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Integrated CAD CAE CAM system for injection moulding by Yuan Zhongshuang Li Dequn Chen Xing Ye Xiangao Gao Xianke and Xiao Jingrong Huazhong University of Science r y represent viscosity and shear rate denotes an average over z the gap wise co ordinate p Cp and K are density specific heat and heat conductivity of the melt respectively and b is the half gap thickness Because the thickness dimension of an injection moulded part is often much smaller than the other two dimensions a powerful numerical scheme which is the hybrid of the finite element and finite difference methods FEM FDM is adopted in the solution In the implementation of the scheme the planar co ordinates are described in terms of finite elements and the gapwise and time derivatives are expressed in terms of finite differences A control volume approach is adopted to derive the finite element formulation and track the melt front movement By use of flow simulation users can acquire information such as pressure velocity and temperature distributions total pressure drop clamp force etc which is very helpful in designing the deliver helpful in designing the delivery system and optimising the process conditions Users can also animate the filling of the cavity and obtain an optimum flow pattern by changing the number and locations of gates Cooling simulation includes 3D steady and transient cooling analyses The 3D steady cooling analysis uses the boundary element method BEM Formulas for modelling the cavity surfaces cooling lines and exterior surfaces have been established and proven to be reliable and effective Based on the steady cooling simulation 3D transient cooling simulation has been developed A novel BEM has been adopted in this module to eliminate numerical body integration With the help of this module users can calculate heat transfer between cavity and cooling channels reduce cooling time and predict temperature along mould and injection moulded part surfaces All results of CAE modules can be displayed dynamically with contour plots shaded colour images and various curve plots to aid users in improving their design Function of CAM module The cutter location files can be created based on the geometry of cavity and core which is modelled at the previous CAD stage NC tapes can then be generated by use of postprocessors for both NC wire cutting machine tools and NC milling machine tools Currently only the function of NC wire cutting is used in practice A lot of injection moulds have been designed and manufactured by using the system HSC 1 1 in factories in our country Conclusions HSC 1 1 is an integrated CAD CAE CAM system for injection moulding All programs in the system are independent of computers except a few programs for the graphic driver It ensures the system s good portability The modular structure of the system guarantees that each module of the system has good expandability and maintainability The practice shows that HSC 1 1 is a powerful tool for mould designing and manufacturing It can assist engineers in cutting mould cost and improving mould quality HSC 1 1 will find more and more applications in the mould industry References 1 WANG K K Polymer Plastics Technology Engineering 1980 1 p 75 2 MENGES G Plastics Engineering 1983 8 p 37 3 KAMAL M R etal Application of computer aided engineering in injection moulding Hanser Publisher 1987 p 247 4 AUSTIN C Application of computer aided engineering in injection moulding Hanser Publisher 1987 p 137 5 WANG V W Ph D thesis Cornell University 1985 IEE 1993 The authors are with Huazhong University of Science Technology Wuhan 430074 People s Republic of China