Plastics Engineering CUTTING-EDGE CONTINUING EDUCATION - FALL 2010 SCE-PLASTICS.UWM.EDU

Transcription

1 Plastics Engineering CUTTING-EDGE CONTINUING EDUCATION - FALL 2010 SCE-PLASTICS.UWM.EDU

2 Optimize Performance. Inspire Innovation. Plastics Engineering is more complex than ever. To answer increased demands, you must be at the forefront of innovation and efficiency. Thankfully, you ve found cutting-edge continuing education. From basic parts to advanced mold design, our comprehensive courses maximize your knowledge, productivity and marketable skills. Each course is led by practitioner instructors who have the real-world experience to ensure your real-life success. They are teachers, innovators and most importantly they are engineers who understand the field. For more details and to learn how we can bring courses to you, contact me at or Sincerely, Murali Vedula Engineering Program Director UWM School of Continuing Education sce-eng.uwm.edu MURALI VEDULA Program Director Dr. Murali Vedula worked in engineering at Dow Chemical Company and Structural Composites Industries for several years before joining UWM in For the past 13 years, Dr. Vedula has used his engineering knowledge and contacts to identify professional development needs, including elastomer and plastics technology, electrical engineering, innovation, mechanical and industrial engineering, and Six Sigma. In response to changing demographics, he has restructured Six Sigma certificate programs to meet the needs of the service industry. In add ition, he recently began offering an Office Lean certificate program and has been involved with internal Lean training. His latest emphasis is on innovation. He currently serves on the Board of the Society of Plastics Engineers Milwaukee Chapter. DEBRA O NEIL Program Associate oneil@uwm.edu Debra O Neil has been with the School of Continuing Education for over15 years, nine of which she was a program associate supporting public and corporate Engineering programs. She assists with the coordination of course scheduling, materials assembly, program content, marketing, inquiries and billing. She is customer service oriented and enjoys working with program participants.

3 HIGHLY RECOMMEND TO SUPERVISORS AND ENGINEERS DESIGNING PLASTIC PARTS." - Sunil Dasara, Terumo Heart Inc. TABLE OF CONTENTS Plastics Technology Plastic Injection Mold Design Basics...4 Plastic Injection Mold Design Advanced...5 Innovative Solutions for Plastic Part Production...6 Designing Plastic Parts for the Injection Molding Process...7 "VERY INFORMATIVE, A LOT OF INFORMATION WAS COVERED IN A VERY SHORT AMOUNT OF TIME." - Anthony Makusi, Tech Molded Plastics, L.P. Innovation Accelerated Product Development - Using Product Realization...8 Quality/BPI Six Sigma Black Belt...9 Instructors...10 General Information...11 Onsite Training...Back Cover Learn how to earn a Plastics Technology Certificate or visit sce-plastics.uwm.edu

4 Plastics. PLASTIC INJECTION MOLD DESIGN BASICS Gain a thorough understanding of injection mold design fundamentals. This practical course gives those involved with injection molds a comprehensive look at injection mold design and demonstrates how to contribute to the success of projects. It offers a unique blend of very detailed mold design concepts set forth in the context of the design process as a whole. On the final day students participate in the mold design process. Who should attend Anyone responsible for procuring, evaluating, building or designing injection mold tools, including tooling engineers, buyers, toolmakers, mold designers, product designers, managers and molders. Mon.-Wed., Aug , 2010 Instructor: Jim Walsh Fee: $990 CEUs: 2.0 Program No Mon.-Wed., Apr , 2011 Program No COURSE OUTLINE Introduction and Overview The Anatomy of a Mold - Mold Types Stripper plate molds Unscrewing molds Quick change molds Hot runner molds Shuttle molds - Basic Mold Construction Use and placement of bolts and dowels Major suppliers and differences between them How to specify and order mold bases and components - Common Components and Their Function Leader pins, return pins, support pillars, rest buttons etc. The Molding Press - How the mold interfaces with the press - Horizontal and vertical clamp - Shuttle and rotary presses Plastic Resin Fundamentals - Amorphous and semi-crystalline - Basic properties and how they affect the mold design Shrink - How to use shrink to your advantage - Factors that affect shrink and warp Plastic Product Design Fundamentals - Common errors - What the mold designer needs to look for in a product design Sprue, Runner and Gate - Common gate design errors - Runner sizing guidelines - Runner pullers Ejection - Determining ejector place - Pin orientation methods - Knock-out patterns - Return pins and springs Basic Mold Inserting - Solid vs. split construction - Criteria for inserting Slides and Lifters - A thorough look at how to mold undercuts - Typical slide and lifter construction - Mechanical vs. hydraulic Cavity Layout - How to efficiently place the cavities in the mold and choose the best parting line - How it affects runners, ejection and gates Cooling - The economic effect of cooling design - General rules for waterline placement - Thermal conductivity of various tool steels Venting - Venting of runners - How venting affects the molded part - Why this should NOT be overlooked Mold Steel - What to look for in a mold steel - A discussion of steel hardness - Alternate materials used in molds Plating and Polishing - A selection chart for mold coatings - When and why to use plating Mold Design from a Project Perspective Student Design Projects - Students will be split into groups to work on actual design projects 4 sce-plastics.uwm.edu

