scholarly journals Processing parameters Optimization of Injection Moulding in DN20 Vent of Water Meter Manufacturing

2020 ◽  
Vol 184 ◽  
pp. 01008
Author(s):  
N. Sateesh ◽  
S. Devakar Reddy ◽  
Ram Subbiah ◽  
D. Siva Nagaraju ◽  
BCh Nookaraju
Keyword(s):  
Cycle Time ◽  
Injection Moulding ◽  
Processing Parameters ◽  
Volumetric Shrinkage ◽  
Shop Floor ◽  
Quality Prediction ◽  
Injection Time ◽  
Mould Temperature ◽  
Melt Temperature ◽  
Water Meter

The conventional optimization process in Injection Moulding includes actual shop floor trials in which melt temperature, mould temperature, injection time, injection pressure, pattern, feeder size, shape and location cores, mould layout, gating etc. are changed in each iteration which involves high machining cost, tooling cost, modification cost, melting cost, and transportation cost as well as, materials, energy, time are wasted in each trial until and unless the required results are obtained. Water meter component (DN20 Vent) is designed in CREO 5.0, and then components are 3D printed to cross check the dimensions and also to confirm whether all the other components can be accommodated or not. Then the mould flow analysis will be performed on a water meter components using different materials and changing the processing parameters. The input processing parameters considered are melt temperature, mould temperature and injection time, whereas the responses are warpage, volumetric shrinkage, cycle time and quality prediction. Grey relational analysis is carried out to determine the optimum injection moulding processing parameters.. The effort has been made to minimize the warpage, volumetric shrinkage, cycle time and maximize the quality prediction mould cavity and core for the components are designed in CREO 5.0 and manufactured using P20 tool steel. Then the water meter components are manufactured by inputting the optimal processing parameters in injection moulding machine to achieve high productivity and quality.

Effect of Injection Moulding Machine Parameters on the Warpage by Applying Taguchi Method

2014 ◽  
Vol 699 ◽  
pp. 20-25 ◽  
Author(s):  
Mohd Amran ◽  
Siti Salmah ◽  
Abdul Faiz ◽  
Raja Izamshah ◽  
Mohd Hadzley ◽  
...  
Keyword(s):  
Taguchi Method ◽  
Injection Moulding ◽  
Injection Time ◽  
Mould Temperature ◽  
Melt Temperature ◽  
Moulding Process ◽  
Optimum Parameters ◽  
Injection Moulding Process ◽  
The Difference ◽  
Packing Time

The application of Taguchi method to reduce warpage in an injection moulding process is studied. The objective of this paper is to analyze the effect of injection moulding parameters, i.e., injection time, packing time, melt temperature and mould temperature, on the warpage defect in dumbbell plastics part. Optical comparator horizontal type was used to measure the difference of warpage value on each part. L9 orthogonal array with 3 replications was done with 27 totals of specimens. The result collected was optimized using Taguchi method and percentage of contribution was calculated using analysis of variance (ANOVA). According to the analysis, it is found that the significant factors affected warpage are injection time (32.01%), packing time (29.73%), mould temperature (24.39%) and melt temperature (13.87%). The optimum parameters for minimizing the warpage were injection time (1s), packing time (5s), melt temperature (270 °C) and the mould temperature (21 °C). By using Taguchi method and ANOVA analysis, optimum parameters and the percentage of contribution of parameters can be obtained. Thus, it shows that design of experiment method is the good quality tools to get the best quality for production.

scholarly journals Multiobjective Optimization of Injection Moulding Process Parameters on Mechanical Properties Using Taguchi Method and Grey Relational Analysis

2018 ◽  
Vol 7 (3.7) ◽  
pp. 14 ◽  
Author(s):  
Mohd Amran Md Ali ◽  
Noorfa Idayu ◽  
Raja Izamshah ◽  
Mohd Shahir Kasim ◽  
Mohd Shukor Salleh ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Taguchi Method ◽  
Grey Relational Analysis ◽  
Injection Moulding ◽  
Cooling Time ◽  
Mould Temperature ◽  
Plastic Part ◽  
Melt Temperature ◽  
Relational Analysis ◽  
Grey Relational

This study presents an optimization of injection moulding parameters on mechanical properties of plastic part using Taguchi method and Grey Relational Analysis (GRA) approach. The orthogonal array with L9 was used as the experimental design. Grey relational analysis for ultimate tensile strength, modulus and percentage of elongation from the Taguchi method can convert optimization of the multiple performance characteristics into optimization of a single performance characteristic called the grey relational grade (GRG). It is found that mould temperature of 62oC, melt temperature of 280oC, injection time of 0.70s and cooling time 15.4s are found as the optimum process setting. Furthermore, ANOVA result shows that the cooling time is the most influenced factor that affects the mechanical properties of plastic part followed by mould temperature and melt temperature.  

