Optimiranje konstrukcije otpreska u cilju minimiranja vitoperenja

master's thesis

• Title (english): Optimisation of moulding design for minimisation of warpage
• Author: Filip Panđa
• Mentor: Damir Godec (mentor)
• Granter: University of Zagreb; Faculty of Mechanical Engineering and Naval Architecture; Zagreb
• Defense date and country: 2023-12-07, Croatia
• Scientific / art field, discipline and subdiscipline: TECHNICAL SCIENCES; Mechanical Engineering; Production Mechanical Engineering

Abstract

U ovom diplomskom radu predstavljena je problematika vitoperenja polimernih otpresaka nakon izbacivanja iz kalupne šupljine, te je postupak kontra-konturiranja geometrije otpresaka predložen kao jedno od potencijalnih rješenja i detaljnije opisan.

Na početku rada dan je kratki opis svojstava polimera te je objašnjen postupak injekcijskog prešanja. Navedene su vrste ubrizgavalica koje je moguće koristiti za injekcijsko prešanje, te je pobliže opisan kalup za injekcijsko prešanje polimera i njegovi glavni podsustavi. Objašnjeno je ponašanje polimerne taljevine prilikom različitih faza procesa na molekularnoj razini, te je pružen uvid u utjecaj parametara poput temperature taljevine i tlaka ubrizgavanja na cjelokupni proces te proizvedeni otpresak. Prikazane su najčešće greške do kojih dolazi prilikom injekcijskog prešanja, razdvojene na vidljive i nevidljive, te su predložena potencijalna rješenja. Poseban je fokus stavljen na vitoperenje, čije je uklanjanje fokus ovog diplomskog rada.

Opisane su mogućnosti računalnih simulacija injekcijskog prešanja te je prikazan postupak postavljanja analize u programskom paketu Autodesk Moldflow 2010. Proces kontra-kontruiranja geometrije otpreska prikazan je na primjeru optimiranja konstrukcije komponente automobilskog konektora koju proizvodi tvrtka Yazaki Europe Limited. Rezultati računalne simulacije, odnosno deformirani oblik otpreska izveden iz programskog paketa Autodesk Moldflow 2010, korišteni su kako bi se optimirala konstrukcija otpreska. Zaključci o optimalnom obliku konstrukcije otpreska doneseni su na temelju poravnavanja nominalne i deformirane geometrije koristeći programski paket za mjeriteljstvo GOM Inspect 2019. Na kraju rada prikazano je smanjenje sile potrebno za montažu komponentne postignuto kontra-konturiranjem, te je donesen zaključak.

Abstract (english)

This Master’s thesis considers the problem of polymer part warpage upon ejection from the mold cavity, and presents the process of reverse engineering of warpage as one of the potential solutions to the problem.

The beginning of the thesis gives a short description of polymer properties and explains the process of injection molding. An overview of injection molding machines as well as the mold itself and its subsystems is given. The behavior of polymer melts during the injection molding process is explained at a molecular level, and an insight into how parameters such as melt temperature and injection pressure impact the process and the produced part is given. The most common errors which occur during injection molding are shown, split systematically into visible and invisible errors, and potential fixes to these errors are presented. Particular attention is given to warpage, whose elimination is the focus of this Master’s thesis.

The capabilities of software for numerical simulation of the injection molding process are described, and the process of setting up such an analysis in Autodesk Moldflow 2010 is shown. The process of reverse engineering of warpage is shown on the example of optimization of molding design of an automotive connector component produced by Yazaki Europe Limited. The results of the numerical simulation, i.e. the deformed shape of the part exported from Autodesk Moldflow 2010, are used to optimize the mold design. Conclusions about the optimal mold design are drawn based on the alignment of nominal and warped geometry of the part using the GOM Inspect 2019 metrology software. The end of the thesis presents the reduction in force necessary to mount the produced part onto its assembly, which is achieved by reverse engineering of warpage, and a conclusion is made.

• Keywords: injekcijsko prešanje; računalne simulacije; vitoperenje; kontra-konturiranje
• Keywords (english): injection molding; numerical simulation; warpage; reverse engineering of warpage
• Language: croatian
• URN:NBN: urn:nbn:hr:235:620135
• Study programme: Title: Mechanical Engineering; Study programme type: university; Study level: graduate; Academic / professional title: magistar/magistra inženjer/inženjerka strojarstva (magistar/magistra inženjer/inženjerka strojarstva)
• Type of resource: Text
• File origin: Born digital
• Access conditions: Embargoed access; Embargo expiration date: 2028-12-07
• Created on: 2023-12-04 21:11:21