5 PLASTIC INJECTION MOLD DESIGN ADVANCED You ve got the basics, now it s time to move to the next level. Examine the inner workings of injection molds, including cost saving techniques. Participants are encouraged to bring current problems to be addressed. Who should attend Mold designers, tooling engineers and toolmakers, product designers, buyers, molders, and managers. Requirements: Completion of Plastic Injection Mold Design Basics or a solid knowledge of the subject matter. Thu.-Fri., Aug , 2010 Instructor: John Vosmeier Fee: $790 CEUs: 1.4 Program No Thu.-Fri.,Apr , 2011 Program No COURSE OUTLINE Introduction and Overview - Course objectives Molding Surface Tolerances - The various fits in a typical mold - The tolerances that should be maintained - How the product tolerances affect tool tolerances - How it affects mold cost Mold Strength and Preformance - Understanding the forces acting against a mold - Various calculations - Designing for strength and longevity Mold Alignment and Interlocking - Various methods of insuring mold alignment - Balancing of forces in a mold - Core shift causes and fixes - How it affects mold longevity Advanced Parting Line and Shut-off Development - A detailed look at shut-off designs - Contoured and stepped parting lines - Common product design errors that complicate parting lines - Examples of complex parting lines Advanced Slide and Lifter Design - When to use a lifter instead of a slide - Methods of slide actuation - A look at the forces involved - Proper heel block and gib design - The use of springs with slides - How and when to delay slides - Dual action slides - Slides in the stationary half - Slide alignment - Designing slides for low maintenance - Determining slide travel - Alternate methods of molding undercuts - Stripping of undercuts - Floating inserts to release undercuts - Collapsible and expandable cores - Slide retention methods Advanced Cavity and Core Inserting - A thorough look at every aspect of inserting - Criteria for deciding whether or not to insert - Pins and other round inserts - Inserting slides and lifters - Laminated inserts - Gate inserts - How inserting affects manufacturing - The economics of inserting - Assembling of inserts - Sub assembly design concept - Quick change inserts 3D Modeling and Mold Design - Improving translation between CAD systems - General problems with CAD exchange - Tips and tricks - Translation options Mold Monitoring - Pressure transducers - Thermocouples - Proximity and limit switches - Vision systems sce-plastics.uwm.edu

6 INNOVATIVE SOLUTIONS FOR PLASTIC PART PRODUCTION Learn to overcome challenges facing the injection molding industry with practical solutions. Explore ways to ensure your needs align with equipment. Identify day-to-day issues that arise surrounding injection molded part quality. Explore solutions and learn innovative ideas to produce high quality, efficient and economical parts for injection molding. Who Should Attend Manufacturing and molding engineers involved with injection molded plastic parts. Also, technical professionals involved with manufacturing injection molded plastic parts, tooling engineers, mold designers, product designers, project engineers and quality control personnel. Thu.-Fri., Oct , 2010 Instructors: John Vosmeier, Nick Brown Fee: $790 CEUs: 1.4 Program No Thu.-Fri., May 19-20, 2011 Program No COURSE OUTLINE The Equipment Introduction & Course Outline Review Molding process particulars Good molding practices - Selecting an injection machine to meet or exceed your needs. - Sizing the equipment list to the operation - Auxiliary equipment needed - Cooling systems Review Scientific Injection Molding Principals Mold construction review (various types) - Review injection mold types. - What to expect from each mold type - Limitations of each mold type - Selecting the correct design (guidelines) - Maintaining your injection molds Product design issues - Design issues - Designing to fit the need - Designing pitfalls Class Project Assigned (Individuals) Problems & Solutions Review Class Project Machine problems - What kind of issues can be machine related? - Injection machine limitations - What are common machine failures and how to prevent them - Maintaining your injection machine Processing / Plastic part problems - Gate Blush - Flow lines / Streaks - Hard to fill parts - Delaminations, Over packing, Excessive Shrinkage, Short Shots, - Splay / Silver Streaks, Surface Blemishes, Flash, Warpage, - Weak Weld Lines, Bubbles vs. Voids, Black Specks. Determining root cause & solutions of each defect Resin problems - Correct selections vs. incorrect selections - Fillers and additives - Shrinkages - Mechanical properties Mold problems - Common issues - Preventing those issues in design - Correcting them once they occur - Don t make matters worse by poor decisions Final Class Project.Groups 6 sce-plastics.uwm.edu

