Abstract:

There is a need to develop active techniques for the teaching of manufacturing processes in engineering studies. Virtual environments are particularly suitable for this purpose because of the advantages of visualization, self-interaction, and process analysis. Besides, the use of these technologies allows engineering students to be introduced into advanced manufacturing processes that are not learned outside of the industrial field, i.e., it is not possible to carry out all manufacturing processes in classroom in an experimental way. In this context, the application of reverse engineering, along with 3D reconstruction industrial techniques, is becoming a noticeable relevance in recent years. Thus, educational strategies must be focused on permitting students to acquire prior knowledge of those new methodologies being necessary to introduce them in the educational field.

In this work, the application of reverse engineering techniques and finite element simulation is proposed for the learning of injection molding processes. Usually, some specific concepts about mold design, process cycle, the influence of process variables on the final product quality cannot be studied in theoretical lessons or laboratory, due to the reasons previously pointed out, i.e., the difficulty of having the elements involved to promote an experimental analysis. Thus, an inductive learning methodology is proposed, and it consists of obtaining information about the injection molding process from a manufactured part with the objective of simulating, analyzing and understanding how the manufacturing process has been developed. First, a structured-light 3D scanner is used to virtualize the real selected product, obtaining an operative CAD model after scanned points are processed by image-analysis software. Then, a finite element simulation of the injection molding process is carried out, drawing conclusions about the influence of the most critical variables on the product quality and suggesting process improvements.

This methodology has been applied for the first time in a final project of the bachelor's degree in Mechanical Engineering at the High Technical School of Industrial Engineers of Albacete. The educational strategy has involved and inductive learning process in which the student has developed skills progressively facing to the scanning equipment and solving many difficulties found during this stage of the work. Similar considerations can be pointed to the use of simulation software and industrial process analysis. All this has supposed a deep learning process that can only be applied in the context of the bachelor thesis. Thus, a more targeted methodology based on this work will be implemented for a fourth-year course belonging to the bachelor degree in Mechanical Engineering in the near future.

Keywords:

Innovation, technology, reverse engineering, manufacturing.