Process Simulation-Based Design, Mold Construction and Mechanical Performance Evaluation of an Insert-Injection Molded Thermoplastic Polyurethane Part

Abstract

Abstract This paper presents a case study of simulation-based design and experimental validation of the insert-injection molding process of a complex polyurethane part. The part under consideration is a dowel holder which is a machine element used in the concrete railway sleepers production. A simulation study was carried out to define the relevant mold design options and optimal molding parameters as well as to evaluate their influence on the part's quality indexes. Simulation was performed using the software Moldex3D. The mold was constructed according to the optimization analysis and a batch of pieces was manufactured under the optimized conditions. A mechanical testing experiment – representing the actual service loading conditions – was designed and performed to validate the mold and process designs and the part performance. Simulation and statistical analysis results allowed determining those conditions that lead to a better assembly between the part and the metallic insert and to its structural integrity. The mechanical performance evaluation demonstrated that the part meets all its functional and structural requirements, validating simulation predictions.