Developing a hybrid expert system program to aid in the design of plastic injection molding process

Experts in injection molding often refer to previous solutions to find a mold design similar to the current mold and use previous successful molding process parameters with intuitive adjustment and modification as a start for the new molding application. This approach saves a substantial amount of time and cost in experimental based corrective actions which are required in order to reach optimum molding conditions. A Case-Based Reasoning (CBR) System can perform the same task by retrieving a similar case which is applied to the new case from the case library and uses the modification rules to adapt a solution to the new case. Therefore, a CBR System can simulate human e~pertise in injection molding process design. This research is aimed at developing an interactive Hybrid Expert System to reduce expert dependency needed on the production floor. The Hybrid Expert System (HES) is comprised of CBR, flow analysis, post-processor and trouble shooting systems. The HES can provide the first set of operating parameters in order to achieve moldability condition and producing moldings free of stress cracks and warpage. In this work C++ programming language is used to implement the expert system. The Case-Based Reasoning sub-system is constructed to derive the optimum magnitude of process parameters in the cavity. Toward this end the Flow Analysis sub-system is employed to calculate the pressure drop and temperature difference in the feed system to determine the required magnitude of parameters at the nozzle. The Post-Processor is implemented to convert the molding parameters to machine setting parameters. The parameters designed by HES are implemented using the injection molding machine. In the presence of any molding defect, a trouble shooting subsystem can determine which combination of process parameters must be changed iii during the process to deal with possible variations. Constraints in relation to the application of this HES are as follows. - flow length (L) constraint: 40 mm < L < I 00 mm, - flow thickness (Th) constraint: -flow type: - material types: I mm < Th < 4 mm, unidirectional flow, High Impact Polystyrene (HIPS) and Acrylic. In order to test the HES, experiments were conducted and satisfactory results were obtained.

Numerical modelling of industrial microwave heating

The numerical modelling of electromagnetic waves has been the focus of many research areas in the past. Some specific applications of electromagnetic wave scattering are in the fields of Microwave Heating and Radar Communication Systems. The equations that govern the fundamental behaviour of electromagnetic wave propagation in waveguides and cavities are the Maxwell's equations. In the literature, a number of methods have been employed to solve these equations. Of these methods, the classical Finite-Difference Time-Domain scheme, which uses a staggered time and space discretisation, is the most well known and widely used. However, it is complicated to implement this method on an irregular computational domain using an unstructured mesh. In this work, a coupled method is introduced for the solution of Maxwell's equations. It is proposed that the free-space component of the solution is computed in the time domain, whilst the load is resolved using the frequency dependent electric field Helmholtz equation. This methodology results in a timefrequency domain hybrid scheme. For the Helmholtz equation, boundary conditions are generated from the time dependent free-space solutions. The boundary information is mapped into the frequency domain using the Discrete Fourier Transform. The solution for the electric field components is obtained by solving a sparse-complex system of linear equations. The hybrid method has been tested for both waveguide and cavity configurations. Numerical tests performed on waveguides and cavities for inhomogeneous lossy materials highlight the accuracy and computational efficiency of the newly proposed hybrid computational electromagnetic strategy.