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Design of Plastic Pieces and

Their Molds Using CAD/CAE


Tools. I
MARIA VIRGINIA CANDAL, ROSA AMALIA MORALES
Departamento de Mecanica, Universidad Simon Bolvar, Seccion de Polmeros, Grupo de Polmeros, Sartenejas,
Apartado 89000, Caracas 1080-A, Venezuela

Received 20 March 2004; accepted 5 March 2005

ABSTRACT: Two experiences based on the use of computer tools for teaching courses
about the design and analysis of plastic pieces and molds are presented. The purpose is to
offer students the opportunity to handle softwares by combining knowledge about plastics,
metals, processing, mechanizing, marketing, stresses, costs, and design.2005 Wiley Periodicals,
Inc. Comput Appl Eng Educ 13: 233239, 2005; Published online in Wiley InterScience (www.interscience.wiley.
com); DOI 10.1002/cae.20046

Keywords: education; computer-assisted design; computer-assisted engineer; plastic pieces


design; mold design

INTRODUCTION
The revision of the programs for the subjects Plastic
Pieces Design and Mold Engineering taught in the
Material Engineering career mention Polymers at the
Simon Bolivar University in Caracas, Venezuela, as
well as, the inclusion of other themes related with the
use of computer tools for designing and evaluating
plastic pieces and their molds is set forth due to the
needed actualization of knowledge to adapt students
to the demands of companies nowadays. On the
other hand, it is necessary that Universities keep a
continuous revision and actualization of the academic
programs for the various degrees offered in order to be
adapted to the actual worldwide situation.

Correspondence to M. V. Candal (mcandal@usb.ve).


2005 Wiley Periodicals Inc.

In the present, having a designing capacity is a


must for any company, which will use it as a strategic
instrument. The competitiveness of a company is
defined by the nature of its relationship with the
market throughout their product. This relationship
allows identifying three key elements: company,
product, and marketing, that when interacting determine the companys competitiveness. A great part of
the function that the various agents participate in a
company do results finally, in the creation and visualization of products and services. With the inclusion of
themes such as this, it is intended that students will be
better prepared so they can discover their creativity
and innovative level. Also, they can start applying all
the knowledge obtained in other areas related and join
them in order to organize the designing processes on
paper as well as on computers to see the differences
on the products and possibly meet costs reductions.
Consequently, they will be able manage and find
233

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CANDAL AND MORALES

solutions for any designing problem they may encounter when working in the real market.
The innovation is essential in all companies
because the clients look for improved products that
they are able to satisfy their desires and necessities
fully or solve their problems. A well-designed product
is demanded by the final consumer, that is ready to
forget incite factors to the purchase like the low price
of the competition before other factors like the
functionality, the esthetics or the symbolic character
of the same ones. For it, the company should be
guided toward the consumers [1,2].
Among some of the aspects that have characterized the development of the plastic industry, it is important to mention the incursion of several computer
softwares that ease all aspects of the manufacturing
process of any plastic article. These packages are tools
type computer-aided design (CAD), computer-aided
engineering (CAE), and computer-aided manufacture
(CAM) developed from the most advanced technology to simplify all stages involved in the manufacturing process of a determined article to their maximum
extent [3].

LITERATURE SURVEY
Product Design
The word design comes from the term desegno
which means delineation of a shape or making of a
drawing. The design is considered as an innovation,
creation, or advance, which relates certain factors
with obtaining more effectiveness. It is also considered as a discipline for projects, technology, and
creativity to be followed when developing products
and studying the interactions between them and in
order to optimize companies resources in regard to
their manufacturing and commercialization processes
[4,5].

Plastic Pieces Design


In the first stages of its development, the plastic
materials were chosen mainly to substitute other
materials. But actually, the plastics are well-defined
materials, with personality apart from the old concept
that they were only cheap materials that substituted
others with higher quality. Nowadays, the polymers
are designing and construction materials. They
compete with iron, glass, wood, and aluminum,
among others. As with all the materials, they are
accepted or rejected according to their behavior
where used because they posses an extensive range

of properties which makes them adaptable to a great


variety of uses [69].

