scholarly journals Multiple Responses Injection Moulding Parameter Optimisation Via Taguchi Method for Polypropylene-Nanoclay-Gigantochloa

2021 ◽  
Vol 2129 (1) ◽  
pp. 012055
Author(s):  
M S Rosli ◽  
M H Othman ◽  
Sri Yulis M Amin ◽  
M A I Azman
Keyword(s):  
Injection Moulding ◽  
Processing Condition ◽  
Natural Fibre ◽  
Flow Index ◽  
Multiple Responses ◽  
Melt Temperature ◽  
Packing Pressure ◽  
Major Interest ◽  
Injection Moulding Process ◽  
Filling Time

Abstract Recently, the reinforcement of natural fibres into the polymer has been the main topic due to ecological which can sustain the life of our earth. Natural plant fibre composite has advantages in production in manufacturing product due to biodegradability and environmental protection. The injection moulding process is a major interest within the field of manufacturing technology because of the issue of archive the good quality of the product while minimizing the defect of the product that has been produced. Therefore, this research purpose describes the effects of gigantochloa scortechinii (natural fibre) mix with the polypropylene-nanoclay by using multiple objective optimisations for instance Taguchi Orthogonal Array method for injection moulding processing condition towards multiple responses such as melt flow index, flexural strength, warpage, and shrinkage. The compounding material used in this research is polypropylene, nanoclay, the compatibilizer which is polypropylene graft maleic anhydride (PP-g-MA), and gigantochloa scortechinii which known as bamboo fibre. For comparison purpose, the contents of natural fibre selected are 0wt.%, 3wt.% and 6wt.% towards the processing condition which are packing pressure, melt temperature, screw speed and filling time. Based on the signal to noise ratio analysis results, the highest value of S/NQP is at 6wt.% which is 160.6451 dBi followed by 3wt.% (158.1919 dBi) and 0wt.% (134.8150 dBi). Furthermore, the most influential parameter changed with the existence of Gigantochloa Scortechinii from melt temperature into packing pressure. In conclusion, the optimum values for multiple responses have been affected by the present of Gigantochloa Scortechinii.

Optimum Injection Moulding Processing Condition to Reduce Shrinkage and Warpage for Polypropylene-Nanoclay-Bamboo Fibre with Compatibilizer

2017 ◽  
Vol 889 ◽  
pp. 51-55 ◽  
Author(s):  
M.H. Othman ◽  
Sulaiman Hasan ◽  
Mohd Halim Irwan Ibrahim ◽  
Siti Zubaidah Khamis
Keyword(s):  
Injection Moulding ◽  
Processing Condition ◽  
Screw Speed ◽  
Melt Temperature ◽  
Moulding Process ◽  
Bamboo Fibre ◽  
Packing Pressure ◽  
Injection Moulding Process ◽  
Filling Time

The purpose of this research is to optimise the processing condition of injection moulding towards samples made from polypropylene-nanoclay-bamboo fibre with compatibilizer. The defects that have been controlled upon the optimisation were shrinkage and warpage. The selection of injection moulding processing condition was packing pressure, melt temperature, screw speed and filling time. The research started by drying the bamboo fibres at 120°C. Then, the 1 wt. % fibres were mixed with 79 wt. % of polypropylene, 15 wt. % of compatibilizer and 5 wt. % of nanoclay. The mixing process was performed by using Brabender Plastograph machine. After that, pallets were produced by using Plastic Granulator machine for injection moulding process. The optimisation process was accomplished by adopting the Taguchi method. According to the results, the value of warpage defect between compounding for 1 wt. % fibre and without fibre content was not significant. However the optimum setting of 170°C melt temperature, 35% packing pressure, 30% screw speed and 2 seconds filling time can significantly reduce shrinkage. In conclusion, the optimum processing condition of polypropylene-nanoclay, fibre bamboo had been achieved, and the existence of fibre obviously giving a promising manufacturing opportunity to improve the quality of the injected moulding products.

Investigating the Effects of Injection Moulding Process Parameters on Multiple Tensile Characteristics of Plastic Spur Gear via Experimental Approach

2013 ◽  
Vol 748 ◽  
pp. 544-548 ◽  
Author(s):  
Nik Mizamzul Mehat ◽  
Shahrul Kamaruddin ◽  
Abdul Rahim Othman
Keyword(s):  
Process Parameters ◽  
Injection Moulding ◽  
Experimental Approach ◽  
Low Cost ◽  
Spur Gear ◽  
Melt Temperature ◽  
Moulding Process ◽  
Packing Pressure ◽  
Injection Moulding Process ◽  
State Of Tension

This paper presents the original development of an experimental approach in studying the multiple tensile characterizations as key quality characteristics for several different plastic gear materials related to various parameters in injection moulding process. In this study, emphases are given on a new low-cost mechanism for the testing of the injection moulded plastic spur gear specimens with various teeth module. The testing fixture are developed and validated to provide uniform state of tension with series of plastic gear specimens produced in accordance with the systematically designed of experiment. The effects of changes in the process parameters including melt temperature, packing pressure, packing time and cooling time at three different levels on the elongation at break and ultimate strength of plastic gear is evaluated and studied through the proposed experimental approach.

