Plastic Analysis
I used the plastic analysis tools within Solidworks to simulate Injection Moulding a PP camping mug I designed. I modelled a core and cavity for the part, in addition to ejector pins and a sliding core that could be used to Injection Mould the part. I then set parameters and simulated Injection Moulding of the part. The below images show the results from the analysis. I made design changes, reran the study and then used the result to produce a comprehensive spreadsheet that calculated the unit cost based on inputs such as fill time, quantity and tooling costs. This project improved my understanding of this commonly used process.
Air Traps
Injection Moulding Tool (Exploded)
Injection Moulding Tool (Compressed)
Sink Marks Result
Cooling Time Result
Fill Time
Finite Element Analysis
I was tasked with designing a mass-optimised mountain bike crank, using Solidworks Simulation. I first modelled a simple beam, and compared the results from the simulation with hand calculations I had completed. I found a 1.12% difference, suggesting that the simulation model was valid. I then modelled a simple crank and ran the same simulation to find the maximum stress in the current design, finding that it was far below the UTS for the material. I then used Design Studies and a Topology Study to help optimise the crank. Each iteration was tested for mass and maximum stress. The final design yielded a 42% mass reduction, while retaining a maximum stress lower than the UTS.
