Abstract that, summarizing an optimized design method applying to

Abstract

A “trial and error” design method, which based on experienced, shows its
weaknesses such as time and cost consumption for design and development
product. Furthermore, even that the product of traditional design method, after
solving all errors and cannot be identified any problems, ultimately satisfy
all the requirements of the customer. However, it is not the best product with
all optimized characteristics. In my previous project – manufacturing project
about fabrication of recycled plastic forming machine – I applied the traditional design method and
based on my experience to create components of the machine, in which the mold
is the most significant part because it directly impact to the quality and
productivity as well as production cost. Base on my own knowledge, experience
and estimation, the mold was created. Then I did the simulation to check
whether it can work well or not. And I pass the strength of material test, but
the quality of the mold is much more over-satisfy my expectation lead to the
cost to product it very high. In this paper, I will apply numerical simulation
in design and develop process to create the optimized product with most
suitable characteristics about material, dimension and structure. After that,
summarizing an optimized design method applying to design the rest of all parts
of the recycled plastic forming machine. Using this method, in order to analyze
every single characteristic of product, in this case it is the mold. I have to
set up a range of values or parameters such as material, temperature, pressure
and structure (solid or metal sheet) and then do numerical simulation to see
the results. Then implementing statistic, analysis and synthesis to generate
the best design of the mold at the first time. And then applying this method to
design all the part of the machine. It saves time and brings cost efficiency.

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Keywords: mold
design, optimization solution, Computer Aided Engineering analysis, plastic
compression machine

 

© 2017 The Authors. Published
by Elsevier B.V.
Peer-review under responsibility
of the scientific committee of the International Conference on Material, Machines
and Methods for Sustainable Development.

Keywords:

 

1. Introduction

Conventional
design method, which based on experienced, “trial and error”, shows its weaknesses
such as time and cost consumption for design and development product.
Furthermore, even that the product of traditional design method, after solving
all errors and cannot be identified any problems, ultimately satisfy all the
requirements of the customer. But it is not the best product with all optimized
characteristics. In my previous project – manufacturing project about
fabrication of recycled plastic forming machine – I applied the traditional
design method and based on my experience to create components of the machine,
in which the mold is the most significant part because it directly impact to
the quality and productivity as well as production cost. Base on my own
knowledge, experience and estimation, the mold was created. Then I did the simulation
to check whether it can work well or not. And I pass the strength of material
test, but the quality of the mold is much more over-satisfy my expectation lead
to the cost to product it very high. In this paper, I will apply numerical
simulation in design and develop process to create the optimized product with
most suitable characteristics about material, dimension and structure. After
that, summarizing an optimized design method applying to design the rest of all
parts of the recycled plastic forming machine. Using this method, in order to
analyze every single characteristic of product, in this case it is the mold. I
have to set up a range of values or parameters for every aspect known as “noise
factors” such as material, temperature, pressure and structure (solid or metal
sheet) and then do numerical simulation to see the results. Then implementing
analysis and synthesis to generate the best design of the mold at the first
time. And then applying this method to design all the part of the machine.

2. Material and method

2.1. Engineering analysis

I do
analyse the mould because these parts work in pressure and temperature
condition. These elements influence on the quality of the finished product.

NX Siemens for Simulation is a
modern simulation environment for advanced analysts and design engineers. It
integrates with NX Nastran, a powerful finite element solver with tremendous
strength in static and dynamic solutions. In addition, in our master program,
we also were introduced this powerful design software, so we had more
experience about it rather than others. Thus, we choose NX for simulation our
product.

2.2. Strength of materials

In theory, the structure would be strong enough
if it satisfies two conditions:

Stiffness
condition: In this case, we refer to the force and displacement graph for
1018 steel tested in tension to estimated acceptable displacement range. In
this range, the object can return to its original shape without permanent
deformation. For estimation, we decide the acceptable displacement range for stainless
steel 401 is from 0 to 1mm.

 

 

 

 

 

 

 

 

 

 

 

 

 

Figure 1: Force as a function of chart
displacement for 1018 steel tested in tension 2

Stress
condition:

Whereas, ?max is the maximum stress applied
to the structure. ? In this case, we choose the maximum Yield strength (the
stress which material can withstand without permanent deformation). Because
after release the pressure, the mould must not be deformed. These conditions is
applied to conclude whether our structure can withstand the load or not.

2.3.

Mould simulation

Upper mould

Set the conditions:

Material: SS410

Figure
2: Direction of applied force and fixed constrain of condition setting for
upper mould

 

Applied force: 15000N (1.5 tons)

Temperature: 250°C

 

 

 

 

 

Bottom mould

Setting up the conditions is
similar to upper mould,

but the direction is upward.

 

 

Figure
3:  Direction of applied force and
fixed constrain of condition setting for bottom mould
 

 

 

3.

Results

 

 

 

 

Figure 4: The result of analysis about displacement (left) and stress
(right) for upper mould

Displacement: 0.588 mm < 1mm Stress: 70.80 MPa <  = 275 MPa 1 This means the upper mould is satisfied two strength conditions. It can work well under the working requirements.                               Figure 4: The result of analysis about displacement (left) and stress (right) for bottom mould   Displacement: 0.665 mm < 1mm Stress: 161.66 MPa <  = 275 MPa 1 This means the bottom mould is satisfied two strength conditions. It can work well under the working requirement 4. Discussion and conclusion All simulation convince that our structure is strong enough. By simulation, we can save time and cost compared with do trial, test and take improvements. For further development, I could use optimized design of all parts of the recycled plastic forming machine.