New Products Development


Many authors have analyzed the creation and launching processes of new products to the market. Based on
the phases to develop or optimize a product, Gonzalez
et al. [10] established a methodology based on the
concurrent engineering (CE) for the specific design
of plastic pieces using computer-aided tools. They
defined CE as a technique used to design products,
services, and organizational processes which allows a
time reduction in the manufacturing of a product and
at the same time minimizes not only the waste but also
the manufacturing and designs costs. In addition, this
technique facilitates obtaining a higher quality and
less designing errors. The stages beforehand mentioned by Gonzalez et al. are: (a) designs conception,
(b) market study, (c) analysis of the different products
existent in the market (similar to the one formulated),
(d) analysis of molds similar to the existent in the
market (if is possible), (e) creation of a complete
model of solids in three dimensions of the piece
existent in the market and of the new design using a
software CAD, (f) creation of the mesh model for
simulating the piece modeling using a CAD or CAE
software, (g) simulation of the designed or optimized
piece using a CAE software, (h) experimental validation of the results obtained from the piece simulation (in case the piece is optimized), (I) creation of
the piece prototype, (j) creation of the mold in three
dimensions, (k) molds construction using codes of
computer numeric control (CNC) obtained from a
CAM software, (l) pieces production, and (m) experimental validation of the mold.

Molds Design
The selection of the mold type to make a determined
plastic piece is the result of a careful element and data
evaluation available to reach the most convenient
solution to the problem since the molds have to work
in the most automatic possible way to mold hundreds
of pieces. A great variety of manufacturing processes
are employed to make plastic pieces such as:
injection, blowing, extrusion, rotational, thermoforming, compression, and transference moldings. Among
all of these, the injection molding is the most characteristic method for the transformation of thermoplastics although it is also applied to the thermostable
ones. The plastic pieces obtained throughout the
injection molding process require an adequate configuration while on their designing stage because it is

DESIGN OF PLASTIC PIECES AND THEIR MOLDS. I

then when the shape of the mold to be used along the


production is determined [1113].

CAD/CAE/CAM Tools
The systematization of the designing and manufacturing processes of plastic articles and injection molds
through the use of computer tools has considerably
helped this long and tedious stage involved in
obtaining a determined piece. If a plastic piece and
its mold are pre-designed using the CAD/CAE tools,
both can be subject to several trials and tests by
simulation methods contained in these kind of softwares. With these programs for designing pieces and
molds, aspects of the assembling and finishing of the
piece can be verified whereas in the process simulation softwares, the feasibility of the product is verified
using the previously elaborated design [14].

EXPERIENCE
One of the studied experiences in this project was
obtained when carrying out a plastic pieces design
course for the Material Engineering career mention
polymers at the Simon Bolivar University in Venezuela. Years ago the courses program included: (a)
introduction to design: study of the creation process,
design and launching new products, (b) considerations
and details of the design to take into account when
using processing methods for plastic pieces such as:
compression, transference, injection, extrusion, blowing, rot molding, and thermoforming, (c) fundaments
of the materials resistance: traction, flexion, sharp
forces, torsion, fatigue, creep, and combined loads, (d)
cost analysis for plastic pieces, (e) design of specific
shapes: thin wall recipients, bottle blowing, and pipes
systems, and (f) design and evaluation of plastic
pieces by computer. It is important to quote that along
this last subject only the methods used by computer
programs to solve the simulation of pieces such as,
finite elements, finite differences, frontier elements,
and control volumes methods, were mentioned along
with softwares present in the market used for evaluating plastic pieces.
Actually, the program was modified separating
the design subject and evaluation of plastic pieces
by computer into two. The first is based on the
explanation of the importance of employing the CAD
tools for making plastic pieces, so students learn to
use a three-dimensional solid modeler software to
draw pieces on the computer. Through the other
theme, evaluating plastic pieces by computer, it is

