components associated with data processing, information
storage, and display technology, in terms of both speed
and memory. These have resulted in the more efficient use
of the solid-modeling functions in a PC-based CAD/CAM
system. With the increased availability of sophisticated,
low-cost software for Windows, more and more engineersare using PC applications to get their jobs done. Thus the
development of a new mold design application based on the
Windows platforms is in high demand.
High-end users are finding that mid-range solid modelers,
such as SolidWorks, have met their needs. Developed from
the beginning as a native Windows application, SolidWorks
is one of the 3D mechanical design softwares for Win-
dows. Its unique combination of production-level power,
ease-of-use, and affordability is unmatched. SolidWorks
99, the seventh major release of the company’s mechan-
ical design software for Windows NT, Windows 98 and
beyond provides an increased power and functionality in a
fully integrated solid modeler. Familiar conventions such as
point-and-click, drag-and-drop, cut-and-paste, and seamless
data sharing with other Windows software lead to produc-
tivity gains. The ease-of-use without extensive training and
at affordable pricing enables companies to install the sys-
tem on every engineer’s desktop. One of its applications is
for mold design in the plastics industry. This latest appli-
cation technology has added an entirely new dimension to
the mold design process.
2. Injection mold design
Injection molding uses temperature-dependent changes in
material properties to obtain the final shapes of discrete
parts to finish or near-finish dimensions through the use of
molds. In this type of manufacturing process, liquid material
is forced to fill and solidify inside the cavity of the mold [2].
Firstly, the creation of a mold model requires a design
model and a containing box. The design model represents
the finished product, whereas the containing box represents
the overall volume of the mold components.
Injectionmold design involves extensive empirical knowl-
edge (heuristic knowledge) about the structure and the func-
tions of the components of the mold. The typical process
of a new mold development can be organized into four ma-
jor phases: product design, moldability assessment, detailed
part design, insert/cavity design, and detailed mold design.
In Phase 0, a product concept is pulled together by a
few people (usually a combination of marketing and engi-
neering). The primary focus of Phase 0 is to analyze the
market opportunity and strategic fit. In Phase I the typical
process-related manufacturing information is then added
to the design to produce a detailed geometry. The concep-
tual design is transformed into a manufacturable one by
using appropriate manufacturing information. In Phase II
the parting direction and parting lines location are added to
inspect the moldability. Otherwise, the part shape is again
modified. In Phase III, the part geometry is used to establish
the shape of the mold core and cavity that will be used to
form the part. Generally shrinkage and expansions need to
be considered so that the molding will be the correct size
and shape at the processing temperature. Gates, runners,
overflows, and vents also need to be added. The association
between geometric data and parting information is critical
at this point. Phase IV is related to the overall mechanical
structure of the mold including the connection of the mold
to the injection machine, a mechanisms for filling, cooling,
and for ejection and mold assembly.
3. Methodology
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