An example of simulation tools use for large injection moulds design: The CONTENUR™ 2400 l solid waste container

Large containers with volumes above 1100 l are usually produced using procedures such as rotomoulding process. These techniques have no part weight or dimensional limits. T.I.I.P., injection moulding plastic group of the Department of Mechanical Engineering of the Zaragoza University, developed with CONTENUR™ a new product under European norms for solid waste containers up to 2000 l volume; the result was a new main body up to 60 kg weight in one part. The design process combined several CAE tools (aesthetical design, mechanical design and rheological simulation) and, in last June, showed final result and passed different tests. Nowadays, more than 5000 samples are on the streets without basic modifications in the mould (more than 100 tonnes weight). The paper focuses on the methodology used to integrate tool and process design with product definition (i.e. injection pressure and clamp force versus thickness and part shape). Some parameters about process control in this particular mould (injection rate, temperature, viscosity, gate location, …) are detailed.