7 DESIGNING PLASTIC PARTS FOR THE INJECTION MOLDING PROCESS To design a high quality injection molded part, the designer must select an appropriate plastic material formulation, develop a functional design and work within the manufacturing limitations associated with the injection molding process. Get a comprehensive overview of plastic part design for the injection molding process. This course covers the fundamentals of plastic materials, behavior and selection, engineering design, manufacturing considerations and assembly methods. Mon.-Wed., Nov. 8-9, 2010 Instructor: Nick Schott Fee: $790 CEUs: 1.4 Program No Who should attend Engineers and designers who are accustomed to working with metals and are faced with metal to plastic concerns. Requirements: You should have some knowledge of plastic materials, injection molding and engineering principles, although the basics are introduced. COURSE OUTLINE An Introduction to Plastic Materials - Historical Development - Fundamental Concepts - Molecular Weight - Repeat Unit Structure - Morphology - Effect of Additives - Mechanical Property Overview - Flow Property Overview - Advantages of Plastic Materials - Limitations of Plastic Materials Review of Injection Molding Equipment Review of the Injection Molding Process Review of Injection Molds Design Considerations for Injection Molded Parts - Mold Filling Considerations - Effect of Gate Location and Type - Molecular and Fiber Orientation - Mold Filling Pressure Drop - Flow Leaders and Flow Hesitation - Mold Filling Simulations - Runner Balancing and Family Molds - Weld or Knit Lines - Shrinkage and Warpage Considerations - Part Ejection Considerations Mechanical Behavior of Plastic Materials Approaching Plastic Product Development - Establishing End Use Requirements - Conceptual Design - Initial Candidate Material Selection Procedures - Design Based Upon the Materials Selected - Final Materials Selection - Manufacturing Related Design Modifications - Prototyping and Testing - Production Tooling and Manufacturing - Plastic Part Prototyping Techniques - Assembly Techniques for Injection Molded Parts sce-plastics.uwm.edu

8 Innovation. ACCELERATED PRODUCT DEVELOPMENT - USING PRODUCT REALIZATION Learn innovative approaches and design processes for developing new products with multidisciplinary teams often located worldwide. Study strategies for optimizing multiple phases of the product realization process including: requirements definition, concept generation, concept selection, prototype generation, design for manufacturing, testing and market penetration. Work on actual new product concepts and discover each phase of the nonlinear process to produce a working prototype. Mon.-Tue., Aug , 2010 Instructor: Michael R. Lovell Fee: $790 CEUs: 1.4 Program No Who should attend Engineers, researchers, scientists, managers and technical leaders of new product development, research and development, manufacturing, marketing and supplier management. COURSE OUTLINE Introduction and Overview Course Objectives - Global Landscape of Technology and Innovation - Overview of Product Realization Process - How new techniques were developed - Product Development Exercise Creating Successful Teams - Team Building Exercise - Understanding teams - Roles of team members - Best Practices and Lessons Learned Project Planning - Role and Rules for project planning - Project planning tools - Project Planning Exercise Developing Project Requirements - Understanding internal requirements - Unique product orientations - Customer needs analysis Concept Generation - What is a design concept? - Potential Failures - Five Step Approach to generating innovative concepts - Concept generation exercise - Concept Selection - Potential Failures - Concept Screening - Concept Scoring - Concept Selection exercise Design for Manufacturing - Understanding product realization from business perspective - Minimize costs while maximizing performance Prototyping - Role of prototyping in design innovation - Prototyping processes - When to generate prototypes Testing - Developing robust test plans - Role of failure in innovative design Penetrating the Market - Making products to gain market niche - Ensuring product safety and reliability 8 sce-plastics.uwm.edu

