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Conveying The Importance Of Manufacturing Process Design Using Simulation Results And Empirical Data

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2010 Annual Conference & Exposition


Louisville, Kentucky

Publication Date

June 20, 2010

Start Date

June 20, 2010

End Date

June 23, 2010



Conference Session

Critical Issues in IT and IET: Focus Group

Tagged Division

Engineering Technology

Page Count


Page Numbers

15.322.1 - 15.322.6



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Paper Authors


Michael Johnson Texas A&M University Orcid 16x16

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Johnson is an assistant professor in the Department of Engineering Technology and Industrial Distribution at Texas A&M University. Prior to joining the faculty at Texas A&M, he was a senior product development engineer at the 3M Corporate Research Laboratory in St. Paul, Minnesota for three years. He received his B.S. in mechanical engineering from Michigan State University and his S.M. and Ph.D. from the Massachusetts Institute of Technology. Johnson’s research focuses on design tools, specifically, the cost modeling and analysis of product development and manufacturing systems; CAD methodology; and engineering education.

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Ram Prasad Diwakaran Texas A&M University

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Diwakaran received his Bachelor of Engineering (Hons.) in Mechanical Engineering from Birla Institute of Technology and Science, Pilani, India in 2005. He is currently pursuing a MS in Mechanical Engineering from Texas A&M University.

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Justin Zsiros Texas A&M University

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Justin Zsiros is currently finishing his MS in Manufacturing Engineering Technology at Brigham Young University after completing an MBA from Texas A&M University (2009), and a BS in Manufacturing Engineering Technology from Brigham Young University (2007). His thesis research is in the area of natural fiber thermoplastic composites. He has taught plastics and composites labs for four years at Texas A&M and Brigham Young University.

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NOTE: The first page of text has been automatically extracted and included below in lieu of an abstract

Conveying the Importance of Manufacturing Process Design Using Simulation Results and Empirical Data Abstract

Manufacturing combines many aspects of engineering and technology. To achieve the desired results, manufacturing engineers must understand how component design, processing equipment design, and process parameters affect the final component. Currently, engineers have access to manufacturing simulation tools in addition to empirical tests. This allows engineers to test theories and do preliminary analyses of manufacturing processes (with simulation tools).

To understand how a process will perform and ensure the desired results usually requires empirical data. Injection molding is a widely used and easily understood process. There are simulation tools available for the injection molding that are accessible to undergraduate engineering and technology students. When simulations performed using these tools are combined with empirical results, students can better comprehend the usefulness and limitations of such tools.

This paper details a laboratory exercise which demonstrates to students how gate location affects the stress and strain properties of injection molded tensile test specimens. The effects of process parameters are also shown. Students are shown process simulations of injection molding using varying parameters and gate locations. They then injection mold tensile test specimens and test them. These results demonstrate the importance of process parameters (e.g., injection pressure, temperature, etc.) and gate location. Process parameters are shown to have a significant effect on the ability to produce an acceptable specimen. Gate location is also shown to affect stress-strain behavior.


Manufacturing is a multidisciplinary that leads to the realization of engineering designs. Students studying manufacturing engineering and manufacturing engineering technology will be expected to use unprecedented amounts of technology to assist in this realization as they enter the workforce. While manufacturing is just one part of a product development process that is becoming more and more important, it is a critical part that can lead to and affect significant investments. Conveying to students the role of technology (and its limitations) should be incorporated into manufacturing engineering and manufacturing engineering technology curricula.

There have been significant advances in computer simulation in recent years. Some have predicted that computer-aided engineering will eliminate the need for prototypes [1]. There are numerous simulation tools of varying rigor and complexity available for manufacturing simulation (e.g., Moldflow or PAM-STAMP). The complexity of building a reliable computer prediction has been noted; when empirical data is absent there is ignorance [2]. A necessary step of producing a reliable model is the comparison of the observed physical event with the prediction of the mathematical model; this is referred to as validation [2-3].

Johnson, M., & Prasad Diwakaran, R., & Zsiros, J. (2010, June), Conveying The Importance Of Manufacturing Process Design Using Simulation Results And Empirical Data Paper presented at 2010 Annual Conference & Exposition, Louisville, Kentucky. 10.18260/1-2--16255

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