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Author

Mohamed Ali

Bio: Mohamed Ali is an academic researcher. The author has contributed to research in topics: Injection moulding. The author has an hindex of 1, co-authored 1 publications receiving 1 citations.

Papers
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Journal Article
TL;DR: The aim of this paper is to model, extract core–cavity and develop injection moulding tool for manufacturing an object.
Abstract: Injection moulding is a manufacturing process for producing plastic parts from both thermoplastic and thermosetting plastic materials. The aim of this paper is to model, extract core–cavity and develop injection moulding tool for manufacturing an object. The part modelling, Core–Cavity design is done using PLM software Pro/ENGINEER 4.0. Mould base design is done according to HASCO standards. The plastic flow analysis is performed. NC code for fabricating the mould is generated using Vericut software. The unit cost to make a component is estimated including all the costs like material cost, tooling cost, machining cost etc.

1 citations


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25 Aug 2016
TL;DR: In this paper, the effects of inserted film on the asymmetric mold temperature field of IMD injection molding process for polypropylene (PP) parts were investigated under various conditions of mold temperature, melt temperature and film thickness.
Abstract: In mold decoration (IMD) injection molding is a relatively new multi-process technique that has been used for improving the surface quality and achieving colorful cosmetic surface of molded parts. During IMD processing, the film having the same shape as mold cavity is first inserted into the mold then molten polymer is injected into the cavity. Heat transfer in the cavity surface is significantly retarded because of the low thermal conductivity of film. As a result of the asymmetric melt and mold temperature, thermal-induced part warpage easily occurs. The effects of inserted film on the asymmetric mold temperature field of IMD injection molding process for polypropylene (PP) parts were investigated. Experiments were conducted under various conditions of mold temperature, melt temperature and film thickness. The associated part warpage and crystallinity due to the asymmetric mold temperature were examined. It was found that the heat transfer retardation results in a delay in mold temperature drop at film–mold interface of the cavity surface and the maximum temperature difference compared with that of conventional injection molding without film may be as high as 10 °C. The retardation-induced mold temperature difference and part warpage increased with increasing melt temperature and film thickness, whereas they decreased with increasing mold temperature. The crystallinity of molded PP parts increased through insertion of film. The mold temperature field of the IMD process and molded part's warpage were predicted via numerical analyses. The predicted values showed reasonable agreement with the experimental results. Asymmetric cooling system design reduced part warpage when IMD processing was used.