Improving the Efficiency of the Bowden Cable Terminal Injection Process for the Automotive Industry

Control cables transfer force between two separate locations by a flexible mean, and hence, they are important in the automotive industry and many others; their terminals interact with both moving and moved mechanisms, so they must be strong. Cable terminals are commonly made of ZAMAK and are create...

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Bibliographic Details
Published in:Processes 2022-10, Vol.10 (10), p.1953
Main Authors: Pereira, José L. T. A., Campilho, Raul D. S. G., Silva, Francisco J. G., Sánchez-Arce, Isidro J., Prakash, Chander, Buddhi, Dharam
Format: Article
Language:English
Subjects:
Automobile industry
Brainstorming
Cables
Casting
Ceramics industry
Cost analysis
Die casting
Equipment costs
Finite element method
Geometry
Injection molding
Mathematical models
Mechanical properties
Porosity
Process controls
Production lines
Production methods
Production processes
Software
Solidification
Sprue
SWOT analysis
Terminals
Transportation equipment industry
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Summary:Control cables transfer force between two separate locations by a flexible mean, and hence, they are important in the automotive industry and many others; their terminals interact with both moving and moved mechanisms, so they must be strong. Cable terminals are commonly made of ZAMAK and are created by injection molding. However, such a production method requires leaving extra material to allow the correct molding, also known as sprues, which are removed later in the process. In this case, the sprues were separating from the terminals in an uncontrolled way. In this work, the cause of sprues separating prematurely from the terminals in a production line is addressed. The whole process was analyzed, and each possible solution was evaluated using process improvement techniques and the Finite Element Method, leading to the best solutions. Molds, mold structures, and auxiliary equipment were improved, resulting in a minimally invasive intervention and remaining compatible with other equipment. Cost analyses were done, indicating an investment return in less than a year. The modification led to a reduction of 62.6% in the sprue mass, while porosity was reduced by 10.2% and 55.9%, corresponding to two terminal models. In conclusion, the interventions fulfilled the requirements and improved the operation of the line.
ISSN:2227-9717
2227-9717
DOI:10.3390/pr10101953