Metal-to-Plastic Part Conversion
Fill-time simulation prediction
Weld line new simulation prediction
Feasibility Study
An idea to permanently eliminate leak issues caused by an aluminum elbow connector by utilizing an MPC-sourced replacement required a study of the feasibility of converting the component to plastic was conducted. This would form the groundwork for a formal proposal to the client.
An initial 3D model was created in NX and simulated in Autodesk Moldflow to determine manufacturability via injection molding. A revised model removed the flange which attached to a hot manifold, as a connection point elsewhere on the assembly made it redundant. This new version was also simulated for manufacturability.
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Unresolved feasibility issues included:
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Heat handling capability of the original design (attaches to hot manifold)
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Preload on the weld joint
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Spin weld quality
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Timing & client interest