Subject Description Form
Subject Code
ISE419
Subject Title
Advanced Mould and Die Design
Credit Value
3
Level
4
Pre-requisite
ISE202 Fundamentals of Manufacturing Processes or ISE301 Process Selection
and Design or ISE306 Tool Design or ISE3006 Materials and Processes
Selection or ISE325 Materials Processing Technologies
Objectives
This subject provides students with:
Intended Learning
Outcomes
Subject Synopsis/
Indicative Syllabus
1.
in-depth knowledge of the design and manufacture of complex moulds
and dies for plastics and metal engineering components;
2.
skills in assessing the related performance of tooling and processes;
3.
the ability to evaluate the effects of tooling design on the quality of
finished products.
Upon completion of the subject, students will be able to:
a.
apply contemporary design principles when designing advanced moulds
and dies;
b.
assess the performance of a given tool design based on the design criteria;
c.
evaluate the effects of a given tool design on the quality of the work.
1.
Review of Basic Tooling Design Principles
Consideration of advanced mould and tool design criteria; selection of
mould and die materials; heat treatment and its effects on tool design.
2.
Net Shape Forming Dies
Die construction for fine-blanking and precision progressive tool, etc.,
special design criteria: production practicability and limitations, shear
behaviour, die clearance.
3.
Die Casting Moulds
Cold and hot chamber die-casting; types of die construction; metal flow
rate and pressure; cavity filling; runner and gate; overflow; venting;
thermal design and analysis.
4.
Injection Moulds
Precision mould construction; melt flow analysis; moulding ejection;
18.3.2014
cooling and warpage; design for advanced plastics processing.
Teaching/Learning
Methodology
The subject is taught through a combination of lectures and tutorials integrated
with practical design mini-projects. The lectures provide students with in-depth
knowledge of contemporary mould and die practices. Laboratory work and
tutorial exercises provide students with opportunities to learn and apply the
teaching materials. Typical mould and die designs are demonstrated and
examined to help students to become familiar with real-life practices.
Assessment Methods
in Alignment with
Intended Learning
Outcomes
Specific assessment
methods/tasks
%
Intended subject learning outcomes to
weighting be assessed
a
b
1. Assignments
20%


2. Tests
40%


3. Mini-group projects
40%


Total
100%
c

The assignments, which are given throughout the course, are designed to
facilitate students to reflect on and apply the in-depth knowledge learnt.
The tests are designed to enable students to demonstrate their learning ability
and comprehension.
Continuous assessment comprises all laboratories, tutorials, assignments,
progress tests, and mini-group projects with presentations and written reports.
All assessment components require students to apply what they have learnt and
show their ability to apply different technologies.
Student Study
Effort Expected
Class contact:

Lectures
27 Hrs.

Tutorials, tests, laboratory work, and miniprojects
12 Hrs.
Other student study effort:

Assignments
20 Hrs.

Test preparation, mini-group projects
(including presentation and report writing)
58 Hrs.
Total student study effort
Reading List and
References
18.3.2014
1.
117 Hrs.
Donaldson, C, LeCain, GH & Goold, VC, Tool Design, latest edition,
McGraw-Hill, New York
18.3.2014
2.
Spitler, D, Lantrip, J, Nee, J & Smith, DA, Fundamentals of Tool Design,
latest edition, Society of Manufacturing Engineers, Dearborn
3.
Eary, DF & Reed, EA, Techniques of Pressworking Sheet Metal, latest
edition, Prentice-Hal, Englewood Cliffs, New Jersey
4.
Menning, G & Stoeckhert, K, Mold-making Handbook: for the Plastics
Engineer, latest edition, Hanser Gardner Publications, Cincinnati
5.
Pye, RGW, Injection Mould Design, latest edition, Affiliated East-west
Press Pvt Ltd, New Delhi
6.
Manzione, LT (ed.), Application of CAE in Injection Moulding, latest
edition, Hanser Gardner Publications, Cincinnati
7.
Gastrow, H, Injection Molds: 108 Proven Designs, latest edition, Hanser
Gardner Publications, Cincinnati
8.
Street, AC (ed.), The Diecasting Book, latest edition, Portcullis Press,
Redhill, Surrey