DESIGN OF INJECTION MOULD TOOL AND MOULD FLOW ANALYSIS OF EXHAUST FAN USING ABS PLASTIC MATERIAL SRIVANI.K & RAHULJIDALA SREE DATTHA COLLEGE OF ENGINEERING &SCIENCE HYDERABAD ABSTRACT An exhaust fan is an electrical device that pushes hot air from a bounded area. All these fans are supposed to pull the hot air from a house, of which it would then commonly be vented into the attic, where it is then forced out of the home fully through different vents. Presently exhaust fans are made with metals. So fan weight is more and consequently high power is required for the fan rotation. The main aim of this project is to develop a mould for the exhaust fan using ABS Plastic material. The parametric modeling of exhaust fan is done in Pro/Engineer. Mould flow analysis is done to check the confidence of fill, fill time, injection pressure, temperatures, quality prediction, pressure drop, air traps, weld lines etc. when the material is filled in to the mould using Plastic Advisor module in Pro/Engineer. Core and Cavity is extracted and total mould base is designed for the exhaust fan using HASCO standards. Manufacturing processes for both core and cavity are also included. CNC program is generated. Using hydraulic injection molding machine plastic prototype of the fan is to be produced. We are providing complete mould base components, its shop floor drawings, material selection for each component, manufacturing processes for each component. In this thesis we are providing all the data required for doing Injection mould tool. Mechanical Fan A fan consists of a rotating vanes or a blade that creates a current of air for cooling or ventilation. This may direct the flowing or increase safety by preventing objects from contacting the fan blades. All fans are runs by electric motors, and it may also run by hydraulic motors and internal combustion engines and solar power. Fans used to produce air flows with high volume and low pressure. A fan blade will often rotate when exposed such as anemometers and wind turbines, often have designs similar to that of a fan.applications include vehicles cooling, machinery cooling system, climate control, personal comfort, ventilation, fume extraction, winnowing removing dust, drying and to provide draft for a fire. It is also cool down and get air the in your home moving. From the late 19th century through the 1950s electric fans manufactured have become a recognized collectible category, and in the U.S.A. an active collector club, the Antique Fan Collectors Association, supports the hobby. Summary of Capabilities Like any software package it s regularly developed to include new functionality. The main point below aim to the scope of capabilities to give an overview rather than giving specific details on the individual functionality of the product. 42
Pro/Engineer is a software package application inside the CAD/CAM/CAE classes, in conjunction with other similar products presently available in the market. Pro/Engineer is a parametric, feature-based modeling architecture incorporated into a single database philosophy with advanced rule-based design capabilities. the product can be split into the three main heading of Engineering Design, Analysis and Manufacturing. This data is then documented in a standard 2D production drawing or the 3D drawing standard. Engineering Design Pro/Engineer offers a spread of tools to modify the generation of a digital representation of the product being designed. In addition to the general geometry tools there is also the ability to generate geometry of other integrated design disciplines such as industrial and standard pipe work and complete wiring definitions. Tools are also available to support collaborative development. A number of concept design tools that provide up-front Industrial Design concepts can then be used in the downstream process of engineering the product. These varying from abstract Industrial design sketches, reverse engineering with purpose cloud data and comprehensive freeform surface tools. AIM OF THE PROJECT The main aim of the project is to model an exhaust fan which is used in small scale industries. The exhaust fans are based upon the principle of axial flow fans. In general, exhaust axial flow fans are conventionally designed with impellers made of aluminum or mild steel. The grey area today is the inconsistency in proper aero foil selection & dimensional stability of the metallic impellers. This leads to high power consumption & high noise levels with lesser efficiency. So, in this project I have used ABS plastic for the exhaust fan. The leading fan manufacturers in the world have been looking at ABS Plastic axial flow fans for higher energy efficiency.the improved design of ABS Plastic fan is aimed higher lift to drag ratio and thereby increasing the overall efficiency. Mould flow analysis is to be done on the fan to check the filling time, confidence of fill, flow temperature, injection pressure, pressure drop, quality prediction, air traps etc. when material is poured in to the mould. Total mould base is to be designed according to the HASCO standards, by extracting core and cavity, designing mould base components. CNC programming is generated for both core and cavity using manufacturing procedures. The modeling, mould flow analysis, core cavity extraction, die design is done using parametric modeling software PRO/ENGINEER. LITERATURE SURVEY A fan that moves air out of an enclosure. Fans located in the wall or ceiling that exhaust air, odors and moisture to the outside. Probably the simplest meaning of an exhaust fan is actually a fan that pushes air off a bounded space, particularly from the interior of a home. These kinds of fans are supposed to pull the hot air