scholarly journals Modeling and Analysis of Injection Moulding Process Parameters for Plastic Gear Industry Application

2013 ◽  
Vol 2013 ◽  
pp. 1-10 ◽  
Author(s):  
Nik Mizamzul Mehat ◽  
Shahrul Kamaruddin ◽  
Abdul Rahim Othman
Keyword(s):  
Polymer Melt ◽  
Optimization Method ◽  
Processing Parameters ◽  
Taguchi Optimization ◽  
Modeling And Analysis ◽  
Moulding Process ◽  
Real Process ◽  
Injection Moulding Process ◽  
Mould Design ◽  
Plastic Gears

The performance of plastic gears in wide variety of power and motion transmission applications is rather limited due to weak mechanical properties and divergent mechanism of failures. A methodical simulation is carried out to analyze the gear performance with various gating system types, gate locations, and processing parameters via grey-based Taguchi optimization method. With the obtained optimum results in simulation stage, the flow patterns of polymer melt inside the mould during filling, packing, and cooling processes are studied and the plastic gear failures mechanism related to processing parameters are predicted. The output results in the future can be used as guidance in selecting the appropriate materials, improving part and mould design, and predicting the performance of the plastic gear before the real process of the part manufacturing takes place.

scholarly journals Optimisation of Mould Design for Injection Moulding – Numerical Approach

2021 ◽  
Vol 15 (2) ◽  
pp. 258-266
Author(s):  
Damir Godec ◽  
Vladimir Brnadić ◽  
Tomislav Breški
Keyword(s):  
Computer Simulation ◽  
Injection Moulding ◽  
Numerical Approach ◽  
Processing Parameters ◽  
Simulation Software ◽  
Moulding Process ◽  
Part Geometry ◽  
Injection Moulding Process ◽  
Mould Cavity ◽  
Mould Design

Computer simulation of injection moulding process is a powerful tool for optimisation of moulded part geometry, mould design and processing parameters. One of the most frequent faults of the injection moulded parts is their warpage, which is a result of uneven cooling conditions in the mould cavity as well as after part ejection from the mould and cooling down to the environmental temperature. With computer simulation of the injection moulding process it is possible to predict potential areas of moulded part warpage and to apply the remedies to compensate/minimize the value of the moulded part warpage. The paper presents application of simulation software Moldex 3D in the process of optimising mould design for injection moulding of thermoplastic casing.

scholarly journals Improving the Performance of Reprocessed ABS Products from the Manufacturing Perspective via the Taguchi Method

2013 ◽  
Vol 2013 ◽  
pp. 1-9 ◽  
Author(s):  
Ng Chin Fei ◽  
Nik Mizamzul Mehat ◽  
Shahrul Kamaruddin ◽  
Zulkifli Mohamad Ariff
Keyword(s):  
Tensile Strength ◽  
Taguchi Method ◽  
Processing Parameters ◽  
Process Conditions ◽  
Optimization Approach ◽  
Taguchi Optimization ◽  
Elongation At Break ◽  
Moulding Process ◽  
Controllable Factors ◽  
Injection Moulding Process

Additives are costly and can have negative environmental effects. Thus, searching for other alternatives to improve recycling plastics without using additives is necessary. This study aims to improve the hoop tensile strength, elongation at break, and shrinkage of the ring stopper made from an acrylonitrile butadiene styrene blend comprising 40% recyclates through the optimization of processing parameters using the Taguchi method. By adopting the L9 Taguchi orthogonal array, four controllable factors each at three levels are tested to determine the optimal combination of factors and levels in the injection moulding process. Considering the multiple quality characteristics involved in this study, we investigate the effects of processing parameters on hoop tensile strength, elongation at break, and shrinkage of the ring stopper both separately and simultaneously because changing a parameter can result in the improvement or deterioration of each quality response and of the overall product performance. The results revealed that the performance of an injection-moulded ring stopper under the optimal process conditions is equivalent or slightly better than that of the part produced from virgin resin. The performance of recycled plastics can be effectively enhanced to levels comparable with virgin resins using the Taguchi optimization approach.

Optimizing Flow for the Two Color Injection Mould Design

2013 ◽  
Vol 441 ◽  
pp. 627-630
Author(s):  
Yan Fang Yin ◽  
Zhen Hui Tian
Keyword(s):  
Analytical Solutions ◽  
Material Behavior ◽  
Governing Equations ◽  
Window Frame ◽  
Moulding Process ◽  
Injection Moulding Process ◽  
Cad Cam ◽  
Pros And Cons ◽  
Mould Design ◽  
Cam Systems

Commercial CAD/CAM systems provide semi-automatic tools to assist the designer in the dimensioning process. Analytical solutions to injection molding problems are very rare due to thecomplexities of the governing equations, the material behavior and the cavity geometry. Study of window frame fabrication by injection moulding process was carried out with the aid of Moldflow® software. Ejector plate designs were created to compare the pros and cons of each design. The investigations were carried out on flowing, packing, cooling and costing of injection moulded window frame. Using the method, good results have been obtained for several basic geometric models.

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.