9 Quality. SIX SIGMA BLACK BELT Six Sigma is a highly disciplined improvement methodology that helps organizations achieve optimal performance in all operations. Learn methods to identify how many defects you have in a process and systematically determine how to reduce them to get as close to zero defect as possible. Who should attend Anyone wanting to improve quality, identify and reduce sources of variation and reduce the rate of non-conformance in products or services. COURSE OUTLINE MODULE I Define & Measure - Overview of Process Improvement Strategies - Why Six Sigma? The DMAIC (Define, Measure, Analyze, Improve, Control) Roadmap - Roles of Champions, Master Black Belts, and Blak Belts - Process mapping flowcharts - Data collection and sampling techniques - Basic statistics location versus variation - Control charges variable and attribute - Control charts for short production runs - Subgroup statistics versus process parameters - Rationale for the 1.5σ symbol MODULE II Measure & Analyze - Gage capability studies - Estimating process parameters - Short- versus long-term variation - Process and machine capability studies - Converting process performance to a σ level - Effect of the 1.5σ shift on capability - Dealing with non-normal distribution - Rolled throughput yield MODULE III Analyze & Improve - Check sheets and matrix diagrams - Multi-vari analysis for families of variation - Component swapping for large assemblies - Brainstorming and cause-and-effect diagrams - Multi-voting and decision-making by consensus - Regression analysis and scatter diagrams - Comparison testing between good and bad parts - Analysis of means (ANOM) MODULE IV Improve & Control - Hypothesis testing and confidence intervals - Analysis of variance (ANOVA) - Developing feasible solutions - Solution FMEAs and pilot studies - Mistake proofing poka-yoke - Advanced control charting concepts - Corrective action plans work instruction - Preserving the process knowledge gained - Kaizen for continuous improvement Module I Tue.-Thu., Sept , 2010 Fee: $1295 CEUs: 2.0 Program No Module II Tue.-Wed., Oct. 5-6, 2010 Fee: $1195 CEUs: 1.4 Program No Module III Tue.-Wed., Oct , 2010 Fee: $1195 CEUs: 1.4 Program No Module IV Tue.-Thu., Nov , 2010 Fee: $1295 CEUs: 2.0 Program No Instructor: Davis R. Bothe sce-plastics.uwm.edu

10 Instructors. Plastics. Nicholas W. Brown has worked in the injection molding industry for over 20 years. He attributes his unique perspective on molding to the fact that he started his career as a molding technician and has held such positions as process engineer, manufacturing engineer, plant superintendent and plant engineer. For the past 12 years he has been the molding manager for a world-wide consumer products company in the department he founded. The company runs a 24/7 operation, which has averaged 358 days of production per year. An avid student, Mr. Brown earned a Bachelor s degree in Business in 2000 and recently received his MBA. He received the Master Molder 1 and Master Molder 2 certifications from RJG in Nick R. Schott completed his B.S. in chemical engineering at UC Berkeley and then went on for an M.S. and Ph.D. in chemical engineering at the University of Arizona. Professor Schott has been at the University of Massachusetts Lowell for the past 32 years. He has taught courses in plastics product design, plastics injection mold design, processing and process control. He is an active researcher and a worldwide lecturer on these subjects. Professor Schott was named a fellow of the SPE in 1986 and is a founding member of the SPE Product Design and Development Division. He is an editor of various books and has authored or co-authored numerous papers in the field of plastics engineering. John Vosmeier has worked as a design manager, senior tooling engineer, senior mold designer and is currently the tooling manager for a consumer products company purchasing molds in the U.S. and worldwide. He has worked with custom and proprietary molders over the years as well as owning DeJohn Innovative Plastics, a design and consulting firm since The business specializes in program development of injection molds and plastic products. Mr. Vosmeier has worked in the U.S. as well as Canada, Portugal, Mexico, Taiwan, Hong Kong and China. His extensive travels over the years have given him the vehicle needed to accumulate a vast amount of knowledge and information which he uses to construct curriculum. He holds a degree in tool engineering technology, is a senior member of SPE and since 1995, he has been very active in developing new educational curriculum for the plastics industry. Innovation. Michael R. Lovell was hired as Dean of Engineering at the University of Wisconsin-Milwaukee in August of He previously served as the Associate Dean for Research in the School of Engineering at the University of Pittsburgh where he held appointments in the industrial, mechanical and bioengineering departments. During his tenure in Pittsburgh, Dean Lovell served as the Executive Director of the Swanson Center for Product Innovation where he spent eight years mentoring more than 200 project teams through the product realization process. After receiving several grants from the National Science Foundation, he was able to perform in-depth research on the product development teams he mentored. Based on this research, Dean Lovell developed unique methodologies that increased the likelihood of a team creating an innovative product from percent. Utilizing his methodology, he mentored student teams that developed 224 new products and formed eight companies over a four-year period. He has launched an Institute for Industrial Innovation at UWM. Quality. Davis R. Bothe has over 27 years of experience working, teaching and consulting in the field of process improvement. His credentials include: ASQ Fellow, IQI certified Master Black Belt, ASQ certified Quality Engineer, ASQ certified Reliability Engineer, member of the US Technical Advisory Group to the ISO Technical Committee 69 on Applications of Statistical Methods, B. S. in applied mathematics and physics, and a Master s degree in business administration. He is author of the quality improvement books "Industrial Problem Solving," "Measuring Process Capability," and "Reducing Process Variation." He is listed in the first edition of "The International Who's Who in Quality." Mr. Bothe has worked at NASA, General Motors, Eastern Michigan University and currently serves as the director of Quality Improvement for the International Quality Institute. Jim Walsh has been involved with injection mold engineering for 30 years and has extensive hands on experience in all aspects of the mold design and development process. Having worked for many years as a mold designer, he has hundreds of successful mold design projects to his credit. His background ranges from small, very intricate molds for the automotive and electronic connector industries to larger molds for consumer products. During his career, Mr. Walsh has held positions of senior mold designer, engineering manager, and is currently a senior plastics/ tooling engineer in the automotive industry and an independent consultant. 10 sce-plastics.uwm.edu

