4.1 Sprue Gate 15
2.4.2 Common Edge Gate 16
2.4.3 Fan Gate 16
2.4.4 Film Gate or Flash Gate 17
2.4.5 Ring Gate 17
2.4.6 Diaphragm Gate 18
2.4.7 Tunnel Gate 19
2.4.8 Pin Point Gate 19
2.4.9 Tab Gate 20
2.5 The Importance of Gate
20 2.5.1 Gate Type and Properties
21 2.5.2 Shear Rate and Shear Stress Limits
22 2.6
Plastic Application 23
2.7 Plastic Additives
30 2.7.1 Introduction
30
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CHAPTER 3: METHODOLOGY 33
3.1 Project Overview
33 3.2
Define the Problem Statement, Objective, and Scope 34
3.3 Literature Review
34 3.4
Flow Chart 35
3.5 Gant Chart
35 3.6
Process Development of the Product 35
3.7 Software
38 3.7.1 SolidWorks
38 3.7.2 CATIA
40 3.7.3 Autodesk Simulation Moldflow Adviser 2014
41 3.7.3.1 Moldflow Analysis Flow Chart
42 3.7.3.2 Procedure Autodesk Simulation Moldflow Adviser 2014 44
3.7.3.2.1 Step 1 44
3.7.3.2.2 Step 2 44
3.7.3.2.3 Step 3 45
3.7.3.2.4 Step 4 45
3.7.3.2.5 Step 5 46
3.7.3.2.6 Step 6 46
3.7.3.2.7 Step 7 47
3.8 Ranking Concept
47 3.9 Result Analysis of the Product
47 3.10 Discussion and Conclusion
48
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CHAPTER 4: RESULT AND DISCUSSION 49
4.1 Autodesk Simulation Moldflow Adviser 2014 on Plastic Name Card
Holder Applied 49
4.1.1 Manipulated Variables 50
4.1.2 Controlled Variables 51
4.2 Simulation Analysis with Autodesk Simulation Moldflow Adviser
52 4.2.1 Phase 1
53 4.2.1.1 Ranking Table for Cycle Time s
58 4.2.1.2 Ranking Table for Confident of fill
59 4.2.1.3 Ranking Table for Quality Prediction
60 4.2.1.4 Ranking Table for Injection Pressure Mpa
61 4.2.1.5 Ranking Table for Max. Clamp Force during Filling Tonne62
4.2.1.6 Final Ranking Phase 1 63
4.2.2 Phase 2 64
4.2.3 Phase 3 67
4.2.3.1 New Design Gate Position 67
4.2 3.2 Ranking Table for Cycle Time s 71
4.2.3.3 Ranking Table for Confident of fill 72
4.2.3.4 Ranking Table for Quality Prediction 73
4.2.3.5 Ranking Table for Injection Pressure Mpa 74
4.2.3.6 Ranking table for Max. Clamp Force during Filling Tonne 75 4.2.3.7 Final Ranking
76
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CHAPTER 5: CONCLUSION AND FUTURE WORK 77
