Rapid tooling of composite aluminium filled epoxy mould for injection moulding of polypropylene parts with small protruded features
-
Abhinay S. Todmal
und
Bharatkumar B. Ahuja
Abstract
Rapid tooling evolved from rapid prototyping is a novel method for developing prototype tooling rapidly using various additive manufacturing techniques. Traditional injection moulding is unsuitable for low-volume production because of the high initial cost. This study is focused on a rapid tooling approach for producing an injection mould insert for the low-volume production of plastic components. A plastic injection mould insert is designed, developed using composite aluminium filled epoxy with minute protruded features and tested on a vertical injection moulding machine as a rapid tool for low-volume production of plastic components. The composite aluminium filled epoxy (CAFE) mould insert is prepared using a wax master from silicon rubber mould prepared using a stereolithography master. Experiments are performed to determine the optimum mixing ratio of epoxy: aluminium powder for making the composite aluminium filled epoxy injection mould. The mould insert prepared was tested for the injection of polypropylene components on a vertical injection moulding machine and analyzed for dimensional accuracy. The analysis of dimensional accuracy and viability of minute features on the injected parts shows promising results for up to 30 injected parts. The injection of parts after 30 pieces resulted in increasing mould erosion and pitting, causing mould damage at the 36th injection shot. The experimental finding supports the feasibility of using the composite aluminium filled epoxy injection mould for low-volume production of the parts; however, the surface finish is inferior. The life of the mould is expected to give better results with a higher surface finish. It is also exposed that using mould release agents improves the life of the composite aluminium-filled epoxy injection mould.
Acknowledgments
Authors would like to extend their sincere appreciation for the support and motivation provided by the Director of the College of Engineering Pune. Furthermore, they express gratitude to the Head of the Department of Manufacturing Engineering and Industrial Management for granting access to essential research facilities. The authors gratefully acknowledge Mr. Avinash Wadkar, Mr. Raj Shevni, and Mr. Prasad Gore of the Auto Cluster Development and Research Institute for their unwavering support throughout the experimentation, particularly for making vacuum casting facilities available. Special thanks are also extended to Mr. Nabeel Momin from Technoplast Industries Pvt. Ltd., for facilitating the injection molding trials. The authors would like to acknowledge the continuous support from all the faculties and staff of the Department of Manufacturing Engineering and Industrial Management.
-
Research ethics: Not applicable.
-
Author contributions: The authors have accepted responsibility for the entire content of this manuscript and approved its submission.
-
Competing interests: The authors state no conflict of interest.
-
Research funding: Not Applicable.
-
Data availability: The raw data can be obtained on request from the corresponding author.
References
1. Chua, C. K., Hong, K. H., Ho, S. L. Int. J. Adv. Manuf. Technol. 1999, 15, 604–608. https://doi.org/10.1007/s001700050108.Suche in Google Scholar
2. Chung, S. I., Im, Y. G., Jeong, H. D., Nakagawa, T. J. Mater. Process. Technol. 2003, 134, 26–34. https://doi.org/10.1016/S0924-0136(02)00275-3.Suche in Google Scholar
3. Cheah, C. M., Chua, C. K., Ong, H. S. Int. J. Adv. Des. Manuf. Technol. 2002, 20, 368–374. https://doi.org/10.1007/s001700200165.Suche in Google Scholar
4. Hilton, P. D., Jacobs, P. F. Rapid Tooling: Technologies and Industrial Applications; Marcel Dekker: New York, 2000.Suche in Google Scholar
5. Pham, D. T., Dimov, S. S. Proc. Inst. Mech. Eng., Part C 2003, 217, 1–23. https://doi.org/10.1243/095440603762554569.Suche in Google Scholar
