Design of Moulds and Dies

Code:

EM0111

Acronym:

CMF

Keywords
Classification	Keyword
OFICIAL	Drawing, Design and Manufacture

Instance: 2020/2021 - 2S

Active?	Yes
Web Page:	http://www.fe.up.pt/~fonseca/FabMoldes/FabMoldes.html
Responsible unit:	Industrial Drawing 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	40	Syllabus since 2006/2007	4	-	6	45,5	162

Teaching language

Portuguese

Objectives

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. Acquisition of knowledge about the manufacturing processes, like milling, turning and electric discharge machining (die sinking and wire).

Learning outcomes and competences

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 and non-conventional machine tools (electric discharge machining, milling, and turning).

Working method

Presencial

Pre-requirements (prior knowledge) and co-requirements (common knowledge)

- Basic notions about drafting and drawing instruments.

- Elements of descriptive geometry (secondary school).

- Technology of Materials and manufacture...

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

Designation	Weight (%)
Exame	50,00
Trabalho prático ou de projeto	50,00
Total:	100,00

Amount of time allocated to each course unit

Designation	Time (hours)
Apresentação/discussão de um trabalho científico	5,00
Elaboração de projeto	40,00
Elaboração de relatório/dissertação/tese	20,00
Frequência das aulas	49,00
Trabalho laboratorial	50,00
Total:	164,00

Eligibility for exams

A aprovação na unidade curricular está condicionada à prévia obtenção de frequência às aulas (número limite de faltas é 25% das previstas).

Calculation formula of final grade

O estudante deve, obrigatoriamente, submeter-se à avaliação em todas as suas componentes: exame final com nota mínima de 7 valores e discussão do(s) trabalho(s) entregue(s) pelo(s) preponente(s).A nota final da disciplina resultará da média pesada das classificações obtidas em cada uma das componentes da avaliação, com os seguintes pesos: Exame: 50% Trabalho(s) prático(s): 50%

Examinations or Special Assignments

Não previsto.

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.