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Computer-Aided Reengineering towards Plastic Part Failure Minimization

The work reported here intends to identify and mitigate the causes for failure in a plastic faucet holder, a part of an integral float faucet with a well-documented history of fracture occurrence. A methodology for the identification of hidden internal defects in plastic parts and the elaboration of...

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Detalles Bibliográficos
Autores principales: Pinho, Tiago, Zhiltsova, Tatiana, Oliveira, Mónica, Costa, Andreia
Formato: Online Artículo Texto
Lenguaje:English
Publicado: MDPI 2021
Materias:
Acceso en línea:https://www.ncbi.nlm.nih.gov/pmc/articles/PMC8585237/
https://www.ncbi.nlm.nih.gov/pubmed/34771830
http://dx.doi.org/10.3390/ma14216303
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author Pinho, Tiago
Zhiltsova, Tatiana
Oliveira, Mónica
Costa, Andreia
author_facet Pinho, Tiago
Zhiltsova, Tatiana
Oliveira, Mónica
Costa, Andreia
author_sort Pinho, Tiago
collection PubMed
description The work reported here intends to identify and mitigate the causes for failure in a plastic faucet holder, a part of an integral float faucet with a well-documented history of fracture occurrence. A methodology for the identification of hidden internal defects in plastic parts and the elaboration of the required corrective actions towards quality improvement is, therefore, presented. Firstly, part defects were identified via injection moulding process numerical simulation. The latter has enabled the prediction of an excessive volumetric shrinkage at the core of the faucet holder, highlighting the presence of internal voids and, hence, the possible deterioration of the load-bearing capacity. The supposition was later confirmed by X-ray topography scans. Part reengineering, consisting of localized thickness reduction, was the option chosen for decreasing the high shrinkage at the core. For validation purposes, structural analyses were carried out, with and without accounting for the injection moulding processing history. The results obtained during part structural analysis have enabled us to conclude that, when taking into account the residual stresses generated during injection moulding, the analysis more closely reflects the experimental data and allows us to implicitly envisage the propensity to fracture. Moreover, the part modifications, undertaken during the faucet holder reengineering, led to the reduction of the cumulative (processing and imposed by load) stresses by 50%, when compared to the original design analysed.
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spelling pubmed-85852372021-11-12 Computer-Aided Reengineering towards Plastic Part Failure Minimization Pinho, Tiago Zhiltsova, Tatiana Oliveira, Mónica Costa, Andreia Materials (Basel) Article The work reported here intends to identify and mitigate the causes for failure in a plastic faucet holder, a part of an integral float faucet with a well-documented history of fracture occurrence. A methodology for the identification of hidden internal defects in plastic parts and the elaboration of the required corrective actions towards quality improvement is, therefore, presented. Firstly, part defects were identified via injection moulding process numerical simulation. The latter has enabled the prediction of an excessive volumetric shrinkage at the core of the faucet holder, highlighting the presence of internal voids and, hence, the possible deterioration of the load-bearing capacity. The supposition was later confirmed by X-ray topography scans. Part reengineering, consisting of localized thickness reduction, was the option chosen for decreasing the high shrinkage at the core. For validation purposes, structural analyses were carried out, with and without accounting for the injection moulding processing history. The results obtained during part structural analysis have enabled us to conclude that, when taking into account the residual stresses generated during injection moulding, the analysis more closely reflects the experimental data and allows us to implicitly envisage the propensity to fracture. Moreover, the part modifications, undertaken during the faucet holder reengineering, led to the reduction of the cumulative (processing and imposed by load) stresses by 50%, when compared to the original design analysed. MDPI 2021-10-22 /pmc/articles/PMC8585237/ /pubmed/34771830 http://dx.doi.org/10.3390/ma14216303 Text en © 2021 by the authors. https://creativecommons.org/licenses/by/4.0/Licensee MDPI, Basel, Switzerland. This article is an open access article distributed under the terms and conditions of the Creative Commons Attribution (CC BY) license (https://creativecommons.org/licenses/by/4.0/).
spellingShingle Article
Pinho, Tiago
Zhiltsova, Tatiana
Oliveira, Mónica
Costa, Andreia
Computer-Aided Reengineering towards Plastic Part Failure Minimization
title Computer-Aided Reengineering towards Plastic Part Failure Minimization
title_full Computer-Aided Reengineering towards Plastic Part Failure Minimization
title_fullStr Computer-Aided Reengineering towards Plastic Part Failure Minimization
title_full_unstemmed Computer-Aided Reengineering towards Plastic Part Failure Minimization
title_short Computer-Aided Reengineering towards Plastic Part Failure Minimization
title_sort computer-aided reengineering towards plastic part failure minimization
topic Article
url https://www.ncbi.nlm.nih.gov/pmc/articles/PMC8585237/
https://www.ncbi.nlm.nih.gov/pubmed/34771830
http://dx.doi.org/10.3390/ma14216303
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