11 General Information. REGISTRATION Phone Mon.-Fri., 8am-5pm Central (toll free) (local) Online sce-registration.uwm.edu Fee The fee includes program materials, continental breakfast, lunch and breaks. Lodging and other meals are not included. Lodging You may make your own lodging arrangement at the facility of your choice. Hotel information will be mailed with your enrollment confirmation. When contacting the hotel, mention that you will be attending a University of Wisconsin Milwaukee seminar to receive a discounted rate. Cancellations Please call at least seven days before the course starts for a refund. Cancellations received less than seven days before the start of the course will be subject to a late cancellation fee. You may enroll a substitute at any time before the course starts, or you may apply the enrollment fee to a future course. In the event the School cancels a class, the University of Wisconsin Milwaukee will reschedule, refund fees or apply the fee payment to any other School of Continuing Education engineering program offered in the next 12 months. Liability of cancellation is specifically limited to the amount of the pre-paid class fee and excludes any incidental or consequential damages. Continuing Education Units (CEUs) All programs in this catalog carry Continuing Education Units (CEUs). CEUs are a means of recognizing and recording satisfactory participation in nondegree programs. One CEU is awarded for each 10 contact hours (or equivalent) in an organized continuing education experience. All CEUs earned through the University of Wisconsin Milwaukee School of Continuing Education noncredit programs become a part of your permanent record. Parking Parking is available in the Shops of Grand Avenue parking structure and other adjacent lots. The School of Continuing Education provides a parking discount for program participants. Inquire for details. Directions For the latest information on getting to and from the School of Continuing Education, visit sce-directions.uwm.edu. The webpage includes access to printable color PDFs of current maps, information about parking and public transportation, and other details relevant to our location. For Further Information Contact Murali Vedula at or mvedula@uwm.edu. RELATED PROGRAMS AND CERTIFICATES Business Process Improvement sce-businessimprovement.uwm.edu Human Resource Management sce-hr.uwm.edu Internet/Systems & Database sce-it.uwm.edu Languages sce-languages.uwm.edu Management Development sce-mgmt.uwm.edu Organizational Development sce-od.uwm.edu Project Management sce-pm.uwm.edu Sustainability sce-sustainability.uwm.edu Train the Trainer sce-ttt.uwm.edu sce-plastics.uwm.edu

12 School of Continuing Education Business, Engineering & Technology 161 W. Wisconsin Ave. Ste Milwaukee, WI Keycode: WPDF Message Code: AP W ONSITE TRAINING Capitalize on our Capabilities Any program can be designed to meet your organization's unique and specific employee development needs. Consider the advantages to partnering with UWM SCE. Contain Costs by eliminating or reducing travel, food and lodging expenses. Maximize Convenience by choosing your optimal dates, times and location. Save Time with staff spending fewer hours away from work. Build Teamwork through group brainstorming and shared learning experiences. Custom Tailor Content to your needs to accomplish specific organizational objectives. Or, use the curriculum as-is. For more information, contact Murali Vedula at or SCE-CUSTOMIZED.UWM.EDU Message Code: AP W