The actual international situation to find a new part program for a new mould on an injection moulding machine for plastics processing is the trial of different settings from experienced personnel on the machine. For mould design advanced CAE-systems with rheological, thermal and mechanical FEM (finite element methods) are available. The aim of the project is to transfer and develop innovative systematics for the machine setter for calculation of a new part program for a new mould on an injection moulding machine. After input of a few data of the part, the plastic material and the mould at first machine size and additional equipment are calculated. After determination of an available machine from the machine setter the first setting is calculated. This setting is optimised in different steps with an expert data base to optimal setting and quality. The know-how for different moulded part classes is memorised and used for a better calculation of settings. The interest of the SME for such a project is the reduction of machine setting time, better part quality by optimised process robustness with minimised variations and computer based know-how collection for moulded part classes to future use not being dedicated to machine setters. The cost reduction of mould proving will be in the range of 30 - 50 %. For large moulds like bumper bars this is up to 50.000 ECU, for medium up to 15.000 ECU per mould. For an average of 30 - 50 new moulds per year for every SME this is an interesting saving potential.
Funding SchemeEAW - Exploratory awards