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Plastic Injection Molding

Introduction

Not only it provides knowledge on polymers, flow analyses and part design, it also acts as a bridge such that effective communications can be established between the part designer, the flow analysts, the mold designers, and the part manufacturers. These interactions are demonstrated by a case study.

Course Objectives

The course aims to highlight the characteristics of plastic injection molding and its impact on part design. It focuses..
(i) on the design of part which could be manufactured cost effectively by plastic injection molding,
(ii) the part manufacturer to design the molds and the molding conditions to produce quality parts
(iii) and an introduction on flow analyses. The course provides the background such that various parties involved could communicate effectively.

Course Outline

Section 1 -- Introduction
1 Introduction – Polymer characteristics
2 Injection Molding Phases and Implication to part quality and production cost
3 Terminologies, flow of plastic in a mold, function of each components
4 Effect of organic and inorganic pigments – melt flow index and TGA for quality assurance

Section 2 – Design for part manufacturing
1. Molding Parameters and its influence on finished parts.
2. Part defects and how to avoid them.
3. Design Principles --
• Number of gates, position of gate, flow pattern, runner design on part quality
• Multi-gating for complex parts and runner design
• Flow leaders and flow defectors
• Positioning of weld and meld lines for complex part, sub-molding concept
• Family mold, runner design and over-packing on part quality.

Section 3 -- Flow Simulation
1. Basic flow equations
2. Runner – 1.5D approximation
3. Cavity - 2.5 D Hele Shaw approximation, Full 3D calculations
4. Runner balancing, cavity balancing and gate optimization, flow path concept

Section 4 -- Introduction to Mold design
1. Types of Molds – implication on cost and quality
2. Runner design
3. Cooling Design
4. Ejection

Section 5 -- Part Design: Loading and Failure Modes
Introduction to stress analysis, various loading and failure modes

Section 6 -- Part Design: Design Features and Other issues in injection molding
1. Shrinkage consideration
2. Wall and rib thickness, rib design – sink mark and hesitation effect
3. Living Hinge – flow field and gate location
4. Draft angles, corner radius and fillet radius
5. Design for joining and assembly
6. Strength consideration for weld and meld lines

Trainer(s)

Professor Lam, Yee Cheong

Dr. Lam graduated in Mechanical Engrg, Melbourne Uni. in 1979 with first class honours and was awarded the Dixon Scholarship for “Outstanding Academic Achievement”. Subsequently, he obtained his Ph.D. in 1983 from the same Uni. and was awarded the M.H. de Fina Memorial Prize for “The Best Postgraduate Student in the Dept”. He had held visiting appointments in the Mechanical Engrg Depts of Imperial College and Uni. of Alberta.

Dr. Lam is currently a Professor in the Division of Manufacturing Engrg, School of Mechanical and Aerospace Engrg (MAE), Nanyang Technological Uni.. Before joining MAE NTU, Dr. Lam was a Reader with the Dept of Mechanical Engrg, Monash Uni., Clayton Campus. He was the National President of the Australian Fracture Group; a Director of the Far East Oceanic Fracture Society, Head (Monash Node) of the Co-operative Research Ctr of Advanced Composite Structures (CRC-ACS), and was the Program Coordinator for its Tooling and Repair Tasks. He was awarded a plaque by CRC-ACS in 1997 “In Recognition of Service to CRC-ACS”. In 1999, he was invited by the Uni. of Melb., Australia to deliver the prestigious Tewksbury Lecture, a lecture series to be delivered by distinguished researchers in engrg science. He was frequently consulted by the industry and had acted as Expert Witness.

Dr. Lam has conducted research in the areas of metal working, fracture mechanics, life extension of structures and finite element analysis. Recently, his research focus is on the modeling of materials and their processing, in particular plastic and powder injection molding, fiber composite manufacturing and the behaviors of polymers. He has published more than 200 technical papers in the areas of plastic injection molding, manufacturing methods, fatigue and fracture, and finite element analysis. His research in plastic injection molding is supported by Moldflow Corp., USA, the leading and dominant co. in plastic injection molding simulation software.

Who Should Attend

Course Details

Date:

29 September to 1 October 2009

Time:

9:00am to 5:00pm

Venue:

NTU@one-north campus, Executive Centre

Closing Date:

15 September 2009

Fee:

Standard: SGD$980 Alumni: SGD$784 Group (3 & Above): SGD$882

Registration fees inclusive of:

Course materials
Light refreshments
Lunch
Complimentary parking (1 entry/day) - applicable at NTU@one-north campus only.
Prevailing GST

Online Registration

>> CLICK HERE to Register Online

Methods of Payment

1. Credit Card (Visa and Mastercard only)

2. Cheque made payable to Nanyang Technological University

3. Invoice to Company (for Company Sponsored Participants)

4. E-invoice (for Government Organizations)

Cancellation & Refund Policy

Written notification to cce@ntu.edu.sg or fax: (+65) 6774 2911 at least 10 days before course commencement	No cancellation charges (Full refund)
Written notification within 4 – 9 days before course commencement	50% of course fees (50% refund)
Written notification within 3 days before course commencement	100% of course fees (No refund)