THE STUDY OF USING CAE FOR PART WEIGHT REDUCING IN 3 DIMENSIONAL PLASTICS INJECTION MOLDING WITH GAS-ASSISTED

Abstract

The objective of this research is to finding the method to reduce the use of plastic for gas-assisted injection molding and to study about the step of design and build the 3D plastic injection molding by using CAD/CAM/CAE including the using of plastic injection machine in production line. This research is started with making the drawing of workpiece from the prototype got from companies who join the project. After that the plastic flow analysis of ABS type, is achieved to find the parameters involving in the injection process before starting the real molding design process. With the completed results, it is used to make the drawing and build the real molding with the CNC by using the 2 plate molding type and specify the nitrogen gas inject into the workpiece via the gas nozzle directly. For the result of injection, with 200 ton injection machine, the best and perfect workpiece is obtained at using injection pressure 600bar, gas pressure 150 bar, gas delay time 1.5 sec, melting temperature of plastic at 215 C, molding temperature at 40 C, and the injection time per cycle at 92.5 sec. The workpiece weight is 317.123 gram, this can reduce the plastic up to 15%.