Advanced plastic product design and behavior analysis study and troubleshooting methods for molding processes

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This proposed joint research project is to further explore an effective technology within the sponsor Company for advanced plastic product development and production. The project is to focus on the following three aspects: (1) Feature-based CAD/CAE analysis to minimize the usage of plastic material in order to achieve the customer required functional strength and performance under specific loading and operating conditions. (2) Material characteristic parameter impacts for the design of plastic parts in order to assure the required manufacturing quality requirements and cost expectations. (3) Specific research related to product faults and investigation of a methodology of troubleshooting analysis for molding processes. All the above research aspects are aiming for generic solutions but to be verified and validated with cases from the Company. The novelty is the design and analysis cyclic data flow and application integration with the modern CAD and CAE technology and system integration. The research approach is to conduct computer aided engineering analysis of plastic product design and manufacturability evaluation via feature development and molding simulation to address the existing issues and needs. More specifically, the following research tasks are to be covered: Warpage simulation and troubleshooting; Material selection evaluation for plastic parts in performance, molding process optimization, and cost engineering; Product performance evaluation under operational conditions, failure model analysis, design enhancement; and Compression of product development cycle time. The key benefits for Company are the development of a well investigated technology framework for effective and high-quality product development and quality enhancement; engineering "know-hows" and the knowledge fusion in the form of technical documents, and manpower training throughout the project. These benefits will essentially lead to direct efficiency and profit gains. The project is also expected to produce research journal or conference papers to be published in the publically available research databases. Canadian industrial companies and researchers can share the results for technological upgrading or further research.