Moulding Technologies

Code:

EM0079

Acronym:

TM

Keywords
Classification	Keyword
OFICIAL	Manufacturing and Automotive Engineering

Instance: 2011/2012 - 1S

Active?	Yes
Responsible unit:	Materials and Technological Processes Group
Course/CS Responsible:	Master in Mechanical Engineering

Cycles of Study/Courses

Acronym	No. of Students	Study Plan	Curricular Years	Credits UCN	Credits ECTS	Contact hours	Total Time
MIEM	2	Syllabus since 2006/2007	5	-	6	70	160

Teaching language

Portuguese

Objectives

This course is divided in two: casting and plastic injection

Casting

To consolidate previous knowledge acquired on the Masters in Mechanical Engineering regarding casting technologies, mainly focused on injection casting of light alloys and casting nozzle in low pressure copper alloys by lost wax: its main and complementary components and mould design.

Plastic injection
Revision of the main concepts of polymeric materials: properties and processing- thermoplastic injection moulding. Specific concepts for the development of plastic technical products; computing tools in thermoplastics project

Program

Casting: properties and the most relevant characteristics of alloys;
Fusion equipment, maintenance and leakage
Materials and technologies used in different processes, namely in moulding, core boxes and wax injection moulds. Reference to complementary tools of sprue cutter, overflow groove, and quality control of flow production and final;
Development and dimensioning of tools and equipments, with a reference to component tolerance;
Production flows and selection processes concerning mechanical properties required by casted components; validation of moulding projects using numerical simulation tools of filling and solidification;

Basic notions of Polymer Science;
Commercial thermoplastic polymers
Main polymer properties
The most relevant properties of plastic to technical application
Database: its usage to material selection and characterization
Flow properties- non-Newtonian behaviour in polymeric fluids
Processing of thermoplastics - its routine
Injection moulding – cycle, main process variables, functional systems of an injection ram, injection moulding cycle control; peripheral auxiliary dispositive;
Functional systems of injection moulding
Thermoplastic flow in injection moulds
Equipment characteristic: closing force, injection capability and mould functioning space; determine system’s capacity of mould refrigeration
Simulation of injection process
Properties and processing
Influence of processing on parts properties
Injection moulding cost
Principles of plastic project

Mandatory literature

Campbell, John; Castings practice. ISBN: 0-7506-4791-4
Apontamentos diversos propostos ao longo das aulas.

Complementary Bibliography

Ashby, Michael F.; Materials selection in mechanical design. ISBN: 0-7506-6168-2
Malloy, Robert A.; Plastic part design for injection molding. ISBN: 3-446-15956-8

Teaching methods and learning activities

The presentation of this course program will be based both on theoretically classes and on visits to relevant companies. There will be visits to companies such as Sonafi for injected casting, to Cifial for casting nozzle leak and low pressure, to Zollern & Comandita for lost wax casting and Simoldes for plastic injection and mould manufacturing.
Students will have the opportunity to see how the injection process works in a practical session that will take place at Universidade do Minho, in Guimarães. On this session the variation of variables in properties of parts will be measured.

Students will be asked to do some assignments in order to practice what they have learned during the semester (it may involve computer programs). Mini exams will assess students’ knowledge on fundamental concepts that have been taught.

It may also be followed the concept of engineering teaching where students have to do some application assignments.

Software

Experto
SolidWorks

keywords

Technological sciences > Engineering > Project engineering
Technological sciences > Technology > Industrial technology > Mechanical design
Technological sciences > Engineering > Simulation engineering
Technological sciences > Engineering > Process engineering

Evaluation Type

Distributed evaluation without final exam

Eligibility for exams

According to Article 4 of General Evaluation Rules of FEUP

Calculation formula of final grade

FM=A*0.5 + B*0.5

FM- Final Mark
A- Average grade of the mini-exams
B- Average grade of the practical assignments

Or

FM- Average grade of projects

Examinations or Special Assignments

According to Article 5 paragraph 6 of General Evaluation Rules of FEUP

Special assessment (TE, DA, ...)

According to Article 6 paragraph 7 of General Evaluation Rules of FEUP

Classification improvement

According to Article 10 of General Evaluation Rules of FEUP