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A feasibility study of manufacturing methods for large size moulds
Author(s)
Li, Wanjun
Date Issued
2004
Type
Thesis
Publisher
Peninsula Technikon
Abstract
Most very large moulds are manufactured in Europe, especially in Germany and Italy.
The main reason being that South Africa does not have enough very large size CNC
machines on which these could be machined. A large size mould half can be split into
two or more smaller parts for machining purposes and then reassembled later. In this
way many large size moulds, especially rotational moulds can be manufactured on
medium size CNC machines. Since the large component has been split into small
parts, these can be distributed to different subcontractors to machine simultaneously,
and thereby reducing the total manufacturing lead-time.
The project then uses three case studies to advance the proposed concept for mould
manufacture. A small size rotational mould for a model drum is manufactured to
confirm that Pentech had both the infrastructure and required skill to make a rotational
mould of any sort. Then a medium size rotational mould of a steering wheel is
manufactured. This case study is the key and longest stage in this project; it consists
of the full process of mould subdivision followed by full mould manufacture, some
subcontracting of parts and lastly full product testing. Finally, a part of a large size
mould was manufactured for purpose of investigating all aspects around the
subcontracting ofmould parts.
In the first case study the clamping strategy used through out as an integral part of the
subdivision strategy is proven. The second case study using the medium size
rotational mould successfully demonstrates the subdivision concept, along with its
material savings. This second case study also introduces the idea of including CNC
lathe parts. Lastly, the third case study using a large size rotational mould proves the
contractibility of the mould segments using NC files, despite certain industry leaders
believing that machine shops would not be interested in accepting work on the basis
ofNC files
The main reason being that South Africa does not have enough very large size CNC
machines on which these could be machined. A large size mould half can be split into
two or more smaller parts for machining purposes and then reassembled later. In this
way many large size moulds, especially rotational moulds can be manufactured on
medium size CNC machines. Since the large component has been split into small
parts, these can be distributed to different subcontractors to machine simultaneously,
and thereby reducing the total manufacturing lead-time.
The project then uses three case studies to advance the proposed concept for mould
manufacture. A small size rotational mould for a model drum is manufactured to
confirm that Pentech had both the infrastructure and required skill to make a rotational
mould of any sort. Then a medium size rotational mould of a steering wheel is
manufactured. This case study is the key and longest stage in this project; it consists
of the full process of mould subdivision followed by full mould manufacture, some
subcontracting of parts and lastly full product testing. Finally, a part of a large size
mould was manufactured for purpose of investigating all aspects around the
subcontracting ofmould parts.
In the first case study the clamping strategy used through out as an integral part of the
subdivision strategy is proven. The second case study using the medium size
rotational mould successfully demonstrates the subdivision concept, along with its
material savings. This second case study also introduces the idea of including CNC
lathe parts. Lastly, the third case study using a large size rotational mould proves the
contractibility of the mould segments using NC files, despite certain industry leaders
believing that machine shops would not be interested in accepting work on the basis
ofNC files
Additional information
Thesis (MTech (Mechanical Engineering))--Peninsula Technikon, Cape Town, 2004
Subjects
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