Improving the Efficiency of the Bowden Cable Terminal Injection Process for the Automotive Industry
Autor(a) principal: | |
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Data de Publicação: | 2022 |
Outros Autores: | , , , , |
Tipo de documento: | Artigo |
Idioma: | eng |
Título da fonte: | Repositório Científico de Acesso Aberto de Portugal (Repositórios Cientìficos) |
Texto Completo: | http://hdl.handle.net/10400.22/21886 |
Resumo: | Control cables transfer force between two separate locations by a flexible mean, and hence, they are important in the automotive industry and many others; their terminals interact with both moving and moved mechanisms, so they must be strong. Cable terminals are commonly made of ZAMAK and are created by injection molding. However, such a production method requires leaving extra material to allow the correct molding, also known as sprues, which are removed later in the process. In this case, the sprues were separating from the terminals in an uncontrolled way. In this work, the cause of sprues separating prematurely from the terminals in a production line is addressed. The whole process was analyzed, and each possible solution was evaluated using process improvement techniques and the Finite Element Method, leading to the best solutions. Molds, mold structures, and auxiliary equipment were improved, resulting in a minimally invasive intervention and remaining compatible with other equipment. Cost analyses were done, indicating an investment return in less than a year. The modification led to a reduction of 62.6% in the sprue mass, while porosity was reduced by 10.2% and 55.9%, corresponding to two terminal models. In conclusion, the interventions fulfilled the requirements and improved the operation of the line. |
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Improving the Efficiency of the Bowden Cable Terminal Injection Process for the Automotive IndustryControl cablesZAMAK injectionDie castingFinite element methodProcess improvementControl cables transfer force between two separate locations by a flexible mean, and hence, they are important in the automotive industry and many others; their terminals interact with both moving and moved mechanisms, so they must be strong. Cable terminals are commonly made of ZAMAK and are created by injection molding. However, such a production method requires leaving extra material to allow the correct molding, also known as sprues, which are removed later in the process. In this case, the sprues were separating from the terminals in an uncontrolled way. In this work, the cause of sprues separating prematurely from the terminals in a production line is addressed. The whole process was analyzed, and each possible solution was evaluated using process improvement techniques and the Finite Element Method, leading to the best solutions. Molds, mold structures, and auxiliary equipment were improved, resulting in a minimally invasive intervention and remaining compatible with other equipment. Cost analyses were done, indicating an investment return in less than a year. The modification led to a reduction of 62.6% in the sprue mass, while porosity was reduced by 10.2% and 55.9%, corresponding to two terminal models. In conclusion, the interventions fulfilled the requirements and improved the operation of the line.MDPIRepositório Científico do Instituto Politécnico do PortoPereira, José L. T. A.Campilho, RaulSilva, Francisco J. G.Sánchez-Arce, Isidro J.Prakash, ChanderBuddhi, Dharam2023-01-26T12:00:21Z20222022-01-01T00:00:00Zinfo:eu-repo/semantics/publishedVersioninfo:eu-repo/semantics/articleapplication/pdfhttp://hdl.handle.net/10400.22/21886eng10.3390/pr10101953info:eu-repo/semantics/openAccessreponame:Repositório Científico de Acesso Aberto de Portugal (Repositórios Cientìficos)instname:Agência para a Sociedade do Conhecimento (UMIC) - FCT - Sociedade da Informaçãoinstacron:RCAAP2023-03-13T13:18:14Zoai:recipp.ipp.pt:10400.22/21886Portal AgregadorONGhttps://www.rcaap.pt/oai/openaireopendoar:71602024-03-19T17:41:58.315632Repositório Científico de Acesso Aberto de Portugal (Repositórios Cientìficos) - Agência para a Sociedade do Conhecimento (UMIC) - FCT - Sociedade da Informaçãofalse |
dc.title.none.fl_str_mv |
Improving the Efficiency of the Bowden Cable Terminal Injection Process for the Automotive Industry |
title |
Improving the Efficiency of the Bowden Cable Terminal Injection Process for the Automotive Industry |
