Conveying The Importance Of Manufacturing Process Design Using Simulation Results And Empirical Data

Manufacturing combines many aspects of engineering and technology. To achieve the desired results, manufacturing engineers must understand how component design, processing equipment design, and process parameters affect the final component. Currently, engineers have access to manufacturing simulation tools in addition to empirical tests. This allows engineers to test theories and do preliminary analyses of manufacturing processes (with simulation tools). To understand how a process will perform and ensure the desired results usually requires empirical data. Injection molding is a widely used and easily understood process. There are simulation tools available for the injection molding that are accessible to undergraduate engineering and technology students. When simulations performed using these tools are combined with empirical results, students can better comprehend the usefulness and limitations of such tools. This paper details a laboratory exercise which demonstrates to students how gate location affects the stress and strain properties of injection molded tensile test specimens. The effects of process parameters are also shown. Students are shown process simulations of injection molding using varying parameters and gate locations. They then injection mold tensile test specimens and test them. These results demonstrate the importance of process parameters (e.g., injection pressure, temperature, etc.) and gate location. Process parameters are shown to have a significant effect on the ability to produce an acceptable specimen. Gate location is also shown to affect stress-strain behavior.