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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
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.
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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].
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
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
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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
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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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
[1] A. Schnarch, Nuevo producto. creatividad, innovacion
y marketing, 2nd ed., McGraw Hill Interamericana,
Colombia, 1998, p 29.
[2] J. Ivanez, La Gestion del Diseno en la Empresa,
McGraw Hill, Spain, 2000, p 123.
[3] Consejo Superior de Investigaciones Cientficas (Ed.),
Solucion Integrada para la Concepcion y la Fabricacion Mecanica, Rev Plas Mod 73 (1997), 149.
[4] G. Rodrguez, Manual de Diseno Industrial. Curso
Basico, Ediciones Gustavo Gili, Mexico.
[5] R. Milani, Diseno para Nuestra Realidad, Editorial
Equinoccio, Venezuela, 1997.
[6] T. L. Richardson and E. Lokensgard, Industria del
Plastico. Plastico Industrial, Editorial Paraninfo, Spain,
1999, p 373.
[7] J. Brydson, Materiales Plasticos, Instituto de Plasticos
y Caucho, Spain, 1977.
[8] I. Rubin, Materiales Plasticos. Propiedades y Aplicaciones, Limusa Noriega Editores, Mexico, 1999.
[9] S. Levy and J. DuBois, Plastics product design
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
inyeccion de termoplasticos, Instituto de plasticos y
Cauchos, Centro Superior de Investigaciones Cientficas, Universidad Politecnica de Cataluna, Spain, 1978.
[12] D. Morton-Jones, Procesamiento de Plasticos, Editorial Limusa, S.A, Mexico, 1999, p 177.
[13] G. Mengues and G. Mohren, Moldes para plasticos de
inyeccion, Editorial Gustavo Gili, S.A, Spain, 1975.
[14] E. Bernhardt, CAE computer aided engineering for
injection molding, Hanser Publishers, USA, 1983.
[15] M. V. Candal, Integrando las Herramientas Computacionales al Curso de Diseno de Piezas Plasticas,
EDUTEC2003, Venezuela, 2003.
[16] P. Freire; Pedagoga de la Autonoma, Siglo Veintiuno
Editores, Mexico, 2000.
[17] Parametric Technology Corporation, Pro/ENGINEER
TRAINING GUIDE 2000i2, Parametric Technology,
USA, 2001.
[18] PuntoCAD.comDescripcion del Autodesk Mechanical Desktop. Disposable: www.puntocad.com/descripcion/mechanical.htm.
[19] Parametric Technology Corporation, Getting Started
with design Wave, Parametric Technology, USA,
1998.
[20] PTC, Pro/DESKTOP. Disposable: www.ptc.com/spain/
products/desktop.
[21] C-MOLD, C-mold getting starting with C-mold,
Advanced CAE Technology, Inc., USA, 1997.
[22] Moldflow. Disposable: www.moldflow.com.
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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.