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The
The 12th
12th International
International Conference
Conference Interdisciplinarity
Interdisciplinarity in
in Engineering
Engineering

Injection
Injection process
process design
design
for
for manufacturing of bicycle plastic bottle holder
manufacturing
Manufacturing of
Engineering bicycle
Society plastic
International bottle holder
Conference using CAx
using2017,
2017, MESIC CAx tools
tools
28-30 June
2017, Vigo (Pontevedra), Spain
Ile Mircheskia,a, *,
Ile Mircheski *, Andrzej
Andrzej Łukaszewicz
b
Łukaszewiczb,, Ryszard
Ryszard Szczebiot
c
Szczebiotc
Costing models Ssfor
Cyrilcapacity optimization in Industry
of Macedonia 4.0: Trade-off
0F

0F

a
and Methodius University
a in Skopje, Skopje, Republic
Ss Cyril and Methodius University in Skopje, Skopje, Republic of Macedonia
between used Lomza capacity
Bialystok University of and operational
Białystok, Poland efficiency
b
Bialystok University of Technology, Białystok, Poland
b
c Technology,
State University of Applied Sciences,
c Łomża, Poland
Lomza State University of Applied Sciences, Łomża, Poland

A. Santanaa, P. Afonsoa,*, A. Zaninb, R. Wernkeb

Abstract a
University of Minho, 4800-058 Guimarães, Portugal
Abstract b
Unochapecó, 89809-000 Chapecó, SC, Brazil
The purpose of the paper is to present the design of new bicycle plastic bottle holder and injection process simulation. The model
The purpose of the paper is to present the design of new bicycle plastic bottle holder and injection process simulation. The model
of plastic bottle holder was designed and simulated to determine injection parameters in SolidWorks environment. Based on main
of plastic bottle holder was designed and simulated to determine injection parameters in SolidWorks environment. Based on main
part’s 3D m0del the mold tool was created. From the virtual testing the most suitable injection point location, material
part’s 3D m0del the mold tool was created. From the virtual testing the most suitable injection point location, material
Abstract
temperature as well as fill time and required injection pressure have been specified.
temperature as well as fill time and required injection pressure have been specified.
Under
© 2018 the concept Published
The Authors. of "Industry 4.0", Ltd.
by Elsevier production processes will be pushed to be increasingly interconnected,
© 2019
2018 The Authors. Published by Elsevier Ltd.
information
This is an openbased
accessonarticle
a realunder
timethebasis and, necessarily,
BY-NC-ND
CC BY-NC-ND licensemuch
license more efficient. In this context, capacity optimization
(https://creativecommons.org/licenses/by-nc-nd/4.0/)
(https://creativecommons.org/licenses/by-nc-nd/4.0/)
This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0/)
Selection
goes and peer-review
beyond under
the traditional aimresponsibility
of capacityof the 12th International
maximization, Conference
contributing Interdisciplinarity
also for organization’sinprofitability
Engineering.and value.
Selection and peer-review under responsibility of the 12th International Conference Interdisciplinarity in Engineering.
Indeed, lean management and continuous improvement approaches suggest capacity optimization instead of
Keywords: injection
maximization. molding;
The studyCAx; SolidWorks;
of capacity bottle holder and costing models is an important research topic that deserves
optimization
Keywords: injection molding; CAx; SolidWorks; bottle holder
contributions from both the practical and theoretical perspectives. This paper presents and discusses a mathematical
model for capacity management based on different costing models (ABC and TDABC). A generic model has been
1. Introduction
1. Introduction
developed and it was used to analyze idle capacity and to design strategies towards the maximization of organization’s
value. The trade-off capacity maximization vs operational efficiency is highlighted and it is shown that capacity
The injection molding process is the most widely used manufacturing process for plastic parts. The process is so
The injection
optimization might molding process is inefficiency.
hide operational the most widely used manufacturing process for plastic parts. The process is so
versatile, that it canPublished
be used to produce small electronic and medical parts and large-volume automotive or building
©versatile,
2017 Thethat it can be used by
Authors. to produce small electronic and medical parts and large-volume automotive or building
Elsevier B.V.
components.
Peer-review [1].
under The technology of the tool and dieoffabrication in plastic injection is one of the world’s fastest
components. [1].responsibility
The technology of the of
scientific
the toolcommittee the Manufacturing
and die fabrication Engineering
in plastic Society
injection is oneInternational Conference
of the world’s fastest
growing industries [2, 3].
2017.
growing industries [2, 3].
CAx (CAD/CAM/CAE) tools are widely used in mechanical engineering field [4-8]. The main advantage of using
CAx (CAD/CAM/CAE) tools are widely used in mechanical engineering field [4-8]. The main advantage of using
CAx systems
Keywords: is a shortening
Cost Models; ABC; TDABC;of the product’s
Capacity time development.
Management; The ability
Idle Capacity; Operational to perform many types of CAE analyses
Efficiency
CAx systems is a shortening of the product’s time development. The ability to perform many types of CAE analyses

1. Introduction
* Corresponding author. Tel.: +38970271185
* The
Corresponding
cost author.
of idle Tel.: +38970271185
capacity is a fundamental information for companies and their management of extreme importance
E-mail address: ile.mircheski@mf.edu.mk
E-mail address: ile.mircheski@mf.edu.mk
in modern production systems. In general, it is defined as unused capacity or production potential and can be measured
in several©ways:
2351-9789 tons
2018 The of production,
Authors. available
Published by Elsevier Ltd.hours of manufacturing, etc. The management of the idle capacity
2351-9789 © 2018 The Authors. Published by Elsevier Ltd.
This is anAfonso.
* Paulo open access
Tel.:article under
+351 253 510the761;
CC BY-NC-ND
+351 253license (https://creativecommons.org/licenses/by-nc-nd/4.0/)
This is an open access article under the CC fax:
BY-NC-ND 604 741
license (https://creativecommons.org/licenses/by-nc-nd/4.0/)
Selection
E-mail and peer-review
address: under responsibility of the 12th International Conference Interdisciplinarity in Engineering.
psafonso@dps.uminho.pt
Selection and peer-review under responsibility of the 12th International Conference Interdisciplinarity in Engineering.

