| The focus of this thesis will concentrate on the utilization of CAD and flow simulation software to select cavity and runner layouts for a four piece plastic part assembly that will provide an optimum level of part quality. This was achieved through proper mold configuration and design, with the objective of keeping the number of molds to a realistic minimum.; Solid models of each of the four parts were imported from the solid model design software, Pro/Engineer, into the plastic filling analysis software, Moldflow. Each plastic part was analyzed individually to evaluate the filling characteristics of the parts themselves. This was followed by the subsequent analysis of each pair of possible part combinations to determine the best way to configure the two cavity family molds. One of the two cavity family mold configurations was also subjected to variations in fill speed, melt temperature changes, and runner geometry to see how these variables affect the balance of melt flowing to each cavity.; The results of the study prove that the proper utilization of the fundamentals of runner, gate, and mold designs, in conjunction with flow simulation software, provide the ability to review a multitude of options in a reasonable amount of time. One can quickly evaluate different cavity layouts for family molds to assist with the decision making process without making financial commitments to tooling. |
