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Computer-Aided Injection Mold Design and Manufacture : Plastics Engineering - Jerry Y. H. Fuh

Computer-Aided Injection Mold Design and Manufacture

Plastics Engineering

Hardcover Published: 2nd August 2004
ISBN: 9780824753146
Number Of Pages: 392

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Examining processes that affect more than 70 percent of consumer products ranging from computers to medical devices and automobiles, this reference presents the latest research in automated plastic injection and die casting mold design and manufacture. It analyzes many industrial examples and methodologies while focusing on the algorithms, implementation procedures, and system architectures that will lead to a fully automated or semi-automated computer-aided injection mold design system (CADIMDS). This invaluable guide in this challenging area of precision engineering summarizes key findings and innovations from the authors' many years of research on intelligent mold design technologies.

"...the most comprehensive and detailed review of all the major developments that have characterized the emergence of these important fields. It will form an indispensable reference work for scientists and engineers in academia and industry for years to come....recommend[ed]." - Dr. Donald Fitzmaurice, Department of Chemistry, University College Dublin, Ireland; "This Encyclopaedia is being assembled at an early stage in the field's development and should bring together the key advances in a coherently organised framework." - Sir Harry Kroto, Nobel Prize Winner in Chemistry (1996), University of Sussex, Brighton, United Kingdom"