spellingShingle |
Improving the Efficiency of the Bowden Cable Terminal Injection Process for the Automotive Industry Pereira, José L. T. A. Control cables ZAMAK injection Die casting Finite element method Process improvement |
title_short |
Improving the Efficiency of the Bowden Cable Terminal Injection Process for the Automotive Industry |
title_full |
Improving the Efficiency of the Bowden Cable Terminal Injection Process for the Automotive Industry |
title_fullStr |
Improving the Efficiency of the Bowden Cable Terminal Injection Process for the Automotive Industry |
title_full_unstemmed |
Improving the Efficiency of the Bowden Cable Terminal Injection Process for the Automotive Industry |
title_sort |
Improving the Efficiency of the Bowden Cable Terminal Injection Process for the Automotive Industry |
author |
Pereira, José L. T. A. |
author_facet |
Pereira, José L. T. A. Campilho, Raul Silva, Francisco J. G. Sánchez-Arce, Isidro J. Prakash, Chander Buddhi, Dharam |
author_role |
author |
author2 |
Campilho, Raul Silva, Francisco J. G. Sánchez-Arce, Isidro J. Prakash, Chander Buddhi, Dharam |
author2_role |
author author author author author |
dc.contributor.none.fl_str_mv |
Repositório Científico do Instituto Politécnico do Porto |
dc.contributor.author.fl_str_mv |
Pereira, José L. T. A. Campilho, Raul Silva, Francisco J. G. Sánchez-Arce, Isidro J. Prakash, Chander Buddhi, Dharam |
dc.subject.por.fl_str_mv |
Control cables ZAMAK injection Die casting Finite element method Process improvement |
topic |
Control cables ZAMAK injection Die casting Finite element method Process improvement |
description |
Control cables transfer force between two separate locations by a flexible mean, and hence, they are important in the automotive industry and many others; their terminals interact with both moving and moved mechanisms, so they must be strong. Cable terminals are commonly made of ZAMAK and are created by injection molding. However, such a production method requires leaving extra material to allow the correct molding, also known as sprues, which are removed later in the process. In this case, the sprues were separating from the terminals in an uncontrolled way. In this work, the cause of sprues separating prematurely from the terminals in a production line is addressed. The whole process was analyzed, and each possible solution was evaluated using process improvement techniques and the Finite Element Method, leading to the best solutions. Molds, mold structures, and auxiliary equipment were improved, resulting in a minimally invasive intervention and remaining compatible with other equipment. Cost analyses were done, indicating an investment return in less than a year. The modification led to a reduction of 62.6% in the sprue mass, while porosity was reduced by 10.2% and 55.9%, corresponding to two terminal models. In conclusion, the interventions fulfilled the requirements and improved the operation of the line. |
publishDate |
2022 |
dc.date.none.fl_str_mv |
2022 2022-01-01T00:00:00Z 2023-01-26T12:00:21Z |
dc.type.status.fl_str_mv |
info:eu-repo/semantics/publishedVersion |
dc.type.driver.fl_str_mv |
info:eu-repo/semantics/article |
format |
article |
status_str |
publishedVersion |
dc.identifier.uri.fl_str_mv |
http://hdl.handle.net/10400.22/21886 |
url |
http://hdl.handle.net/10400.22/21886 |
dc.language.iso.fl_str_mv |
eng |
language |
eng |
dc.relation.none.fl_str_mv |
10.3390/pr10101953 |
dc.rights.driver.fl_str_mv |
info:eu-repo/semantics/openAccess |
eu_rights_str_mv |
openAccess |
dc.format.none.fl_str_mv |
application/pdf |
dc.publisher.none.fl_str_mv |
MDPI |
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MDPI |
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Agência para a Sociedade do Conhecimento (UMIC) - FCT - Sociedade da Informação |
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RCAAP |
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RCAAP |
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Repositório Científico de Acesso Aberto de Portugal (Repositórios Cientìficos) |
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Repositório Científico de Acesso Aberto de Portugal (Repositórios Cientìficos) |
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Repositório Científico de Acesso Aberto de Portugal (Repositórios Cientìficos) - Agência para a Sociedade do Conhecimento (UMIC) - FCT - Sociedade da Informação |
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