Mould and Die Manufacture

Code:

EM0080

Acronym:

FM

Keywords
Classification	Keyword
OFICIAL	Manufacturing and Automotive Engineering

Instance: 2011/2012 - 1S

Active?	Yes
Web Page:	http://www.fe.up.pt/~fonseca/FabMoldes/FabMoldes.html
Responsible unit:	Industrial Design Section
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	3	Syllabus since 2006/2007	5	-	6	56	160

Teaching language

Portuguese

Objectives

BACKGROUND

Portugal is a world leader in the moulds Industry. Mould making is today one of Portuguese industry’s most competitive sectors at an international level. The moulds sector in Portugal comprises more than 250 companies most of them are small to medium sized. Portuguese mould companies are today among the leading pioneers in the use of CAD/CAE/CAM and other computerised technologies for mould design and engineering. Taking into account the level of quality achieved by the mould makers industry our students are encouraged to learn important subjects, such as CAD, electrical discharge machining, milling, and turning using computer numerical control, to ingress in mould’s industry.

SPECIFIC AIMS:

To familiarize the students with many aspects of tool design and mould construction, and with types of injection moulds, standardized components and machining processes. To implement the design with the aid of 3D CAD systems and databases, including the definition of parting lines and surfaces.

PREVIOUS KNOWLEDGE

- Basic notions about drafting and drawing instruments (secondary school).
- Elements of descriptive geometry (secondary school).
- Thecnology of Materials and technology of manufact...

PERCENTUAL DISTRIBUTION

Estimated percentual distribution for the scientific and technological contents:
- Scientific component: 50 %.
- Technological component: 50 %.

LEARNING OUTCOMES:

At the end of the course, the students shall be able to:

1) Know the usual components of an injection mould.
2) Understand the mechanics of the usual solutions to part demolding difficulties.
3) Determine the dimensions of the mould, runner systems, heat exchange system, and clamping devices.
4) Create a 3D model of a mould showing the parting surfaces and the respective 2D drawing.
5) Create CNC programs using CAD/CAM software and select among the several conventional machine tools (spark erosion, milling, and turning lathe).

Program

Mould design: mould components, design solutions (linear and rotational movements, two or three plate mould, cores, etc)
Catalogues and commercial databases
Introduction to a CAD program related with mould design
Brief reference to the most important machining processes of mould design (milling and turnery)
Electrical Discharge Machining (EDM): definition, discharge mechanism, discharge models
History of electrical discharge
Methods of impulse regulation
Electrical Discharge Machining: polarity, dielectrics, cutting, theoretical curve, usage
Electrode materials: characteristics, wear resistance (metals), performance of these materials
Production process of electrode
Electrical discharge materials
White layer: definition, physical-chemical characteristics
Black layer: definition, physical-chemical characteristics, new cutting methodology
Environment and security
Rapid prototyping and rapid tool development: new industrial sectors, new challenges, the necessity of developing internationally competitive product; why rapid prototyping is necessary; rapid manufacturing
Selection criteria of machining processes regarding shape and other characteristics (finishing, thermal treatments, etc)
Development of injection mould projects: three-dimensional modelling through a CAD system; mould system dimensioning (feeding, refrigeration and extraction);
Material flux analysis at filling stage: localization of feeding points and cooling analysis
CAD/CAM and CNC systems- development of post-processors for APT and CLData languages
Injection mould project

Mandatory literature

Menges, Georg; How to make injection molds. ISBN: 3-446-21256-6
Gastrow, Hans; Injection molds. ISBN: 3-446-15682-8
Pye, R. G. W.; Injection mould design. ISBN: 0-7114-3906-0
Mink Spe, Walter; Injección de plásticos
Gastrow, Hans; Injection molds. ISBN: 3-446-21448-8
José Duarte Marafona; Tecnologia e aplicações da electroerosão
E. Bud Guitrau; The EDM handbook. ISBN: 1-56990-242-9

Complementary Bibliography

Dym, Joseph B.; Injection molds and molding. ISBN: 0-442-21785-4
Walker, John R; Machining fundamentals. ISBN: 1-56637-662-9

Teaching methods and learning activities

Course themes are presented in classes, as well as relevant examples. Students have the opportunity to apply their knowledge by doing some computer exercises and laboratory assignments on electrical discharge. During the semester students will learn how to carry out their projects on CAD mould.

keywords

Technological sciences > Engineering > Project engineering
Technological sciences > Technology > Materials technology > Plastics technology

Evaluation Type

Distributed evaluation with final exam

Assessment Components

Description	Type	Time (hours)	Weight (%)	End date
Attendance (estimated)	Participação presencial	56,00
	Total:	-	0,00

Eligibility for exams

Students will only complete the course if they attend to the mandatory number of classes (75%).

Calculation formula of final grade

Students must also attend a written exam in which they must obtain the minimum mark of 7/20, as well as doing a practical assignment. Final mark will be based on the marks achieved on the written exam (50% of the final mark) and practical assignment (50% of the final mark).

Examinations or Special Assignments

Not applicable

Special assessment (TE, DA, ...)

According to article 4 paragraph a) 3b of General Evaluation Rules of FEUP, students must attend an exam and present a practical assignment.

Classification improvement

According to article 10 of General Evaluation Rules of FEUP, students can either do another practical assignment or a written exam.