A Study of Injection Moulding Optimum Parameters to Control Shrinkage and Warpage of Polypropylene-Nanoclay Hinges Samples

2013 ◽  
Vol 465-466 ◽  
pp. 1011-1015 ◽  
Author(s):  
Wan Nur Azrina Wan Muhammad ◽  
Mohd Hilmi Othman ◽  
Sulaiman Hasan ◽  
Muhammad Faiz Ruslee
Keyword(s):  
Mass Production ◽  
Injection Moulding ◽  
Complex Geometry ◽  
Signal To Noise Ratio ◽  
Parameter Setting ◽  
Melt Temperature ◽  
Optimum Parameters ◽  
Packing Pressure ◽  
Filling Time

Injection moulding is one of the most efficient processes in mass production that can easily attain up to complex geometry product within a very short cycle time. To choose a suitable setting of parameter was very crucial, in controlling the quality of product with regard to their function. The main propose of this research is to optimize the injection moulding parameter for controlling the shrinkage and warpage of thermoplastics sample through practical injection moulding. The additional study for this project is to investigate the effect of nanoclay contents towards the parameter setting. In this experiment, the selected parameters were packing pressure; melt temperature, screw speed and filling time. The material that was selected for this project was a mixture of polypropylene and nanoclay with the addition of polypropylene-grafted-maleic anhydride as the compatibilizer. Three formulations were chosen, which was 0 wt%, 3 wt% and 5 wt% of Nanoclay. Each formulation was added with 15 wt% of compatibilizer. The experiment design for this project shall adopt the L943Orthogonal Array of Taguchi Method. By using the Signal to Noise Ratio responses, the optimum parameter for each formulation has been obtained. The findings of this experiment shall be useful for future manufacturing process in order to control shrinkage and warpage specifically for products made from polypropylene-nanoclay.

Visualization of Injection Moulding Process

2008 ◽  
Vol 587-588 ◽  
pp. 716-720 ◽  
Author(s):  
A.S. Yanev ◽  
Gustavo R. Dias ◽  
António M. Cunha
Keyword(s):  
Injection Moulding ◽  
High Speed ◽  
Processing Condition ◽  
Polymer Melt ◽  
Video Camera ◽  
Flow Index ◽  
Moulding Process ◽  
High Speed Video Camera ◽  
Injection Moulding Process ◽  
Materials Used

A special tool-transparent mould designed to visualize the melt flow inside the cavity is used in this research. The aim of the work is to assess the polymer melt behavior under different processing conditions-close to industrial, in conventional and two materials non-conventional injection moulding techniques. The mould is designed with two injection locations and has possibility to change the geometry of the cavity in order to investigate the melt behavior in differently shaped cavities. Visual access in the mould is allowed by the sapphire windows, surrounding the cavity. For image acquisition a high speed video camera NAC 1000 is used. Materials used in the research are three polypropylenes with different flow index. Results are obtained for conventional injection moulding, two material monosandwich and two material biinjection moulding. Apart from visualization, instrumentation of the mould allows to be obtained PT data for each processing condition. Results from conventional injection moulding are compared with MPI5.0 simulations.

Application of RSM to Optimize Moulding Conditions for Minimizing Shrinkage in Thermoplastic Processing

2016 ◽  
Vol 700 ◽  
pp. 12-21 ◽  
Author(s):  
S.M. Nasir ◽  
K.A. Ismail ◽  
Z. Shayfull
Keyword(s):  
Injection Moulding ◽  
Variable Parameter ◽  
Acrylonitrile Butadiene Styrene ◽  
Cooling Time ◽  
Inlet Temperature ◽  
Melt Temperature ◽  
Mould Material ◽  
Moulding Process ◽  
Packing Pressure ◽  
Injection Moulding Process

This study focuses on the analysis of plastic injection moulding process simulation using Autodesk Moldflow Insight (AMI) software in order to minimize shrinkage by optimizing the process parameters. Two types of gates which is single and dual gates have been analysed. Nessei NEX 1000 injection moulding machine and P20 mould material details are incorporated in this study on top of Acrylonitrile Butadiene Styrene (ABS) as a moulded thermoplastic material. Coolant inlet temperature, melt temperature, packing pressure and cooling time are selected as a variable parameter. Design Expert software is obtained as a medium for analysis and optimisation to minimize the shrinkage. The polynomial models are obtained using Design of Experiment (DOE) integrated with RSM Center Composite Design (CCD) method in this study. The results show that packing pressure is a main factor that contributed to shrinkage followed by coolant inlet temperature, while melt temperature and cooling time has less significant for both single and dual gates. Meanwhile, single gate shows a better result of shrinkage compared to the dual gates.

