Optimise Plastic Part Design in the initial stages of development

Design plastic parts more efficiently and accurately.

Take the complexity out of getting your injection molds right the VERY first time . In a matter of minutes you can test your designs for possible flaws and defects, eliminating rework of expensive molds and reducing costs.

SolidWorks Plastics makes it easy for parts and injection molds. You don’t have to be an expert to easily identify and address companies that design plastic parts or potential defects by making changes to the part or mold design, plastics material, or injection molds to predict and avoid processing parameters, saving resources, time and money.

Manufacturing defects during the earliest stages of design, eliminating costly rework, improving quality, and accelerating time-to- intuitive workflow and design advise to market. Fully integrated with SolidWorks CAD, SolidWorks Plastics works directly on your 3D model, avoiding model conversion issues. You see this intuitive software helps part designers, the impact of design changes right away.

Powerful and fast state of the art meshing covers mold designers and mold makers optimize geometries from thin walled parts to very thick and solid parts. Design for manufacturability without leaving their familiar 3D design experience.

An intuitive interface leads you step by step. Guided analysis, intelligent defaults  and automated processes ensure correct setup, even if you rarely use simulation tools.

The SolidWorks Plastics material database contains thousands of commercial plastics and is fully customizable.

• Part designers get rapid feedback on how modifications to wall thickness, gate locations, materials, or geometry can affect the manufacturing of their part.
• while mold designers can quickly optimize multi-cavity and family mold layouts and feed systems including sprues, runners and gates. Analyse and Optimise a range of geometries including thin walled plastic parts.  
• The Results Adviser provides practical design advice and troubleshooting tips to help diagnose and solve potential problems. This powerful information gives users tremendous insight into the injection molding process, leading to informed design decisions and better quality products. 

While the cost of making changes is low in the early stages of product development, the impact is highest. The sooner you can optimize your plastic parts and injection molds for manufacturability, the better. Design changes in the early stages of product development cost less and have the greatest impact on improving manufacturability. 

The cost of change increases substantially further downstream and can lead to significant time-to-market delays. The challenge in plastics part production is determining how your part or mold design impacts manufacturing and how manufacturing  will impact your design, and then communicating that information early and often throughout the design to manufacturing process. 

SolidWorks Plastics gives you the tools to quickly identify potential problems so you can make changes early in the design process. The most cost effective time to optimize plastic parts for manufacturability is during the initial stages of product design.

Advantages

• Fully embedded in the SolidWorks 3D design environment so you can analyze and modify designs for manufacturability at the same time you optimize for  fit, form and function
• Easy to learn, use and does not require extensive analysis or plastics expertise
• Facilitates design team communication: web-based HTML reports make it fast and easy to communicate simulation results and design advice to all members of the design-to-manufacturing team
• Unbalanced filling in family molds can be predicted and avoided with SolidWorks Plastics.

Click the below image for more idea

For Demo on SolidWorks Plastics, mail us @ lakshmipriya@egs.co.in

Design for Manufacturing and Assembly using SOLIDWORKS

Design for Manufacturing (DFM) and Assembly (DFA) always has been a challenging proposition when it comes to new product development or cost savings on existing products. At the end of the day, products have to meet the requirements of our end customers.

This presentation is about design for manufacturing and assembly, how we use our CAD tools day-in and day-out, in terms of leveraging on the capabilities of 3D CAD, specifically as addressed by quality requirements. It starts with manufacturing of the individual parts and assembling of the same.

Benefits of DFM and A using SOLIDWORKS

• First time right
• Improved profitability
• Reduced service calls
• Enhance Quality

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Best Design using SOLIDWORKS SIMULATION Standard

Which design works best? How do you know you have the best design?

When it comes to choosing the best design for your project, do you:

• Go with your gut?
• Cross your fingers and hope for the best?
• Methodically test a series of expensive physical prototypes?

Now there is a better way.

Validate your designs before Prototype and manufacture Products, with design validation tools from SolidWorks Simulation. 

 

SolidWorks Simulation Standard is recently introduced by SolidWorks to enable every designer and engineer to simulate and analyze their product performance with fast, easy-to-use CAD-embedded analysis solution. It will also keep your investment low. 