Prefacep. v
Acknowledgmentsp. ix
Introductionp. 1
CAD/CAM Technology in Tooling Applicationsp. 1
Fixture Designp. 2
Die and Mold Designp. 4
CAD/CAM of Injection Moldsp. 6
Plastic Injection Moldsp. 8
Die Casting Moldsp. 9
Summaryp. 9
Referencesp. 10
Plastic Injection Mold Design and Assemblyp. 13
Introductionp. 13
Plastic Injection Mold Designp. 15
Injection Molding and Moldp. 15
Injection Mold Design Processp. 16
Detailed Mold Designp. 20
Mold Assemblyp. 32
Mold Design Methodologyp. 33
The Mold Development Processp. 33
Top-Down vs. Bottom-Up Approachp. 35
Computer-Aided Injection Mold Design and Assemblyp. 35
Assembly Modeling of Injection Moldsp. 36
Summaryp. 41
Referencesp. 42
Intelligent Mold Design and Assemblyp. 45
Introductionp. 45
Feature and Associativity-Based Injection Mold Designp. 46
Feature Modelingp. 47
Associativity Within Injection Moldsp. 50
Representation of Injection Mold Assembliesp. 54
Concepts and Notations for Object-Oriented Modelingp. 54
Object-Oriented Representation of Mold Assemblyp. 55
Optimal Parting Design for Core and Cavity Creationp. 58
Optimal Parting Directionp. 59
Generation of Parting Linesp. 64
Determination of Parting Surfacesp. 75
Automatic Generation of Core and Cavityp. 78
Automatic Cavity Layout Designp. 82
Cavity Layout and Numberp. 82
Automatic Layout of Multi-Cavityp. 87
Recognition and Extraction of Undercut Featuresp. 91
Definitions and Classifications of Undercut Featuresp. 91
Undercut Features Recognitionp. 92
Draw Range and Direction of Undercut Featuresp. 94
Graph Representation of Solid Modelsp. 97
Recognition Algorithmsp. 106
Generation of Side-Cores for Sliders and Liftersp. 110
Slider and Lifter Mechanismp. 110
Designing Side-Coresp. 112
Recognition of Undercuts from Core and Cavityp. 113
Automatic Generation of Side-Coresp. 117
System Implementations and Case Studiesp. 120
System Architecturep. 120
Development Platforms and Programming Languagesp. 120
Functional Modules and Graphical User Interfacesp. 121
Case Studyp. 128
Summaryp. 133
Referencesp. 133
Semi-Automated Die Casting Die Designp. 137
Introductionp. 137
Principles of Die Casting Die Designp. 139
Die Casting Die Designp. 139
Gating and Runner System Designp. 140
Die-Base Designp. 142
Computer-Aided Die Casting Die Designp. 143
Automated Design of Die Casting Diep. 143
Computer-Aided Design of Gating Systemp. 144
Design of Cavity Layout and Gating Systemp. 145
Determination of Cavity Numberp. 145
Automatic Creation of Cavity Layoutp. 147
Determining the Parameters of Gating Systemp. 148
Design of Gating Featuresp. 154
Conforming the Gate Geometry to the Die-Casting Partp. 159
Design of Shot Sleeve, Sprue, and Spreaderp. 159
Die-Base Designp. 161
Design of Die-Basep. 161
Die-Base Structure and Variablesp. 162
Creating the Parametric Assembly Models of Die-Basep. 162
Building the Die-Base Databasep. 165
Automatic Generation of Die-Basep. 165
Generation of Core and Cavityp. 166
Automatic Subtraction of Die Componentp. 167
System Implementation and Examplesp. 169
Development Platforms and Languagesp. 169
System Architecture--DieWizardp. 170
Examplesp. 175
Summaryp. 184
Referencesp. 184
CAE Applications in Mold Designp. 187
Introductionp. 187
CAE Analysis Procedures and Functionalitiesp. 189
Analysis Proceduresp. 190
CAE Functionalitiesp. 190
CAE in the Mold Development Life Cyclep. 192
CAE Details in Mold Developmentp. 193
What CAE Revealsp. 195
CAE in Part Designp. 198
CAE in Mold Designp. 199
CAE in Process Designp. 202
CAE in Product Quality Assurancep. 202
Application Examplesp. 204
Injection Mold Cooling Analysisp. 205
Simulation of the Casting Processp. 210
CAE Challenges in Mold Designp. 214
Summaryp. 217
Referencesp. 218
Computer-Aided Die and Mold Manufacturep. 221
Introductionp. 221
Interference-Detection in Mold Machiningp. 223
Machining Interferencep. 223
Methods of Interference Detectionp. 224
3-Axis End-Mill Interference Detectionp. 230
Local and Global Interferencep. 232
Illustrative Examplep. 245
Optimal Cutter Selectionp. 246
Previous Workp. 246
Criteria of Selectionp. 248
Machining Time and Machining Areap. 250
Step-Over and Machining Time Estimationp. 252
Cutter Selection Algorithmsp. 253
Computer-Aided Electrode Design and Machiningp. 254
Introductionp. 254
Principles of EDM Electrode Designp. 257
Electrode Tool Designp. 258
Electrode Holder Designp. 265
Sharp Corner Interference Detectionp. 265
Illustrative Examplesp. 270
Modification of Mold Design and Tool Path Regenerationp. 275
Introductionp. 275
Basic Concepts and Notationsp. 275
Proposed Algorithmp. 276
Illustrative Examplesp. 281
Summaryp. 282
Referencesp. 283
Computer-Aided Process Planning in Mold Makingp. 287
Introductionp. 287
An Optimization Modeling Approach to CAPPp. 290
CAPP for Sliders and Liftersp. 292
Design of Sliders and Liftersp. 292
A Hybrid CAPP Approachp. 293
Process Planning Problem Formulationp. 296
Optimization Techniques for Process Planningp. 298
Discussionsp. 304
System Implementation and an Examplep. 305
The IMOLD_CAPP Systemp. 305
An Examplep. 309
Summaryp. 311
Referencesp. 312
Early Cost Estimation of Injection Moldsp. 315
Introductionp. 315
Cost Function Approximation Using Neural Networksp. 317
Cost-Related Factors for Injection Moldsp. 320
The Neural Network Trainingp. 325
The Neural Network Architecturep. 325
The Training Processp. 327
Training and Validation Resultsp. 328
Neural Networks for Different Cost Rangesp. 329
Summaryp. 331
Referencesp. 332
Case Studies: IMOLD and IMOLD-Works for Mold Designp. 335
Intelligent Mold Design and Assembly Systemsp. 335
Knowledge-Based Mold Design Systemsp. 335
IMOLD Overviewp. 338
Development Platformsp. 339
Functional Modulesp. 340
A Windows-Based Mold Design and Assembly Systemp. 344
3D Windows-Native CAD Systemsp. 345
System Implementationsp. 351
Graphical User Interfaces (GUIs)p. 352
Windows-Based Die Casting Die Design Systemsp. 357
Illustrative Examplesp. 358
Summaryp. 362
Referencesp. 362
Glossaryp. 365
Indexp. 369
Table of Contents provided by Rittenhouse. All Rights Reserved.

ISBN: 9780824753146
ISBN-10: 0824753143
Series: Plastics Engineering
Audience: Professional
Format: Hardcover
Language: English
Number Of Pages: 392
Published: 2nd August 2004
Publisher: Taylor & Francis Inc
Country of Publication: US
Dimensions (cm): 22.9 x 15.2  x 3.18
Weight (kg): 0.68
Edition Number: 1