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Modeling and analysis of cavity modification effect on quality of injection molded polymer gear
To improve the productivity of the injection molding, it is essential to manufacture the part in the shortest possible period of time while minimising the waste. Additionally, quality of the manufactured part must be ensured by having lowest dimensional deviation, surface defects, and induced residual stresses. However, it is challenging to get a uniform temperature throughout the thick-walled part or complex parts like gear. Therefore, effective design of the gear cavity is essential to minimise volume and maximise surface area to reduce temperature variations. In the present work, modeling and analysis of cavity modification is carried out on involute spur gear to be manufactured by injection molding. The generation of spur gear was carried out using Solidworks software. The same is validated with the data of the sample manufactured gear and found in close agreement for deflection and weight. Further, modifications in the geometry of the generated gear namely rim shape, hub diameter and rim width were made to improve the fill time, core temperature, weight, and maximum ejection time using gear volume reduction and surface area expansion technique. Modification in the gear geometry would result in gear cavity modification. The Moldflow analysis was performed to investigate the effect of cavity modification. The results show decrease in filling time from 0.2024 to 0.1017 s, core temperature from 200.7 to 164.1 °C, weight from 10.26 to 8.17 g, and ejection time from 143.5 to 49.2 s. However, structural analysis result shows increase in deformation from 0.059 to 0.075 mm and root stress from 18.02 to 21.88 MPa. In addition, Moldflow analysis outcomes confirm decrease in teeth deflection from 0.459 to 0.439 mm and residual stress from 28.84 to 25.88 MPa.
Modeling and analysis of cavity modification effect on quality of injection molded polymer gear
To improve the productivity of the injection molding, it is essential to manufacture the part in the shortest possible period of time while minimising the waste. Additionally, quality of the manufactured part must be ensured by having lowest dimensional deviation, surface defects, and induced residual stresses. However, it is challenging to get a uniform temperature throughout the thick-walled part or complex parts like gear. Therefore, effective design of the gear cavity is essential to minimise volume and maximise surface area to reduce temperature variations. In the present work, modeling and analysis of cavity modification is carried out on involute spur gear to be manufactured by injection molding. The generation of spur gear was carried out using Solidworks software. The same is validated with the data of the sample manufactured gear and found in close agreement for deflection and weight. Further, modifications in the geometry of the generated gear namely rim shape, hub diameter and rim width were made to improve the fill time, core temperature, weight, and maximum ejection time using gear volume reduction and surface area expansion technique. Modification in the gear geometry would result in gear cavity modification. The Moldflow analysis was performed to investigate the effect of cavity modification. The results show decrease in filling time from 0.2024 to 0.1017 s, core temperature from 200.7 to 164.1 °C, weight from 10.26 to 8.17 g, and ejection time from 143.5 to 49.2 s. However, structural analysis result shows increase in deformation from 0.059 to 0.075 mm and root stress from 18.02 to 21.88 MPa. In addition, Moldflow analysis outcomes confirm decrease in teeth deflection from 0.459 to 0.439 mm and residual stress from 28.84 to 25.88 MPa.
Modeling and analysis of cavity modification effect on quality of injection molded polymer gear
Int J Interact Des Manuf
Solanki, Bikram Singh (author) / Singh, Harpreet (author) / Sheorey, Tanuja (author)
2022-12-01
18 pages
Article (Journal)
Electronic Resource
English
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