 SolidWorks Simulation Standard can helps you to predict product performance accurately, while your in design stage itself and to speedup your design process, innovate faster, and more confident in the product performance.

SolidWorks Simulation Standard software is used to virtually test your new concepts, develop new designs, and reduce time to market your products. SolidWorks Simulation Standard gives you an intuitive virtual testing environment for linear static Analysis, Kinematic Analysis ( motion ) and fatigue Analysis, so you can answer common engineering challenges with SolidWorks 3D CAD embedded solution.

Problems solved using SolidWorks Simulation Standard:

• Weld Failure Elimination

• Analysis-to-test correlations for strains & Deflections

• Deflection and Stress Calculations for Parts and Assemblies

• Durability & Fatigue Life Prediction

• Life Improvement for Equipments

• Kinematic Simulation of Mechanisms

• Factor of Safety Calculations for load combinations

Benefits:

• Development of Cost-effective Designs that meet Durability Targets
• Elimination of Design Failures due to Service Loads
• Leveraging your existing CAD models
• Improve Process Efficiency and Product Effectiveness
• Increase Innovation and Market Share

Math behind Style Spline in Solidworks

Whether occurring in nature or in the mind of a designer, curves and surfaces that are pleasing to the eye are not necessarily easy to express mathematically. In Solidworks 2014, Solidworks introduced a new entity called Style Spline. I would like to share about mathematical concepts in style spline.

Style spline is something differs from spline which we are using currently, Because Spline curve is a piecewise cubic curve, made of pieces of different cubic curves glued together. Style spline is a Bezier curve. A Bezier curve is one of the parametric curve frequently used in computer graphics and related fields. But Bezier curves differ from other types of parametric curves by the type of basis polynomials used to form them

The study of these curves was however first developed in 1959 by mathematician Paul de Casteljau using de Casteljau algorithm at Citroën. The idea of this algorithm is plotting the curve through repeated linear interpolation by using given control points (P₀, P₁, P₂, P₃... P_n ). The following discussion will explain how Bezier curve has been derived mathematically. For an example, Lets we discuss about methodology of deriving Quadric Bezier curve (i.e. Parabola).

Generic Linear interpolation formula between two points P₀P₁ is P(u) = (1-u)P₀ + uP₁, for 0 ≤ u ≤ 1

For better understanding, Lets we take "u" = 0.2, 0.4, 0.6, 0.8 ,between the limit 0 to 1

We know that the value of starting (P₀), control (P₁) and ending (P₂) points. Firstly , we have to do linear interpolation between P₀ and P₁ as well as P₁ and P₂ (for u=0.2), so we get P₀₁ and P₀₂ points respectively . And again we have to do linear interpolation between P₀₁ and P₀₂ , finally we will get P(u) point (for u=0.2). So for Quadric Bezier curve, we need three iteration to find the curve points. We have to repeat these three iteration with changing value of "u".

Note: The tangent vector formed by the starting point is tangent to the curve at point (P0). The derived lines from calculations at every stage (like P0P1 ) is tangent to the curve at point P(u). Likewise, Tangency of the curve is controlled.

Lets we see the animation of curve formation in Higher order (4 point) Bezier curve which is created... Click Here

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DFMXpress turn-rules

Are you striving to solve your Quality Issues upfront @ the Design Stage?

SOLIDWORKS 3D CAD provides a 3D workspace which showcases your final results before getting it for production.

As a part of DFMXpress, the analysis tool which helps in upstream validation of difficult areas of manufacturing, following are the set of turn-rules based checks. 

Sequencing with our earlier posts, following are the turn-rules:

TURN RULES

1. MINIMUM CORNER RADII FOR TURNED PARTS

• Avoid sharp inside corners. Provide a generous inside radius to accommodate a tool with a large nose radius, which is less prone to breakage

• A turn-down surface perpendicular to an un-machined (cast) surface might cause burrs

Minimum corner radii for turned parts

2. BORE RELIEF FOR TURNED PARTS:

• Provide tool relief for the bottoms of blind bored holes in turning operations.

Bore relief for turned parts

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