An expert system for injection mold cost estimation
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Abstract In recent years, the notion of the expert system (ES) has become very popular, and its enormous potential to industry and ways in which it could improve decision‐making have been recognized. This article presents the research work of an expert system (ESIMCOST) the authors developed to assist the manufacturers in the injection mold cost estimation at the early product design stage. The system domain is concerned with the concurrent decision‐making of the plastic part design, injection mold design, and mold‐making process planning during the cost estimation process. Numerous interrelated variables and technical data for estimating the injection mold cost are well organized. With the inputs of the features of a plastic part, the ESIMCOST will generate an estimated cost of the injection mold required to produce the part. Some of the projected benefits from the system implementation are addressed in the article. © 1995 John Wiley & Sons, Inc.The working condition of the plastic injection mold were analyzed,proposed that design the plastic parts and the injection mold with reasonable,can guarantee the structure of the inject mold become more reasonable.Selected the mold material and the heat treatment method with reasonable,can guarantee the operation requirements of inject mold;optimized the fabrication technology,can guarantee the manufacture quality of the inject mold;Intensified surface,can enhances the surface quality of the injection mold work components;Used and maintained correctly,can optimize the working condition of inject mold;The service life of the plastic inject mold were enhanced through the methods that presented above.
Service life
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The element technology items which are necessary to improve the functionality of the mold are the runnerless-system, filling of rubber into a decompressed mold, the cassette-mold, the flashless-mold, the heating method of the mold, the mold surface which prevents deposition from sticking, the washing of the mold, the automatic mold release of the cast, and others.The main technical points that we should aim at in future are as follows:· The complete runnerless-system which is made no runner to leave.· High level molding in the vacuum by transferring its function to the molding machine.· The switching for cassette-mold applications from all function collection design to a function differentiation design.· The expansion of the object of the flashless-molding to the complicated shape products and larger products.· The effective mold heating method by the three-dimensional placement of the heat source or electromagnetic induction.· Lowering of energy of the mold surface that deposition prevents from sticking.· The use of dry washing method without damage to the mold surface.· The direct mold release method of the cast in the complete runnerless-system that cannot catch a runner.
Molding (decorative)
Transfer molding
Deposition
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One of the major drawbacks of present cost estimation models is their incapability of embracing effectively complete product development stage. Parametric estimation works well in early design stage, but when it comes to detail design stage, a more complete estimation is provided by process model based and detail estimation techniques. A major paradigm shift is proposed in this paper whereby “Cost” is to be considered as a design parameter from scientific perspective and it is to be treated as a design consequence rather than as an operational outcome. A comprehensive framework using System Analysis fundamentals is designed to study ‘’Process Cost” aspects of a part or a design. The paper gives detailed implementation of this new approach for objects manufactured largely by milling operation. The paper also suggests a methodology to extend this approach to other manufacturing processes. The proposed Generic Cost Estimation Model shows good agreement with cost estimation by commercial estimation software when applied to the objects manufactured by milling process. It also promises integration of “Cost” with other disciplines in Multidisciplinary Optimization and Collaborative Engineering. The integration is achievable through new information technology interface tools.
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In order to investigate the relationship between the thermal characteristics of the various molds as green sand mold, dry sand mold, mold and shell mold, and the solidification characteristics of molten metal, the thermal analysis of rarious molds and melt were performed. The structure of Al-Castings was a/so observed. Results obtained in this experiment were as follows : 1) The heating rate of the molds was increased in the order of green sand mold, mold, dry sand mold and shell mold, On the other hand the solidification time of the melts was shortened in the order of dry sand mold castings, mold castings, green sand mold castings and shell mold castings. 2) The arrest temperature period in the heating curve of the green sand mold was resulted from the eraporation of moisture contained in mold, which was transfered to the outer side of the mold. 3) The temperature fluctuation of the melt in the shell mold was considered to be resulted from the combution heat of resin contained in the mold. 4) The amounts of heat absorption of the molds were increased in the order of dry sand mold, mold, green sand mold and shell mold. 5) The higher the solidification rate was, the longer was its shrinkage pipe and the finer its grain size.
Shrinkage
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In order to raise the high temperature extrusion mold the life which uses under the high temperature high pressure,selected,the mold hot prescription law from the mold material to mold aspects and so on processing has carried on the analysis,proposed the extension mold life new method,for used this kind of mold the enterprise to provide the reference.
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Purpose The objectives of this paper are to discuss the constraints stemming from the unstructured nature of the cost estimation practice in Turkey and introduce a generic computer aided building cost estimation model based on a cost significant technique for Turkish construction sector public projects in its detailed design phase. Design/methodology/approach The research design was based on the simplified version of the bill of quantities method and a cost significant estimating model works on a cost database was suggested to overcome the problems. Underlying principles and basic steps of cost estimation based on cost significant work packages was explained by means of manual calculations. Findings In order to automate the manual building cost estimation process, the software based on cost significant work packages was developed. Research limitations/implications The software is currently in the testing phase and is being used for educational purposes. Making use of both public sector and current market prices in the cost estimation process, increasing number of projects stored in the database for more accurate results, estimating costs of different types of projects and calculating the cost significant value factor more precisely by using statistical techniques, those being employed by global cost models are suggested for future research. Practical implications As the number of the similar projects in database is increased, the accuracy of the cost estimation is also increased. Originality/value Estimators and graduate students can use the software to estimate building cost of public housing projects in its detailed design phase.
Cost contingency
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Dynamic mold temperature (DMT) injection molding is a molding process that the mold cavity is first rapidly heated to a high temperature before plastic melt injection, and then cooled quickly after filling and packing stages. With this technique, plastic parts with very good surface performance can be produced. However, as the special mold structure and its worse working process, large stress concentration can be caused in the mold. Consequently, the mold for this new injection technology can be easily fatigue and the lifetime of the mold is inevitably decreased. In this paper, the structure of the mold was presented first, and then the working process and factors influencing the lifetime of the mold were analyzed. Through numerical simulation, the fatigue source of the mold was evaluated. Results showed that the evaluation process presented in this paper was very in accordance with the practical failure mold.
Molding (decorative)
Transfer molding
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Abstract Today many complex systems are built starting from certain prior products. Traditional cost estimation methods assuming products are built from scratch and using simple methods such as linear regressions can lead to significant errors. This paper studies the switching costs, the costs of developing a new product that is built based upon a previously developed product. It presents a series of systematic study results including its concept, properties, an estimation method, and operation principles. Our approach is an automated method that is able to minimize manual efforts. It can leverage historical data, acquisition information, existing cost models, commercial costing tools, and Expert Judgments (EJ). An HVAC (Heating, Ventilation, and Air Conditioning) system design example case was used to demonstrate our approach.
Leverage (statistics)
Scratch
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The author believes that the usual method to determine the quality of the cast iron ingot mold is concentrated only for iis chemical composition. Therefore many papers already published upon the similar subject are nearly all concerned to the latter. But practical men very often experience that the molds with equal analysis do not always show the above mentioned result. consequently, it is quite important to do further investigations beyond this extent.The author comes to the conclusion by research that the mold life chiefly depends on the following six items.1. The design of the mold.2. The chemical composition of the mold.3. The grade of pig irons for the mold.4. The casting method of the mold.5. The annealing of the mold.6. The using conditions of the mold.
Ingot
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