235

basically explained the same that was being done


previously but examples of other simulations realized
with several CAE softwares were also annexed. In
addition, the students learn to do the meshing of the
pieces with a modeling program that was necessary to
do such simulations but which is not part of this
specific subject.
Moreover from the regular evaluation of the
course, tests, and homework, two projects are
assigned. One is about making a simple plastic piece,
generally a bottle and cap, using a three-dimensional
solid modeler software and the second project consists
of designing a more complex piece [15]. The first
project has the following sections: (a) defining the
piece, (b) use and need of the design, (c) final use
conditions, (d) selection of the manufacturing polymer, (e) selection of the manufacturing process, (f)
design in three dimensions of the two parts that form
the piece on the modeling program, (g) assembling the
two parts, and (h) making sketches with views for
each of the parts. The second project is conformed by
the following sections: (a) use and need of the design,
(b) use conditions, (c) initial material selection, (d)
selection of the manufacturing process, (e) analysis of
similar market products, (f) creation of the threedimensional model of the piece and its views using a
solid modeling software (CAD), (g) analysis of the
stresses of the designed piece, (h) cost analysis, (I)
piece innovation, (j) piece marketing, (k) national
production feasibility, and (l) wood or carton piece
prototype [15].
The second experience occurs when carrying out
the Mold Engineering course for the previously
mentioned career. The course program consists of
the following themes: (a) materials used in the manufacture of the mold, (b) manufacturing processes for
iron and or metals to make molds used to transform
the polymers, (c) injection molds for polymers,
(d) molds used for compression, transference, and
thermoform, and (e) extrusion dies.
In addition to the regular evaluation that consists
of tests, the course has the purpose of making a project
about designing a mold, generally an injection one, for
manufacturing a particular piece previously assigned
by the teacher. Such project has various stages:
(a) designing the piece in three dimensions using a
CAD software, (b) determining the material to be used
to manufacture the mold, (c) designing the mold
with its places and pieces using a CAD software,
(d) simulating the piece manufacturing process using
a CAE software, (e) evaluating the piece final properties: shrinkage, warpage, residual stresses, among
others, (f) making sketches with their respective views
and cuts for the designed mold, and (g) determining

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CANDAL AND MORALES

the mechanizing processes required for the construction of the mold.


These experiences adapt to what was mentioned
beforehand by Freire [16] related to the learning
process: Men and women are the only creatures that
socially and historically are able to learn. We are the
only ones for whom learning is a creative adventure,
something much more rich than simply repeating the
given lesson. Learning to us is constructing, reconstructing, and verifying to change what is not done by
being opened to risks and to the adventure of the
spirit.

SOFTWARE
In order to carry out both subjects, a solid software
in three dimensions (CAD) is required. Among the
recommended ones are: Pro-ENGINEER, Mechanical
Desktop, Pro-Desktop, Design Wave, among others.
The Pro-ENGINEER is a CAD/CAM software
conceived to create and modify articles geometries.
This tool allows the creation of virtual prototypes in
the first stages of the designing process, even before
doing schemes or physical approaches of the article
to be made. The software permits to design pieces,
create assemblies making it possible for the pieces to
coincide and to align different parts of the product,
make planes including general views, auxiliary,
detailed and partial projections and, also, transversal
sections. This software has a series of advantages such
as: a more efficient use of the tools and mechanized
equipment available, rapid product market placement,
and process optimization [17].
The Mechanical Desktop allows the performance,
from a unique environment, of practically all the
design assignments in 2D and 3D, as well as, the
analysis and manufacture needed for a fast and low
cost production. The AutoDesk Mechanical Desktop,
which is integrated within AutoCAD, is the most
complete and powerful parametric modeling software
for solids, assemblies, and surfaces for the design of
complex pieces. In addition, it automatically generates the planes starting simply from the 3D model
[18].
The Design Wave is a parametric modeling
software for solids that allows the user to directly do
a three-dimensional representation of the desired
model. Consequently, it is easier to visualize the
model in order to do any quick corrections right at
initial stages of the process and so, prevent possible
failures even previous prototype construction. This
software is superior to many other 2D or contourdesigning softwares; therefore, it facilitates and speeds

the work of the designer allowing him to obtain threedimensional views and sketches using the same
drawing, as well as, to make quick corrections on
the 3D model [19].
The Pro-Desktop software provides a modeling
technology that has proven to be rather efficient to the
industry in an interface that will ultimately result
familiar to the user and that permits capturing the
product designing ideas in a rapid and effective
way. Its main characteristics are: easy learning and
handling that makes it productive in just a few hours,
efficient 2D sketch, parametric solids modeling based
on functions, 2D and 3D movement study, and moreover permits making drawings based on both intelligent and associative functions [20].
On the contrary, the use of CAE computer tools is
also required for simulating the piece manufacturing
process. Among these software the C-MOLD, Moldflow, Moldex 3-D, T-SIM, B-SIM, among others, are
strongly recommended.
The C-MOLD software is a tool that permits
designing a mold by injection and simulate the complete manufacturing process by providing the information needed to prevent failures in its manufacture
or in the piece to be produced, as well as, in preestablished process conditions. Not only this software
allows the filling, post-filling, and cooling simulations
along the injection molding, but also allows studying
the shrinkage and warpage of pieces, the co-injection
molding, gas-assisted injection, and ultimately the
reactive injection. This tool provides solutions in all
the designing and manufacturing stages that at last
improve the productivity and quality of the piece [21].
The Moldflow software is a tool that helps
prevent and solve problems in the injection mold for
plastic pieces along early stages of the process. Also,
the designers of pieces and molds can verify if
whether or not their production is a feasible one even
before cutting the iron when modification costs are
still low. The perfect integration with the CAD solid
models permits making simulations on solid models
therefore, directly visualizing the result. Moreover,
the software identifies possible manufacturing and
quality problems suggesting forward solution steps. It
is important to note that this tool substitutes the actual
C-MOLD one although they work on the same platform [22].
The Moldex 3D is nowadays a software that has
already reached the first practical implantation of the
3D simulation by plastics injection because the previously mentioned softwares only work on 2 dimension objects. To achieve this, it uses a method based
on computer fluid dynamics (CDF) that uses the finite
volume method to solve the thermal flow equations

