| CODE | MFE4210 | ||||||||||||
| TITLE | Introduction to Tool Design and Manufacture | ||||||||||||
| UM LEVEL | 04 - Years 4, 5 in Modular UG or PG Cert Course | ||||||||||||
| ECTS CREDITS | 5 | ||||||||||||
| DEPARTMENT | Industrial and Manufacturing Engineering | ||||||||||||
| DESCRIPTION | This study-unit focuses on the design and manufacture of injection moulding tools. It will first give an overview of polymer materials, injection moulding process and part design guidelines for injection moulding. The study-unit will give students an understanding of: - tools components and their functions; - different runner systems including the gate design and cavities layout; - cooling (for thermoplastics) and heating systems (for thermosets); - active and passive tool ventings; - ejection or demoulding systems; - hot runner technology; - melt flow and cavity filling simulation; - step by step tool design; - problems solving in injection moulding related to tool design including its modification; - tool materials; - tool machining techniques; - rapid tooling particularly using additive manufacturing techniques; - special injection moulding tools; - cost calculation methods. Study-unit Aims: The main aims are: - to familiarise students with the necessary components to build proper injection moulding tools; - to provide students with fundamental knowledge to design and manufacture injection moulding tools; - to enable students an understanding of the important relation between the injection moulding process and injection moulding tool that affects the quality of the final products. Learning Outcomes: 1. Knowledge & Understanding By the end of the study-unit the student will be able to: - describe the types, properties and processibility of polymer materials; - understand melt flow and cavity filling; - define the nomenclature and function of injection moulding tool components; - summarize various tool types; - understand the principle of tool design; - explain the principle and the use of rapid tooling using additive manufacturing techniques; - illustrate tool manufacturing techniques; - discuss the correlation between product quality and tool design. 2. Skills By the end of the study-unit the student will be able to: - simulate cavity filling and predict product quality; - select correct tool components for particular application; - select, design and manufacture proper injection moulding tool for the chosen polymer material; - analyse and explain product quality and failures affected by tool design; - redesign a product and tool respectively to solve certain moulding problems. Main Text/s and any supplementary readings: - Georg Menges / Paul Mohren: How to make injection molds, Hanser, 1993. - Douglas M. Bryce: Plastic injection molding: mold design and construction fundamentals, SME, 1998. |
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| STUDY-UNIT TYPE | Lecture, Independent Study and Practical | ||||||||||||
| METHOD OF ASSESSMENT |
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| LECTURER/S | Arif Rochman |
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The University makes every effort to ensure that the published Courses Plans, Programmes of Study and Study-Unit information are complete and up-to-date at the time of publication. The University reserves the right to make changes in case errors are detected after publication.
The availability of optional units may be subject to timetabling constraints. Units not attracting a sufficient number of registrations may be withdrawn without notice. It should be noted that all the information in the description above applies to study-units available during the academic year 2023/4. It may be subject to change in subsequent years. |
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