Influence of Injection and Cavity Pressure on the Demoulding Force in Micro-Injection Moulding

2014 ◽  
Vol 136 (3) ◽  
Author(s):  
C. A. Griffiths ◽  
S. S. Dimov ◽  
S. G. Scholz ◽  
G. Tosello ◽  
A. Rees
Keyword(s):  
Experimental Study ◽  
Process Parameters ◽  
Design Of Experiment ◽  
Injection Moulding ◽  
Processing Conditions ◽  
Cavity Pressure ◽  
Mould Temperature ◽  
Melt Temperature ◽  
Injection Speed ◽  
Micro Injection Moulding

The paper reports an experimental study that investigates part demoulding behavior in micro-injection moulding with a focus on the effects of pressure and temperature on the demoulding forces. In particular, the demoulding performance of a representative microfluidics part was studied as a function of four process parameters, melt temperature, mould temperature, holding pressure, and injection speed, employing the design of experiment approach. In addition, the results obtained using different combinations of process parameters were analyzed to identify the best processing conditions in regards to demoulding behavior of microparts when utilizing a COC polymer to mould them.

An empirical study of gas penetration in full-shot gas-assisted injection moulded parts

2002 ◽  
Vol 216 (12) ◽  
pp. 1549-1559 ◽  
Author(s):  
S-J Liu ◽  
K-H Chang
Keyword(s):  
Injection Moulding ◽  
Bending Strength ◽  
Hold Time ◽  
Gas Injection ◽  
Processing Parameters ◽  
Melt Temperature ◽  
Relative Significance ◽  
Short Shot ◽  
Gas Penetration ◽  
Sink Mark

Full-shot gas-assisted injection moulding has increasingly become one of the most important methods used to produce plastic components. It has the advantage of eliminating the switchover mark, which usually occurs on the surface of short-shot gas-assisted injection moulded parts. This paper is devoted to an investigation of the effects of different processing parameters on the length of gas penetration in full-shot gas-assisted injection moulded parts. The first part of this report shows how the gas penetration of moulded parts is optimized. An L'18 experimental matrix design based on the Taguchi method was conducted to investigate the processing factors that affect the length of gas penetration in full-shot moulded parts. The second part of this paper identifies the relative significance of each processing parameter on the gas penetration of moulded products. The materials used were general-purpose polystyrene and polypropylene. Experiments were carried out on an 80 ton injection-moulding machine equipped with a high-pressure nitrogen gas injection unit. For the factors selected in the main experiments, melt temperature, gas injection delay time and gas hold time were found to be the key processing parameters affecting the length of gas penetration in full-shot gas-assisted injection moulded parts. In addition, the sink mark of full-shot moulded parts decreases with the length of gas penetration. Bending strength of full-shot gas-assisted injection moulded parts is higher than that of short-shot moulded parts.

Simulation of Micro-Gear Manufactured by Differential Injection Molding Based on Moldex 3D

2012 ◽  
Vol 501 ◽  
pp. 269-273
Author(s):  
Peng Cheng Xie ◽  
Li Lei Miao ◽  
Pan Pan Zhang ◽  
Wei Min Yang
Keyword(s):  
Mold Temperature ◽  
Processing Parameters ◽  
Simulation Software ◽  
Injection System ◽  
Mechanical Transmission ◽  
Injection Time ◽  
Melt Temperature ◽  
The Core ◽  
Packing Time ◽  
Core Part

In this article, the structure of the differential pump is introduced, which is the core part of the differential injection system. The micro-gear with a shaft collar is simulated as it is an important micro-part and has great potential application in mechanical transmission. The Moldex 3D simulation software is used to investigate effects of processing parameters on the micro-gear such as melt temperature, mold temperature, injection time and packing time etc. By comparing the micro-gear's warpage under different processing parameters, it can be concluded that melt temperature has a greater impact on the molding quality than mold temperature. In addition, the effects of injection time and packing time on the micro-gear's molding quality are also investigated.

Warpage Analysis of Different Number Cooling Channels for Dumbbell Plastic Part in Injection Moulding

2015 ◽  
Vol 761 ◽  
pp. 8-11 ◽  
Author(s):  
Mohd Amran ◽  
Siti Salmah ◽  
Raja Izamshah ◽  
Mohd Shahir ◽  
Mohd Amri ◽  
...  
Keyword(s):  
Injection Moulding ◽  
Simulation Analysis ◽  
Cooling System ◽  
Cooling Channel ◽  
Mould Temperature ◽  
Plastic Part ◽  
Melt Temperature ◽  
Moulding Process ◽  
Cooling Channels ◽  
Injection Moulding Process

Warpage deflection is one of the common pitfalls in plastic injection moulding which is always affected the quality and accuracy of the plastic products. It occurs due to the influences of mould temperature during injection moulding process and it is related to the number of cooling system existed in the mould. Therefore, this paper studies the effect of cooling channels on warpage of dumbbell plastic part having different number of cooling channel using Moldflow software. Warpage analysis was run using four and eight cooling channels. Parameters involved in this study are injection time, packing time, melt temperature and mould temperature. The result of warpage from simulation analysis was projected on the graphic having different colour which is presented the actual value of warpage. It is found from warpage simulation result that the maximum warpage for four cooling channels is 1.283mm and the maximum warpage for eight cooling channels is 1.280mm. It shows that the increasing of the number of cooling channel from four to eight channels in the injection mould reduces the warpage deflection about 0.2%. Thus, the result shows that the number of cooling system in the mould plays an important role on the quality of plastic part during injection moulding process.