DESIGN OF PLASTIC PIECES AND THEIR MOLDS. I

and at the same time continuously watches to make


the front-melt advancement (liquid volume study at
every moment). Moldex is the abbreviation of Mold
Expert and is the first CAE software satisfactorily
developed by the Taiwanese for the molding by
injection process for plastic pieces. This software is
capable of simulating the filling, packing, and cooling
processes of the piece that are injection molded, as
well as, the shrinkage when ejection of the pieces is
taking place. In addition, it helps predict variables
such as, stresses, pressures, clamping force, temperatures, etc. [23].
The T-SIM is a software used for the simulation
of the thermoforming process. It predicts the final
thickness distribution of the wall based on the specified process parameters (pressure level, tool velocity,
film or sheet temperature distribution, and so on).
Additionally, it allows predicting an image distortion
after the thermoforming process, as well as, the
pre-distortion regardless of the forming technique
used [24].
The B-SIM is a software used for the blowing
molding simulation. It permits anticipating the final
thickness distribution of the wall based on the previously specified process parameters (pressure level,
tools velocity, initial temperature distribution in the
parison/pre-form, etc., regardless of the blowing technique used: extrusion-blowing, or injection-blowing)
[25].
The experiences presented were done using
Pentium III computers with Windows NT 4.0. Such
computers have Ethernet net cards needed for working
with the computer tools used. A minimum of 128 MB
in the hard drive and 800 MB RAM physical memory
have to be available for the adequate functioning of
such computer tools.

EXPERIENCES JUSTIFICATION
Actually, the conventional method for making plastic
pieces and their molds involves a great amount of
errors that are translated as a time and waste of money
resulting on very expensive products, and long manufacturing periods which do not guarantee out coming
satisfactory products quality. When these obstacles
are finally avoided, the plastic industry gets many
advantages [14].
The group of computer-aided techniques CAD/
CAE/CAM have experienced a great evolution along
these last years and thus, can be considered mature
enough as to be applied in a favorable manner at any
stage of the designing and manufacturing processes.
In addition, the manufacturing companies for plastic

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products have found that with the appropriate use and


right interpretation of their results, it is possible to
save time, money, waste of material, as well as, to
reduce the returning rate of damaged pieces, and
improve the quality of the product in order to introduce new products to the market in a fast and reliable
way [2628].
These experiences have the purpose of creating
the foundations for the manufacture of plastic pieces
and their molds by using CAD/CAE/CAM computer
tools in Venezuela and other countries of the world
that wish to applied what has been proposed on this
essay. Emphasis will be made to the use of threedimensional solid modeler softwares in and to the
simulation of the polymer transformation process with
computer tools that recently have become popular
among the Venezuelan engineering community. Consequently, it is mandatory the rapid inclusion of these
type of computer tools into the Venezuelan and other
countries industries that do not have it yet, so that high
quality standards can be met for all manufactured
products resulting on more competitiveness not only
at a national but international level.
The main objective of these experiences is
proposing a methodology for the design of plastic
pieces and their molds by using computer tools on
both classrooms and companies. Also, the intention is
to create a framework of change in order to generate
learning environments in the classrooms, which are
the places wherein learning strategies through the use
of technological equipments (computers) are developed [29].
The idea of making plastic pieces and their molds
using CAD/CAE/CAM computer tools in our country
is a project that even though is an ambitious one is
very feasible. When such experiences take place, the
needed foundations will be available to show the
Venezuelan and foreign manufacturers of plastic
products that even though the simulation softwares
are very expensive, they ultimately help cheapen their
products at a moderate term. Also, they will be able to
simulate molds for new products that will improve
their sales in both the national and international
market. Other countries mainly America or Europe
have been able to successfully accomplish this and
their experiences can serve as an example.