Warpage Analysis of Single and Dual Gates Designed for Injection Moulding Using Response Surface Methodology

2015 ◽  
Vol 754-755 ◽  
pp. 775-783 ◽  
Author(s):  
S.M. Nasir ◽  
Khairul Azwan Ismail ◽  
Z. Shayfull ◽  
M.A. Fairuz
Keyword(s):  
Injection Moulding ◽  
Variable Parameter ◽  
Acrylonitrile Butadiene Styrene ◽  
Inlet Temperature ◽  
Melt Temperature ◽  
Mould Material ◽  
Moulding Process ◽  
Packing Pressure ◽  
Injection Moulding Process ◽  
Mould Design

This study focuses on the analysis of plastic injection moulding process simulation using Autodesk Moldflow Insight (AMI) software in order to correlate between process parameters as an input and warpage as an output for single and dual gates mould design. Nessei NEX 1000 injection moulding machine and P20 mould material details are incorporated in this study on top of Acrylonitrile Butadiene Styrene (ABS) as a moulded thermoplastic material. Coolant inlet temperature, material melt temperature, packing pressure and packing time are selected as a variable parameter. Design Expert software is obtained as a medium for analysis and optimization of input variables in order to minimize the warpage. RSM method as well as Analysis of Variance (ANOVA) has been applied in this study. The results of ANOVA show that some interactions between factors are significant towards warpage existence, which is coolant inlet temperature, material melt temperature and packing pressure. Furthermore, the model created using RSM can be used for warpage prediction and improvement due to a minimum value of error. From this study, the dual gate is the best solution which able to improve the warpage up to 80% instead of single.

Application of Grey Taguchi based Response Surface Methodology (GT-RSM) in Injection Moulding of Polypropylene/E-glass Composite

2015 ◽  
Vol 5 (1) ◽  
pp. 35-48 ◽  
Author(s):  
M. Santhanakumar ◽  
R. Adalarasan
Keyword(s):  
Response Surface Methodology ◽  
Response Surface ◽  
Injection Moulding ◽  
Statistical Significance ◽  
Rheological Behaviour ◽  
Quality Characteristics ◽  
Melt Temperature ◽  
Glass Composites ◽  
Packing Pressure ◽  
Grey Taguchi

Strong non-linearity combined with the complicated rheological behaviour of polymers makes the quality characteristics of products unpredictable in plastic injection moulding. The purpose of this work is to study the mechanical properties of injection moulded polypropylene/E-glass composites. The process parameters like the melt temperature, injection pressure, packing pressure and cooling time were found to influence the quality characteristics of the produced parts. These four parameters were varied at three levels and a L18 orthogonal array was used for designing and conducting the experiments. Tensile and impact strength (Charpy-notched) were observed as the responses and a new integrated technique of grey Taguchi based response surface methodology (GT-RSM) was disclosed to predict the optimal operating condition. A confirmation test was conducted to demonstrate the accuracy of GT-RSM approach. Injection and packing pressure were found to have statistical significance in influencing the strength of injection moulded polypropylene/E-glass composites.

scholarly journals Thermal Expansion Anisotropy in Injection-Moulded Natural-Fibre Composites

2001 ◽  
Vol 10 (6) ◽  
pp. 096369350101000
Author(s):  
F. R. Cichocki
Keyword(s):  
Thermal Expansion ◽  
Injection Moulding ◽  
Flow Direction ◽  
Natural Fibre ◽  
Sisal Fibre ◽  
Thermal Expansion Coefficients ◽  
Thermal Expansion Anisotropy ◽  
Fibre Composites ◽  
Injection Moulding Process ◽  
Expansion Coefficients

Recently much effort has been devoted to the development of natural-fibre composites produced via injection moulding. Although several processing-cost benefits may be associated with the injection moulding process, the microstructures of injection-moulded composites can be quite complex and anisotropic. In this study, the thermal expansion anisotropy that may develop in injection moulded natural-fibre composites has been investigated. A thermal mechanical analyser (TMA) has been employed to determine the thermal expansion properties of jute and sisal-fibre reinforced polypropylene composites injection-moulded into the form of tensile bars and disks. Measurements indicated that thermal expansion coefficients of tensile bars in the melt-flow direction may be 5 to 7 times less than thermal expansion coefficients in the cross-flow direction.

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.

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.

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