6. Ferreira, J. C., Mateus, A. J. Mater. Process. Technol. 2003, 142, 508–516. https://doi.org/10.1016/S0924-0136(03)00650-2.Suche in Google Scholar
7. Khushairi, M. T. M., Sharif, S., Jamaludin, K. R., Mohruni, A. S. Int. J. Adv. Sci. Eng. Inf. Technol. 2017, 7, 1155–1161. https://doi.org/10.18517/ijaseit.7.4.2480.Suche in Google Scholar
8. Vasconcelos, P. V., Lino, F. J., Neto, R. J. L., Henrique, P. Mater. Sci. Forum 2004, 455–456, 635–638. https://doi.org/10.4028/www.scientific.net/msf.455-456.635.Suche in Google Scholar
9. Khushairi, M. T. M., Sharif, S., Ani, J. S. M. Appl. Mech. Mater. 2015, 735, 13–18. https://doi.org/10.4028/www.scientific.net/amm.735.13.Suche in Google Scholar
10. Goyanes, S., Rubiolo, G., Marzocca, A., Salgueiro, W., Somoza, A., Consolati, G., Mondragon, I. Polymer 2003, 44, 3193–3199. https://doi.org/10.1016/S0032-3861(03)00229-5.Suche in Google Scholar
11. Kim, H. J., Jung, D. H., Jung, I. H., Cifuentes, J. I., Rhee, K. Y., Hui, D. Composites, Part B 2012, 43, 1743–1748. https://doi.org/10.1016/j.compositesb.2011.12.010.Suche in Google Scholar
12. Yue, Y. F., di Zhang, Y., Yang, G., Wang, J. Y., Wei, B. Adv. Mater. Res. 2011, 189–193, 777–780. https://doi.org/10.4028/www.scientific.net/AMR.189-193.777.Suche in Google Scholar
13. Chaowasakoo, T., Sombatsompop, N. Compos. Sci. Technol. 2007, 67, 2282–2291. https://doi.org/10.1016/j.compscitech.2007.01.016.Suche in Google Scholar
14. Kuo, C. C. Mater. Manuf. Processes 2012, 27, 383–388. https://doi.org/10.1080/10426914.2011.551906.Suche in Google Scholar
15. Kuo, C. C., Chen, W. H., Xu, W. C. Int. J. Adv. Manuf. Technol. 2017, 91, 1689–1695. https://doi.org/10.1007/s00170-016-9886-4.Suche in Google Scholar
16. Iftikhar, A., Khan, M., Alam, K., Jaffery, S. H. I., Ali, L., Ayaz, Y., Khan, A. Mater. Manuf. Process. 2013, 28, 534–538. https://doi.org/10.1080/10426914.2012.746698.Suche in Google Scholar
17. Hussin, R., Sharif, S., Nabiałek, M., Zamree, A. S., Khushairi, M. T. M., Suhaimi, M. A., Abdullah, M. M. A. B., Hanid, M. H. M., Wysłocki, J. J., Błoch, K. Hybrid mold: comparative study of rapid and hard tooling for injection molding application using metal epoxy composite (MEC). Materials 2021, 14, 665. https://doi.org/10.3390/ma14030665.Suche in Google Scholar PubMed PubMed Central
18. De, A., Fernandes, C., De Souza, A. F., Lisi, J., Howarth, L. Int. J. Mater. Prod. Technol. 2016, 52, 37. https://doi.org/10.1504/IJMPT.2016.073618.Suche in Google Scholar
© 2023 Walter de Gruyter GmbH, Berlin/Boston
Artikel in diesem Heft
- Frontmatter
- Editorial
- Additive manufacturing and allied technologies
- Original Papers
- Influence of process parameters on ageing and free vibration characteristics of fiber-reinforced polymer composites by fusion filament fabrication process
- 3D biomimetic scaffold’s dimensional accuracy: a crucial geometrical response for bone tissue engineering
- Investigation of mechanical and microstructure properties of metal inert gas based wire arc additive manufactured Inconel 600 superalloy
- Study on the influence of surface roughness on tensile and low-cycle fatigue behavior of electron beam melted Ti‐6Al‐4V
- Effect of tool pin profile on the heat generation model of the friction stir welding of aluminium alloy
- Effect of clamping position on the residual stress in wire arc additive manufacturing
- Effect of welding speed on butt joint quality of laser powder bed fusion AlSi10Mg parts welded using Nd:YAG laser
- Mechanical behaviour, microstructure and texture studies of wire arc additive manufactured 304L stainless steel
- Evolution of microstructure and properties of CoCrFeMnNi high entropy alloy fabricated by selective laser melting
- Effect of laser energy density on surface morphology, microstructure and mechanical behaviour of direct metal laser melted 17-4 PH stainless steel
- The influence of rheology in the fabrication of ceramic-based scaffold for bone tissue engineering