EXPERIENCE ALONG THE


PLASTIC PIECES DESIGN COURSE
The first aspect to mention is that the didactic
formulation of the plastic pieces designing course
begins with an extensive period of five classes of 2 h

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CANDAL AND MORALES

each about how to handle the chosen modeling


program for solids with its own theoretic explanations
and 12 guided exercises about how to do extrusions,
threats, holes, rounds, chamfers, cuts, revolutions,
constrains, dimensions placement, assembling, drawings needed for modeling the pieces, and meshing. It
is important to note that whenever there are students
who are more motivated, they have to be treated
differently than others for whom the software could be
harder to understand and thus, will need more
attention. On the contrary, some other students are
more creative and can do whatever they please with
the software without further aid. Nevertheless at the
end, the course is still a great experience for students
and teachers because everybody learns from each
other.
It is very important that all students learn to
handle the software because in the next course (molds
engineering) they have to draw a piece and its mold in
three dimensions for which they will need to use the
modeling program for solids and a manufacturing
process simulator, which they learn to use along this
specific class.

EXPERIENCE ALONG THE


MOLDS ENGINEERING COURSE
The Molds Engineering is a course that lasts five
classes of 2 h and teaches students how to handle the
chosen manufacturing of plastic pieces simulation
software by theoretic explanations and a guided
exercise about how to make a injection mold for two
plastic plaques. First of all, every characteristic of
each of the molds to be design is defined. Afterwards,
the solid modeler software is used to represent the
different pieces and to obtain the finite element netting
that describes each of their geometries. Even when the
simulation software has a place capable of modeling
geometries and representing both the feeding and
cooling system for each of the molds, the mesh pieces
molding was imported from the type CAD modeler
software due to the fact that it has been proven to be
more reliable regarding its reported results [29,30].

CONCLUSIONS
Universities and other educational institutions should
actually have the computer tools needed to use the
information technologies available so their courses
can be attractive for new students who will need them
in todays world. The information technology is very
relevant for the development of strategies by any

company because it allows obtaining sustained competitive advantages on top of accelerating the creation
and development of new products in order to reach a
time and cost reduction on their manufacture.
The use of computer tools when teaching courses
related to the design of plastic pieces and their molds
have offered students the possibility of absorbing
a greater amount of knowledge acquired along the
course on top of improving their personal satisfaction
and output.
The uses of CAD and CAE as additional tools
have improved the communication between the
teacher and the student. Moreover, when teaching
the courses related to the design of plastic pieces and
their molds, it is very important to include computer
tools that allow students to satisfactorily face cases as
a way to practice before applying them to reality.

REFERENCES
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engineering, Van Nostrand Reinhold Company, USA,
1977.
[10] O. Gonzalez, M. V. Candal, R. A. Morales, and S.
Villarroel, A mold design methodology by using CAD/
CAM/CAE tools, TMT2003, Spain, 2003.
[11] O. Laguna and R. Arganza, Manual de moldes para
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[14] E. Bernhardt, CAE computer aided engineering for
injection molding, Hanser Publishers, USA, 1983.

DESIGN OF PLASTIC PIECES AND THEIR MOLDS. I

[15] M. V. Candal, Integrando las Herramientas Computacionales al Curso de Diseno de Piezas Plasticas,
EDUTEC2003, Venezuela, 2003.
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Editores, Mexico, 2000.
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TRAINING GUIDE 2000i2, Parametric Technology,
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with design Wave, Parametric Technology, USA,
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[23] Moldes 3-DSimulacion en inyeccion de plasticos.


Disposable: www.plastunivers.es/Tecnica/Hemeroteca/
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BIOGRAPHIES
Mara Virginia Candal Pazos has been a
professor in the Department of Mechanics
at Simon Bolivar University in Caracas,
Venezuela, since 1998. She obtained a
bachelors degree in materials engineering
polymers from the same university in
1997, a management degree from Santa
Mara University in 2000, and a masters
degree in mechanical engineering from the
Simon Bolvar University in 2001. She has authored 6 refereed
publications and 20 conference papers. Her work areas are focused
on plastic part design, mold design, and thermoplastics process
technology.

Rosa Amalia Morales Nieves obtained


her bachelors degree inmaterials engineeringpolymers from Simon Bolvar
University in Caracas, Venezuela, in 1989.
She received her masters degree in
materials engineering in 1995. Since
1992, she has been a professor of
plastics processing and technology in the
Department of Mechanics at Simon Bolivar University. She has had
more than 20 refereed publications in seven international journals
and in conference proceedings. Her recent research lines are in
plastic part design, mold design, and thermoplastics process
technology.

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