Title: Manufacturing Strategy of a Mould Insert

Name: Nur Nabilah binti Mohammad Mustafa

Matrix no: MKM173009
Programme: Individual Project (MKMP1703)
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1. Introduction

i. Aims of the project

The aims of this project are:
(a) To develop a manufacturing strategy for the effective manufacture of an engineering
product/component.
(b) To evaluate and analyse commercial CADCAM application software in apply to ease
of use, features, off-line operation verification, time estimation and post processing.

ii. Principle Objectives

(a) To draw on previous knowledge to select suitable processes for the manufacture of the
product/component.
(b) To develop a complete manufacturing schemes from selection component.
(c) To estimate the cost based on different manufacturing strategies
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2. Process Planning
Process planning is also called: manufacturing planning, process planning, material
processing, process engineering, and machine routing.

Figure 2.1: Flowchart of Process Planning

Process Planning Step:

Figure 2.1: Steps of Process Planning

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• Study the overall shape of the part. Use this information to classify the
part and determine the type of workstation needed.

• Thoroughly study the drawing. Try to identify every manufacturing

features and notes.

• If raw stock is not given, determine the best raw material shape to use.

Figure 2.3: Phone casing design

• Select tools for each operation. Try to use the same tool for several
operations if it is possible. Keep in mind the trade off on tool
change time and estimated machining time.

• Evaluate the plan generate thus far and make necessary

modifications.

• Select cutting parameters for each operation.

• Prepare the final process plan document.

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CASING PART
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MOLD CAVITY
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Process Plans
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3. Results

Material : Carbon steel

TRIAL 1:
End Mill Cavity mill Zlevel Profile Contour Area
Cutting Parameters Operation
Rough Semi finish Finish
Cutting Strategy Follow part Follow periphery
Tool Mill tool with Mill tool with Mill tool with
diameter 10mm diameter 5 mm diameter 5mm
Feed rate 51.57 49.66 49.66
Feed rate per tooth 0.027 0.013 0.013
Spindle speed 955 1910 1910

TRIAL 2:
End Mill Cavity mill Zlevel Profile Contour Area
Cutting Parameters Operation
Rough Semi finish Finish
Cutting Strategy Follow part Follow periphery
Tool Mill tool with Mill tool with Mill tool with
diameter 10mm diameter 5 mm diameter 5mm
Feed rate 240 240 200
Feed rate per tooth 0.1256 0.628 0.525
Spindle speed 955 1910 1910
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Cutter Paths
1) Roughing

2) External Trim
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3) Semi-finishing

4) Finishing
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4. Mold Manufacturing Cost Estimation

(1)

4.1 Cavity Material Cost

(2)

Vcavity_material = Volume of the cavity

𝜌cavity_material = Density of the cavity
ĸcavity_material = Cost of the material per kilogram

(3)

(4)
(5)
(6)

Lcavity = Length of cavity

Wcavity = Width of cavity
Hcavity = Height of cavity

Lpart = Length of part

Wpart = Width of part
Hpart = Height of part
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From the detail drawing the in Figure the values for the part are listed below:

Lpart = 142.6 mm
Wpart = 71.1mm
Hpart = 8.9 mm

Calculation A:
To calculate the length of cavity, width of cavity and height of cavity equation (4), (5) and (6)
are used.

Lcavity = 0.1426 + max [0.1(0.1426), 8.9(10−3 ),] = 0.15686m

Wcavity = 0.0711 + max [0.1(0.0711), 8.9(10−3 )] = 0.07821 m
Hcavity = max [0.057,2(8.9(10−3 ) ] = 0.057 m
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To find the volume of the cavity material use equation (3).

Vcavitymaterial = (0.15686m) (0.07821 m) (0.057 m)

= 6.99(10−4)) 𝑚3
Table show the list of different type of mold materials.

To calculate the cost of cavity material using equation (2). The material used is carbon steel
with density of 7670kg/ 𝑚3 and cost 21.4 $/kg as shown in table.

Ccavity_material = (6.99(10−4) )𝑚3 ) (7670kg/ 𝑚3 ) (21.4 $/kg) =$114.73= RM458.06

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4.2 Cavity Machining Cost

The machining labor rate, Rmachining_rate, varies substantially with the cost of living in the
location where the mold is manufactured. A mold maker in a high cost of living area will tend
to have a higher labor cost than a mold maker in a low cost of living area

The cavity machining time is estimated as the sum of the volume machining time,
tcavity_volume, and the area machining time, tcavity_area.To take application specific
requirements into account,cavity machining time is then multiplied by a complexity factor,
fcavity_complexity, to consider geometric complexity as well as a machining factor,
fmachining, then divided by an efficiency factor, fmachining_efficiency.

Table: Machining factor for various processes Complexity factor for various example part
designs
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Table 4.2: Complexity factor for various example part designs

8.52(10−4) ) 𝑚3
t cavity_volume = =1.217 hr
7(10−4) )𝑚3 /ℎ𝑟

0.0125
t cavity_area = = 0.735 hr
0.017 𝑚2 /ℎ𝑟

Assuming efficiency factor by 50%.

1.217ℎ𝑟+0.735ℎ𝑟
t cavity_machining = ( )(2.5)(1)= 7.96hr
50%

ccavity_machining = 7.96(50$/hr) =$ 398= RM 1589.02

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Assume the cost for mold finishing is negligible in this project.

ccavity= ccavity_material + ccavity_machining

= 𝑅𝑀 458.06 + 𝑅𝑀 1589.02
= 𝑅𝑀 2047.08
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5.0 Conformal Cooling

Conformal molds have straight-line cooling channels (top), whereas conformal
cooling makes use of cooling lines in an injection mold that curve and closely follow the
geometry of the part

Vacuum-brazing technology produces the largest conformally cooled production

molds. Large molds for automotive parts and housings have been made by this process.
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6. Conclusion

This study provided additional knowledge and a clearer understanding of the

influence of cutting strategies in time. For roughing follow path is selected and z-level profile
for semi-finish and follow periphery for finishing. Total time for these selected operation is 4
hr 11 min. From the mold estimation calculation the total time is 7.96 hrs.
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Post Processing
============================================================
Information listing created by : NABILAH'S
Date : 6/1/2018 2:49:18 PM
Current work part : D:\cadcam_data_nx8\Machining_37.prt
Node name : nabilah
============================================================
N10 ;Start of Program
N20 ;
N30 ;PART NAME :D:\cadcam_data_nx8\Machining_37.prt
N40 ;DATE TIME :Sat Jan 06 14:49:07 2018
N50 ;
N60 DEF REAL _camtolerance
N70 DEF REAL _X_HOME, _Y_HOME, _Z_HOME, _A_HOME, _C_HOME
N80 DEF REAL _F_CUTTING, _F_ENGAGE, _F_RETRACT
N90 ;
N100 G40 G17 G700 G94 G90 G60 G601 FNORM
N110 ;Start of Path
N120 ;
N130 ;TECHNOLOGY: MILL_ROUGH
N140 ;TOOL NAME : MILL-10
N150 ;TOOL TYPE : Milling Tool-5 Parameters
N160 ;TOOL DIAMETER : 0.393701
N170 ;TOOL LENGTH : 2.952756
N180 ;TOOL CORNER RADIUS: 0.000000