- Behaviour of glass fiber reinforced polymer (GFRP) structural profile columns under axial compression
- Desirability function analysis approach for optimization of fused deposition modelling process parameters
- Effect of robotic weaving motion on mechanical and microstructural characteristics of wire arc additively manufactured NiTi shape memory alloy
- Rapid tooling of composite aluminium filled epoxy mould for injection moulding of polypropylene parts with small protruded features
- Investigation of microstructural evolution in a hybrid additively manufactured steel bead
- Fused filament fabricated PEEK based polymer composites for orthopaedic implants: a review
- Design of fixture for ultrasonic assisted gas tungsten arc welding using an integrated approach
- Effect of post-processing treatment on 3D-printed polylactic acid parts: layer interfaces and mechanical properties
- Investigating the effect of input parameters on tool wear in incremental sheet metal forming
- Microstructural evolution and improved corrosion resistance of NiCrSiFeB coatings prepared by laser cladding
- Microstructure and electrochemical behaviour of laser clad stainless steel 410 substrate with stainless steel 420 particles
- News
- DGM – Deutsche Gesellschaft für Materialkunde
Artikel in diesem Heft
- Frontmatter
- Editorial
- Additive manufacturing and allied technologies
- Original Papers
- Influence of process parameters on ageing and free vibration characteristics of fiber-reinforced polymer composites by fusion filament fabrication process
- 3D biomimetic scaffold’s dimensional accuracy: a crucial geometrical response for bone tissue engineering
- Investigation of mechanical and microstructure properties of metal inert gas based wire arc additive manufactured Inconel 600 superalloy
- Study on the influence of surface roughness on tensile and low-cycle fatigue behavior of electron beam melted Ti‐6Al‐4V
- Effect of tool pin profile on the heat generation model of the friction stir welding of aluminium alloy
- Effect of clamping position on the residual stress in wire arc additive manufacturing
- Effect of welding speed on butt joint quality of laser powder bed fusion AlSi10Mg parts welded using Nd:YAG laser
- Mechanical behaviour, microstructure and texture studies of wire arc additive manufactured 304L stainless steel
- Evolution of microstructure and properties of CoCrFeMnNi high entropy alloy fabricated by selective laser melting
- Effect of laser energy density on surface morphology, microstructure and mechanical behaviour of direct metal laser melted 17-4 PH stainless steel
- The influence of rheology in the fabrication of ceramic-based scaffold for bone tissue engineering
- Behaviour of glass fiber reinforced polymer (GFRP) structural profile columns under axial compression
- Desirability function analysis approach for optimization of fused deposition modelling process parameters
- Effect of robotic weaving motion on mechanical and microstructural characteristics of wire arc additively manufactured NiTi shape memory alloy
- Rapid tooling of composite aluminium filled epoxy mould for injection moulding of polypropylene parts with small protruded features
- Investigation of microstructural evolution in a hybrid additively manufactured steel bead
- Fused filament fabricated PEEK based polymer composites for orthopaedic implants: a review
- Design of fixture for ultrasonic assisted gas tungsten arc welding using an integrated approach
- Effect of post-processing treatment on 3D-printed polylactic acid parts: layer interfaces and mechanical properties
- Investigating the effect of input parameters on tool wear in incremental sheet metal forming
- Microstructural evolution and improved corrosion resistance of NiCrSiFeB coatings prepared by laser cladding
- Microstructure and electrochemical behaviour of laser clad stainless steel 410 substrate with stainless steel 420 particles
- News
- DGM – Deutsche Gesellschaft für Materialkunde