from a house, of which it'll then normally be vented into the attic, where it is then forced out of the home entirely via different vents. The push-pull pressure that results from this kind of system creates the power to draw in cold air from the outside when the house's windows are open. This type of system is a good way to quickly cool the home, or any other sort of enclosed building; it is also an amazing cost-effective alternative to utilizing an air conditioner. One other added benefit is that these fans are energy efficient, are smaller in size, and are generally quiet. Exhaust fans are available in two varieties: ceiling mounted and ducted; there is also a 'do-it-yourself' set up, for those home owners who are handy-men. When thinking of the house, a good home ventilation system will include both a cooking area exhaust fan and a toilet exhaust fan. On the subject of the restroom, bathroom exhaust fans are made to be quite powerful; they've got a particular use as to ridding the area of odors, or ridding the location and the rest of the house, of humid air. With these kinds of fans, it's important however, to ensure they're correctly installed, as the result of a terrible installation can result in the presence of mould, and coincidentally, the rotting of wood. Putting in the fan vent via the roof of a home is often the most effective course of action.the kitchen type will easily rid the 43
kitchen area of both its different odors as well as its smoke. It's important that kitchen exhaust fans are venting air directly outside of the home, not only to get the most out of the fan, but additionally for the safety of those who stay inside the home. Kitchens typically come with a standard exhaust fan, however these standard fans re- circulate the air they take in, to then direct it higher within the area, instead of extracting it out of the room completely. ABOUT MATERIAL ABS PLASTIC Acrylonitrile Butadiene Styrene (ABS) ABS is a thermoplastics polymer family. This material is comes from acrylonitrile, butadiene and styrene. Usual compositions are about half styrene with the balance divided between butadiene and acrylonitrile. Considerable variation, possible resulting in many several grades of acrylonitrile butadiene styrene with a wide range of features and applications. In addition, many blends with other materials such as polyvinylchloride, polycarbonates and polysulfones have been developed. crylonitrile Acrylonitrile Butadiene Styrene (ABS) polymer was first discovered during World War II when its basis, SBR, was used for alternatives to rubber. In the early 1950s acrylonitrile butadiene styrene polymers first available material to get the good properties of both polystyrene and styrene acrylonitrile. Features Flame Retardant High Heat Resistance Good Impact Resistance High Impact Resistance High Flow General Purpose Good Flow Good Process ability High Gloss Good Dimensional Stability Uses Automotive Applications Electrical/Electronic Applications General Purpose Housings Appliances Business Equipment Automotive Interior Parts Appliance Components Thin-walled Parts Computer Components Disadvantages Limited weathering resistance Moderate heat, moisture and chemical resistance Relatively high cost Flammable with high smoke generation Manufacturing By using the fundamental of the software with regards to the single data source principle, it provides a rich set of tools in the manufacturing environment in the form of tooling design and simulated CNC machining and output. Tooling options gives information about tools for molding, die-casting and progressive tooling design. Different Modules in Pro/Engineer PART DESIGN ASSEMBLY DRAWING SHEETMETAL 44
MOULD DESIGN MOULD FLOW ANALYSIS 5. MOULD FLOW ANALYS Mould flow, 3D solids-based plastics flow simulation that enable plastics part designers to, which can lead to delays and over runs cost. Following are the benefits: determine the manufacturability of their parts during the preliminary design stages and avoid potential problems Optimize the thickness of part wall to attain uniform filling patterns, minimum cycle time and lowest part cost Identify and eliminate cosmetic problem such as sink marks, weld lines and air traps. Mould flow analysis gives you the ability to maintain the integrity of your product designs. It provides you the tools to quickly optimize part designs and check the impact of critical design decisions on the manufacturability and quality of the product early in the design process. There is no need to: Compromise the aesthetics of your design concept for manufacturability; Go through a lengthy trial and error process to find the most suitable material to produce the part with the highest possible quality and the lowest possible cost Find out during trial runs find out that the produced part has visual blemishes, such as sink marks, weld lines, air traps or Plastic Advisor in Pro/Engineer Problems found after tooling development. For plastic part design and manufacture, there is a better way. By simulating the plastic-filling process for injection-molded parts, Pro/ENGINEER Plastic Advisor enables engineers to design for manufacturability, uncover problems, and propose remedies, reducing development time and expense. Advanced features gives valuable manufacturability insight - insight that can significantly reduce late-cycle design changes and mould reengineering prices. Features & Benefits Animates plastic injection fill process and automatically creates Web reports within Pro/ENGINEER browser Access library of common plastic materials and automatically select from typical injection-molding machine parameters Improve design quality and reduces manufacturing cycle times and rework of molds To do analysis the following commands are used Select applications > plastic advisor > pick datum point for injection location > ok > select molding parameter icon > select specific material > select manufacturer >relian M60075 (ABS)> select processing conditions > enter melt temperature > enter mold temperature > enter maximum injection pressure limit > enter clamp time > ok. 45