2351-9789 © 2017 The Authors. Published by Elsevier B.V.

Peer-review
2351-9789 © under
2019responsibility
The Authors. of the scientificbycommittee
Published Elsevier of the Manufacturing Engineering Society International Conference 2017.
Ltd.
This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0/)
Selection and peer-review under responsibility of the 12th International Conference Interdisciplinarity in Engineering.
10.1016/j.promfg.2019.02.184
 Ile Mircheski et al. / Procedia Manufacturing 32 (2019) 68–73 69
2 Mircheski I., Łukaszewicz A., Szczebiot R. / Procedia Manufacturing 00 (2018) 000–000

[9-15], visualization and technical documentation in the design phase allows you to better fit the assumptions.
Development of modern manufacturing techniques (e.g., CNC, Rapid Prototyping (RP), Reverse Engineering
(RE)) requires use of CAx. The applications of CAx systems used in manufacturing and CNC field are outlined in
many papers [16-18]. The RE methods can be used to accurately reproduce free-form shapes using contact [19] and
non-contact [20] measurement techniques.
Nowadays mold modelling required a complex CAx environment with simulation of the injection process [21].
These systems allow predicting of anomalous in early stage of the plastic part design and their elimination [22].
The objective of this paper is to present the design of bicycle plastic bottle holder and testing, using CAE module,
of the injection molding for obtain proper process’ parameters and at the end a plastic part without manufacturing
defects

2. Design of bicycle plastic bottle holder

These kinds of products are available at the market in many designs and colours (Fig. 1). Consumption of the
bicycles grows by reason to decrease travelling charges and encourage healthy lifestyle. The bicycle comes with a
plastic bottle holder as embedded at the bike and most bikes come without them. Therefore, it is imperative to buy
this kind of product as accessory of the bike which will be to fasten a plastic bottle and will perform its function
properly.

Fig. 1. The bicycle plastic bottle holders at the market

According to the above-mentioned designs, a new design of the bicycle plastic bottle holder was created with a
modular cage construction which allows either right-hand or left-hand bottle insertion. In Fig. 2 is shown new
concept in various 3D views and terms of use which is based on the design style naturalism. The 3D solid model of
bicycle plastic bottle holder was created in parametric 3D MCAD (Mechanical CAD) modeller – SolidWorks [23,
24]. Into design are incorporated the social, economic and technological factors [25].
70 Ile Mircheski
Mircheski I., Łukaszewicz et al. / Procedia
A., Szczebiot Manufacturing
R. / Procedia 32 (2019)
Manufacturing 68–73
00 (2018) 000–000 3

Fig. 2. The different 3D views and terms of use of a new design of bicycle plastic bottle holder modelling in SolidWorks

3. Mold Design

The designing of injection molding tool is based on interactive analyses of all design parameters and
manufacturing process needed to define complex shape of mold’s core and cavity. Multibody techniques [26] and
special mold features were used in 3D modelling. Fig. 3 shows mold tool consisting of four parts.

Fig. 3. The injection mold core and cavity

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4 Mircheski I., Łukaszewicz A., Szczebiot R. / Procedia Manufacturing 00 (2018) 000–000

4. Virtual testing of the injection process

Before starting the virtual testing of the injection process the material was selected from SolidWorks database.
The bicycle plastic bottle holder is made from polycarbonate. Fig. 4 shows the 3D solid model with gate location
placing on the model. The red colour cone shape shows the injection location in this analysis. Fill time (Fig. 5) is
time taken to fill up the part inside the cavity and it is 3,65 sec. The injection maximum pressure (Fig. 6) at the end
of fill for hold the closed mold parts is 70,41 MPa (red colour). The maximum temperature at the end of filling
process is 324,4˚C (Fig. 7). Next the ait traps (Fig. 8) and weld lines (Fig. 9) were presented.

Gate location

Fig.4. Solid model with gate location Fig.5. Fill time of plastic part

Fig.6. The maximum pressure Fig.7. The maximum temperature

72 Ile Mircheski et al. / Procedia Manufacturing 32 (2019) 68–73
Mircheski I., Łukaszewicz A., Szczebiot R. / Procedia Manufacturing 00 (2018) 000–000 5

Fig.8. The air traps Fig.9. The weld lines

5. Conclusion

In this paper a new design of bicycle plastic bottle holder and simulation of some manufacturing aspects was
developed. The solid model of plastic bottle holder was created in parametric 3D MCAD modeller SolidWorks using
advanced techniques. Virtual testing of injection process using SolidWorks Plastic provides sufficient information
results such as: fill time, injection maximum pressure and temperature at the end of filling. With these results the
designers can avoid the anomalies or defects, in real plastic things with actual injection’s process parameters, like:
air traps, weld lines and sink mark.
Such analyses allow the designer to develop a proper mold 3D model, to save the mold setup time as well as to
reduce cost for manufacturing of mold.

Acknowledgements

The paper was performed within a framework of S/WM/1/2018 realised in the Bialystok University of
Technology and financed with funds from the Ministry of Science and Higher Education.

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