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Volumetric shrinkage estimation of benchmark parts developed by rapid tooling mold insert

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Abstract

This paper estimates the volumetric shrinkage for thermoplastic Polypropylene (PP) injection molded components made using digital Acrylonitrile butadiene styrene (ABS) mold. The parameters affecting volumetric shrinkage for the digital ABS mold are mold temperature and injection temperature, cooling time, hold pressure and injecting speed. Therefore, twelve standard benchmark CAD model were selected with different geometric attributes. Subsequently, simulation analysis was performed on all CAD model using Moldflow® (MFA) simulation software. Additionally, regression analysis is applied to identify the effect of injection molding parameters on the volumetric shrinkage of part made using rapid tooling mold insert of digital ABS material. It is found that maximum volumetric shrinkage (18.75%) is observed for square pyramid frustum, conical frustum, and solid torus. On the contrary, hollow rectangular prism shows minimum shrinkage effect having 12.61% of volumetric shrinkage. This study predicted that shrinkage is the main concern for these three geometric features (i.e., square pyramid frustum, conical frustum, and solid torus) and must be looked for its minimization. The results are experimentally validated, with 3D scanner integrated with COMET plus and Inspect plus softwares. Since shrinkage estimation for digital ABS mold using Rapid Tooling technique has not been attempted before, therefore, this study provides guidance for the optimum parameter selection and assigning suitable shrinkage compensation values for digital ABS mold made using direct rapid tooling.

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Abbreviations

PP:

polypropylene

ABS:

acrylonitrile butadiene styrene

CAD:

computer aided design

MFA:

moldflow analysis

RT:

rapid tooling

PRT:

polymer rapid tools

RP:

rapid prototyping

AM:

additive manufacturing

ANOVA:

analysis of variance

STL:

stereolithography

VR:

volume ratio

V:

benchmark parts volume

VB :

bounding box volume

S:

shrinkage ratio

TR :

thickness ratio

Tmin :

minimum thickness of benchmark part

Hmax :

maximum height

DR :

draft angle ratio

DA :

draft angle

SDA :

standard draft angle

WR :

part weight ratio

W:

part weight

WT :

total part weight

QR :

quality prediction ratio

Qp%:

quality prediction percentage

Qp100%:

desired quality

CTR :

cycle time ratio

CT :

cooling time

TCT :

total cycle time

VS%:

volumetric shrinkage percentage

R2 :

correlation coefficients

STEP:

standard for the exchange of product

IGES:

initial graphics exchange specification

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Authors and Affiliations

  1. Department of Mechanical Engineering, Malaviya National Institute of Technology, Jaipur, 302017, India

    Sagar Kumar & Amit Kumar Singh

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  1. Sagar Kumar
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  2. Amit Kumar Singh
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Correspondence to Sagar Kumar.

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Kumar, S., Singh, A.K. Volumetric shrinkage estimation of benchmark parts developed by rapid tooling mold insert. Sādhanā 45, 139 (2020). https://doi.org/10.1007/s12046-020-01373-7

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  • DOI: https://doi.org/10.1007/s12046-020-01373-7

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