Plastic Flow Analysis The Flow Analysis summary page gives an overview of the model's analysis, including information about actual injection time and pressure and whether weld lines and air traps are Fill Time -it shows the plastic flow path through the part by plotting contours which join regions filling at the same time. These contours are displayed in a range of colors from red,blue, to indicate the first region to fill and the last region to fill. A short shot is a part of the model will be displayed as translucent Confidence of Fill- The boldness of fill result displays the chance inside the cavity filling with plastic at standard injection molding conditions. This result is derived from the pressure and temperature results. Pressure Results Derivation During Filling at any point, there is a pressure gradient from a maximum value at the injection location down to atmospheric pressure at the flow front. The Adviser calculates this pressure distribution continuously throughout cavity filling and presents you with 2 pressure results considered with reference to the following simple part that has a single polymer injection location at one end: This graph shows how pressure varies over time at both the polymer injection location and at the point marked X. The above graph also displays where the Adviser calculates both of its pressure results.thepressure Drop result is a contour plot showing the pressure required to flow material to each point in the cavity. Calculate the values of pressure at the injection location as a point (X in our example) fills and plotted this values at the point corresponding to X on the model. the Injection Pressure result, the Pressure Drop is not displayed for any one moment in time. The values shows relate to the time that the location in question (X) actually filled. Acontour plot of the pressure distribution throughout the cavity at the end of filling is a Injection Pressure result. This is effectively a "snapshot" at one instant of time. At the Injection Location The maximum value, and at the last point of the cavity will be Result of the flow front temperature uses Varity of colors to point of lowest temperature (colored blue) through to the region of highest temperature (colored red). The colors represent the material temperature at each point as that point was filled. The result shows the changes in the temperature of the flow front during filling. CONCLUSION Presently exhaust fans are made with metals. So fan weight is more and consequently high power is required for the fan rotation. The main aim of this project is to develop a mould for the exhaust fan using ABS Plastic material. The parametric modeling of exhaust fan is done in Pro/Engineer. Mould flow analysis is done using Plastic Advisor module in Pro/Engineer. The input parameters to check the mould flow are Maximum Injection Pressure 180MPa, Mold temperature 60deg C and Melt Temperature 230deg C. By checking the analysis results, the confidence of fill is high and quality prediction is also high. That is the part can be easily filled with acceptable quality using the current injection locations. The injection time is 1.7 secs, Injection pressure is 89.67Mpa, Shot Volume 65.49 cucm, Filling Clamp Force 47.3 tons and cycle time is 12.09secs. Mould calculations are done to determine the cycle time, clamp force, machine capacity etc. The injection moulding 46
machine capacity to be selected is 180tons, the cycle time needed for one component is 11.7secs and total number of components produced per hour is 307. The clamping force required is 148.86 tons and shot weight is 92.639gms. the heat flow per hour is 7689592.834 Cal/hr. Core and Cavity is extracted and total mould base is designed for the exhaust fan using HASCO standards. Manufacturing processes for both core and cavity are also included. CNC program is generated. We are providing complete mould base components, it s shop floor drawings, material selection for each component, manufacturing processes for each component. In this thesis we are providing all the data required for doing Injection mould tool. REFERENCES [1] R. G. Desavale, A. M. Patil, Theoretical and Experimental Analysis of Torsional and Bending Effect on Four Cylinders Engine Crankshafts by Using Finite Element Approach, International Journal of sudheeraarunengineering Research, 2013, 2, 379-385. [2] G. Rui, Jang, Choi, Torsional vibration analysis of lathe spindle system with unbalanced workpiece, J. Cent. South Univ. Technol., 2011, 18, 171-176. [3] K. A. Gul, Thesis: Modeling and Analysis of Engine Cold-Test Cells for Optimizing Driveline Design for Structural Reliability and Engine Assembly Defect Diagnostics, 2013. [4] G. Genta, Vibration dynamic and control, Springer, 2009, pp.764-766. [5] A. Boysal, H. Rahnejat, Torsional vibration analysis of multi-body single cylinder internal combustion engine model, Appl. Math. Modelling, 1997, 21, 481-493. [6] A. Pitchaikani, S. Venkataraman, K. K. Koppu, Powertrain torsional vibration system model development in Modelica for NVH studies, in Proceedings 7 th Modelica Conference, The Modelica Association, 444-453. H. Zenpeng, G. Wenqin, X. Weisong, NVH and reliability analyses of the engine with different interaction models between the cranckshaft and bearing, Applied Acoustics, 2016, 101, 185-200 47