Improving the Efficiency of the Bowden Cable Terminal Injection Process for the Automotive Industry

Author:

Pereira José L. T. A.,Campilho Raul D. S. G.ORCID,Silva Francisco J. G.ORCID,Sánchez-Arce Isidro J.,Prakash ChanderORCID,Buddhi DharamORCID

Abstract

Control cables transfer force between two separate locations by a flexible mean, and hence, they are important in the automotive industry and many others; their terminals interact with both moving and moved mechanisms, so they must be strong. Cable terminals are commonly made of ZAMAK and are created by injection molding. However, such a production method requires leaving extra material to allow the correct molding, also known as sprues, which are removed later in the process. In this case, the sprues were separating from the terminals in an uncontrolled way. In this work, the cause of sprues separating prematurely from the terminals in a production line is addressed. The whole process was analyzed, and each possible solution was evaluated using process improvement techniques and the Finite Element Method, leading to the best solutions. Molds, mold structures, and auxiliary equipment were improved, resulting in a minimally invasive intervention and remaining compatible with other equipment. Cost analyses were done, indicating an investment return in less than a year. The modification led to a reduction of 62.6% in the sprue mass, while porosity was reduced by 10.2% and 55.9%, corresponding to two terminal models. In conclusion, the interventions fulfilled the requirements and improved the operation of the line.

Publisher

MDPI AG

Subject

Process Chemistry and Technology,Chemical Engineering (miscellaneous),Bioengineering

Cited by 5 articles. 订阅此论文施引文献 订阅此论文施引文献,注册后可以免费订阅5篇论文的施引文献,订阅后可以查看论文全部施引文献

1. Process improvement in Zamak injection machines for automotive component fabrication;Proceedings of the Institution of Mechanical Engineers, Part C: Journal of Mechanical Engineering Science;2024-07-23

2. Productivity improvement of control cable manufacturing machine for the automotive industry;Mechanics Based Design of Structures and Machines;2024-05-07

3. A Novel Fully Automatic Concept to Produce First Subset of Bowden Cables, Improving Productivity, Flexibility, and Safety;Machines;2023-10-26

4. Process Improvement in Zamak Injection Machines for Automotive Component Fabrication;Flexible Automation and Intelligent Manufacturing: Establishing Bridges for More Sustainable Manufacturing Systems;2023-08-24

5. Forecasting the output using ANN models and effect of input factors on machinability of Duplex Steel 2205 in dry-turning operation for high strength and anti-corrosive applications;Advances in Materials and Processing Technologies;2022-10-31

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