A Study of Hybrid Optimization of Injection Moulding Process Parameters for Plastic Gear

2012 ◽  
Vol 591-593 ◽  
pp. 2135-2138 ◽  
Author(s):  
Nik Mizamzul Mehat ◽  
Shahrul Kamaruddin ◽  
Abdul Rahim Othman
Keyword(s):  
Process Parameters ◽  
Injection Moulding ◽  
Principal Component ◽  
Optimization Method ◽  
Hybrid Optimization ◽  
Quality Characteristic ◽  
Statistical Solution ◽  
Moulding Process ◽  
Hybrid Optimization Method ◽  
Injection Moulding Process

This paper presents a hybrid optimization method for optimizing the injection moulding process parameters for plastic gear. This proposed method combines the Taguchi robust design, grey relational analysis (GRA) and principal component analysis (PCA) in designing the experiments and analyzing the behaviour of shrinkage in addendum circles (AC), dedendum circles (DC) and tooth thickness (TT) of the moulded gear. The proposed hybrid optimization method appears to be a necessity to overcome the shortcomings in multiple quality characteristics optimization as well as provides a statistical solution in defining a weight for each quality characteristic.

Defect Analysis of 316LSS during the Powder Injection Moulding Process

2012 ◽  
Vol 329 ◽  
pp. 35-43 ◽  
Author(s):  
M. Rafi Raza ◽  
Faiz Ahmad ◽  
M.A. Omar ◽  
R.M. German ◽  
Ali S. Muhsan
Keyword(s):  
Solvent Extraction ◽  
Complete Removal ◽  
Processing Parameters ◽  
Powder Injection ◽  
Extraction Temperature ◽  
Heating Rates ◽  
Process Step ◽  
Moulding Process ◽  
Aerospace Applications ◽  
Injection Moulding Process

Austenitic Stainless Steel Has a FCC Structure at Room Temperature and the Temperature Range of the Austenite Phase Depends upon its Composition. 316L SS Is Widely Used in Medical, Marine, Industrial, Sporting and Aerospace Applications due to its Excellent Combination of Mechanical Properties and Corrosion Resistance. this Study Presents the Defects Observed during Optimization of the Processing Parameters for the Fabrication of Powder Injection Molding (PIM) of 316L SS Parts. in this Study, Five Formulations of Feedstock Containing 60-71vol% of Metal Powder Were Prepared Using a Wax-Based Binder. Green Samples Were Injection-Moulded, Followed by Binder Removal by Solvent and Thermal Means. Paraffin Wax (major Binder) Was Extracted at Various Temperatures in Order to Determine the Solvent Extraction Temperature. the Thermal De-Binding Was Performed Successfully at a Temperature of 450°C by Varying the Heating Rate from 1°C/min -10°C/min. SEM Results Showed Complete Removal of the Plastic Binder. Test Samples Were Sintered at Various Temperatures and Atmospheres. the Defects Observed during Solvent Extraction Were Swelling, Cracks and, at the Thermal De-Binding Step, Collection of Binder, Swelling and Holes. Sintered Samples Showed a Loss of Dimensional Control. these Types of Defect Were Considered to Be due to Inappropriate Heating Rates, Temperature and Dwell Time at each Process Step.

The Effect of Thermo-Mechanical Environment on the Shrinkage and Warpage in Thermoplastic Parts

2008 ◽  
Vol 587-588 ◽  
pp. 558-562 ◽  
Author(s):  
P.S. Alves ◽  
A.J. Pontes
Keyword(s):  
Material Properties ◽  
Injection Moulding ◽  
Data Acquisition System ◽  
Monitoring And Control ◽  
Process Variables ◽  
Mechanical Environment ◽  
Moulding Process ◽  
Injection Moulding Process ◽  
Mould Design ◽  
And Control

During the injection moulding process, the material is subjected to successive transformations, being submitted to a thermo-mechanical environment that determines the final dimensions of the part. This environment is characterized by several parameters which are related to material properties, the mould design, equipment and process variables. As a result, deviations of the dimensions of the moulded parts from the dimensions of the cavity cannot be avoided. If differences on shrinkage occur, caused for example by anisotropies of the material or non-uniform cooling, distortions will happen. In order to predict this two effects on the injection cycles is require one strategy to monitoring and control the process variables. The aim is to achieve highest quality control of all manufacture parts. This paper presents the effect of different holding pressures and mould temperatures on shrinkage and warpage in two different materials, one amorphous (PC) and another semi crystalline (PP). An instrumented mould was manufactured. During the injection moulding process sensors signals were continuously monitored by a Data Acquisition System. The experimental results were compared with predictions made by commercial software.

Mould Filling and Pressure Distribution for Polymer Resins

2011 ◽  
Vol 264-265 ◽  
pp. 771-776
Author(s):  
A. Mohd ◽  
C. Hindle ◽  
W.A.Y. Yusoff
Keyword(s):  
Simulation Software ◽  
Cylindrical Shape ◽  
Moulding Process ◽  
Polymer Resin ◽  
Mould Filling ◽  
Packing Pressure ◽  
Injection Moulding Process ◽  
Mould Cavity ◽  
Mould Design ◽  
Market Needs

The application of simulation software packages for mould design and injection moulding process is becoming importance to optimizing the moulding quality and satisfy market needs. This paper presents the simulation of mould filling and packing for various polymer resin types. The filling and packing pressure phases for different type of polymer resins as well as the flow behaviour of molten resin in the mould cavity were investigated. Three common polymer resins which are amorphous and crystalline thermoplastics were used. Cylinder component cups with variation of wall thicknesses were designed. Two-cavity prototype moulds for cylindrical shape component were constructed by using AutoCAD 2006 including assembly and part drawings. The 3D model was produced by using Autodesk Inventor Professional. The result successfully revealed that polyamide resin required shorter time for filling the cavity and less pressure compared to PS and ABS.

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