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MMSE 641 Injection Molding,
Die Casting & Related Net Shape Processes
(Current course Number is ETLS 772)

Dr. Dennis E. Ferguson, P.E.

Fall 2001

Course Description Class Outline About the Instructor E-Mail Instructor Grad Engineering Home

 

Instructor: Dr. Dennis E. Ferguson, P.E.
3M Center, Bldg. 518-1-01, St. Paul, MN 55144
 
Time: Section 13 - Thursday Evenings, 6:00 - 9:00 p.m.
Fall Semester 2001
 
Location: St. Paul
 
Telephone: (651) 736-7238 (Work)
E-Mail: DEFerguson@mmm.com
 
Required Text: Handouts in class.
 
Optional Text: Malloy, Robert A. Plastic Part Design for Injection Molding: An Introduction, Hanser Gardner Pubns, 1994. (This excellent book should be on anyone's desk that is involved with molding.)
 
Course Description: This course covers the creation of tooling for thermoplastic injection molding, die casting, blow molding, and other related net shape processes. In-depth coverage is given to mold design and process parameters. Part design issues related to these processes are investigated including material selection, part geometry, and cost estimating. Computer tools applicable to net shape manufacturing are also discussed including CAD, flow analysis, rapid prototyping systems, and expert systems.
Prerequisite: MMSE 601 Manufacturing Process
 
Course Objectives: Introduction to tool design and manufacturing fundamentals for net shape processes with an in depth study of injection molding. Emphasis will be on product design as it relates to mold design and manufacturing cost. CAD/CAM, FEA, Expert Systems, and Rapid Prototyping will be discussed as aids to the part design and tooling process.

In general, each class period will begin with one hour of new material presented by the instructor, followed by a one hour group problem solving session with 2-3 students per group. The last hour will be discussion and review of the results of the group session and material presented.

 
Course Methodology: This course will use printed materials and video tapes. Student presentations will be made during the second half of the semester in conjunction with the lecture.
 
Major Assignments:
  1. An oral report on a net shape process problem will be presented in class by each student. An abstract (a one paragraph summary) will be submitted before the presentation.
  2. A research paper of approximately ten pages will be due in class twelve. The topic will be a net shape tooling proposal to solve a tooling problem (can be same as oral report) on a net shape process of the students choice.
  3. There will be a midterm exam class seven and a final exam in class thirteen.
 
Grading Policy: Class Participation
Oral report
Midterm
Final Exam
Research paper 		15%
20%
20%
20%
25%
 
Attendance Policy: Students are expected to attend all class sessions. Circumstances which prevent attendance will be honored up to two instances. Absences in excess of two times may result in an incomplete grade for the course. Contact the instructor when a special situation arises. All absences require that the instructor be informed in advance.

 

 

MMSE 641-13 Injection Molding, Die Casting & Related Net Shape Processes

Fall Semester 2001

Date

Topics

Assignments
September 6

Class 1

 1. Orientation and description of course

2. General discussion of net shape processes, tool engineering, money

3. Net shape processes overview

 
September 13

Class 2

 1. Blow molding

2. Forging

3. Powder metallurgy

4. Investment casting

Design Problem
September 20

Class 3

 1. Introduction to injection molding

2. Introduction to mold design

3. Introduction to part design/materials

Design Problem
September 27

Class 4

 1. Polymer rheology

2. Student presentation

Design Problem
October 4

Class 5

 1. Heat transfer, cycle time

2. Stress Analysis

3. Student presentation

Cooling problem
October 11

Class 6

 1. Plant Tour  
October 18

Class 7

 1. Mid-term Exam

2. Mid-semester Course Review

 
October 25

Class 8

 1. CAD/CAM and mold design

2. CNC tools

3. Student presentation

Runner Balance Problem
November 1

Class 9

 1. Plant Tour Design Problem

Matrix Problem
November 8

Class 10

 1. CAD/CAM and mold fabrication discussion

2. Sculptured Surfaces

3. Student presentations

 
November 15

Class 11

 1. Video SLA

2. Expert Systems

3. Student presentations

Design Problem
November 22 No Class  
November 29

Class 12

 1. Review for Final Exam

2. Student Presentation make-ups

 
December 6

Class 13

 1. Final Exam

2. Final Course/Instructor Evaluation

 
December 13

Class 14

 1. Wrap-up discussion: Video: "Simultaneous Engineering"

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