Process Factor Optimization for Reducing Warpage and Shrinkage in Injection Molding Using Design of Experiments

2014 ◽  
Vol 541-542 ◽  
pp. 359-362 ◽  
Author(s):  
Gyung Ju Kang
Keyword(s):  
Injection Molding ◽  
Design Of Experiments ◽  
Optimization Method ◽  
Processing Parameters ◽  
Cooling Time ◽  
Volumetric Shrinkage ◽  
Injection Time ◽  
Taguchi Optimization ◽  
Process Factor ◽  
Packing Pressure

This Paper Presents the Optimization of Injection Molding Conditions to Minimize the Warpage and Volumetric Shrinkage Using Design of Experiments and Taguchi Optimization Method. Considering the Process Parameters such as Injection Time, Packing Pressure, Packing Pressure Time, and Cooling Time, a Series of Mold Analysis are Performed. Orthogonal Arrays of Taguchi, the Signal-to-Noise(S/N) and Analysis of Variance (ANOVA) are Utilized to Determine the Optimization Parameter Levels and to Find out Principal Processing Parameters on Warpage and Volumetric Shrinkage. from the Results it is Clear that Warpage and Volumetric Shrinkage are Reduced. also, the Dominant Parameters were Cooling Time and Packing Time for Warpage, on the other Hand, the most Important Factor for Shrinkage was Injection Time. from this, it can be Concluded that Taguchi Method is very Suitable to Solve the Warpage and Volumetric Shrinkage Problems in Injection Molding Parts.

Shrinkage and Warpage in the Permanent Shape of Sape-Memory Polyurethane Parts

2022 ◽  
Vol 58 (4) ◽  
pp. 102-113
Author(s):  
Sukran Katmer ◽  
Cetin Karatas
Keyword(s):  
Shape Memory ◽  
Injection Moulding ◽  
Flow Direction ◽  
Injection Pressure ◽  
Cooling Time ◽  
Mould Temperature ◽  
Melt Temperature ◽  
Packing Pressure ◽  
Permanent Shape ◽  
Packing Time

The shape memory effect, as the most important ability of shape memory polymers, is a working property and provides the design ability to shape memory polymer features. Shrinkage and warpage are important parameters to control the dimensional accuracy of permanent and temporary shapes of an injection moulded shape memory polyurethane (SMPU) part. In this study, the effects of injection moulding parameters on the shrinkage and warpage of the permanent shape of moulded SMPU parts were experimentally investigated. The parameters of injection pressure, melt temperature, mould temperature, packing pressure, packing time, and cooling time, were chosen as the injection moulding control factors. Taguchi�s L27 orthogonal array design table was used with six injection moulding parameters and their three levels. The results showed that the part has different shrinkage ratios in three main directions, namely, the flow direction, perpendicular to the flow direction, and the direction through the thickness. The results of the analysis of variance showed that the cooling time is the most influential parameter on both the shrinkage (except in thickness) and warpage. The shrinkage in the flow direction as well as in perpendicular to the flow direction decreased with increasing the cooling time. Warpage also decreased with increasing the cooling time. Injection pressure and melt temperature were found to be effective on shrinkage in thickness. Effects of mould temperature, packing pressure, and packing time were found to be limited. A statistically significant relationship has been noticed among shrinkage, warpage, and residual stresses during the study.

Analysis of Volumetric Shrinkage and Optimization of Process Parameters in Injection Molding

2012 ◽  
Vol 217-219 ◽  
pp. 2065-2069 ◽  
Author(s):  
Ji Ping Chen ◽  
Zhi Ping Ding
Keyword(s):  
Injection Molding ◽  
Regression Model ◽  
Linear Regression Analysis ◽  
Multiple Linear Regression Analysis ◽  
Processing Parameters ◽  
Volumetric Shrinkage ◽  
Plastic Part ◽  
Melt Temperature ◽  
Optimization Of Process Parameters ◽  
Design Variables

Based on experimental method of factorial design, numerical simulation of injection molding using Moldflow software has been done. The effects of the gate number-distribution, melt temperature, packing pressure, packing time, injection time, etc. on volumetric shrinkage and the two-way interactions among factors in injection molding of plastic part have been researched. The regression model for volumetric shrinkage of plastic part has been obtained through multiple linear regression analysis of the experimental data. The optimization model has been established to optimize processing parameters setting leading factors which effect volumetric shrinkage as design variables and regression model of volumetric shrinkage as objective function. The volumetric shrinkage value of plastic part is less than the minimum volumetric shrinkage value of the main experiment, which indicates that the method has a good practical value in engineering.

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