scholarly journals Optimization of Injection Molding of Automotive Plastic Horn Cover Part Using Taguchi Method and Reverse Engineering

2022 ◽  
Vol 58 (4) ◽  
pp. 114-129
Author(s):  
Yongsun Lee ◽  
Jinrae Cho ◽  
Seongryeol Han
Keyword(s):  
Injection Molding ◽  
Taguchi Method ◽  
Surface Quality ◽  
Resin Flow ◽  
Injection Mold ◽  
Mold Surface ◽  
Commercial Vehicles ◽  
3D Scanner ◽  
Optimal Injection

The aim of the paper consisted in the development of an injection mold for plastic horn cover parts in commercial vehicles. Three mold types were designed in anticipation of the structure and quality of molds, and injection molding numerical analyses were conducted for the three types of molds. One mold type was selected in consideration of the resin flow patterns inside the mold, surface quality, and final deflection amount of the horn cover. To perform optimal injection molding using the selected mold, optimization of injection molding parameters was performed using the Taguchi method, one of the designs of experiment (DOE) and ANOVA methods. As a result, it was confirmed that the deflection amount of the molding under optimal molding parameters decreased by about 34.3% compared to the deflection amount before optimization of the molding parameters. Based on these encouraging results, the previously selected mold type was actually manufactured. The horn cover was molded using the obtained optimal injection molding parameters to the manufactured mold. To verify the precision of the molded horn cover, the deflection amount of the molding was measured with a 3D scanner. The deflection amount of the horn cover was estimated to be about 11% to 43% larger for each measurement position than the deflection amounts in the analysis results. The manufactured mold was revised to solve the problem that the deflection amount of the actual molding is larger than the deflection amount predicted by injection molding analysis. The dimensions and surface quality of the horn cover with a revised mold were satisfactory.

OPTIMIZATION OF INJECTION MOLDING PARAMETERS FOR LED LAMPSHADE

2013 ◽  
Vol 37 (3) ◽  
pp. 313-323 ◽  
Author(s):  
Kingsun Lee ◽  
Jui-Chang Lin
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Injection Molding ◽  
Taguchi Method ◽  
Design Of Experiments ◽  
Light Emitting Diodes ◽  
Injection Mold ◽  
Element Analysis ◽  
Light Emitting ◽  
Injection Parameters

The unibody of LED (light-emitting diodes) lampshades is fabricated by injection mold; the forming technique is complicated, especially for multi-cavity molds. This study applies a finite element analysis to explore the influences of the shrinkage of LED lampshades. The effect of selected injection parameters and their levels on shrinkage size, and the subsequent design of experiments were accomplished using the Taguchi method. The results were confirmed by experiments, which indicated that the selected injection parameters effectively reduce the shrinkage. The error between optimal estimated value and verified value is within 3.82%.

Study of the Structural Characteristics of Mold for Precise Injection Molding

2011 ◽  
Vol 291-294 ◽  
pp. 610-613
Author(s):  
Hong Lin Li ◽  
Zhi Xin Jia
Keyword(s):  
Injection Molding ◽  
Process Parameters ◽  
Structural Characteristics ◽  
Injection Mold ◽  
Industrial Products ◽  
Balance System ◽  
Molded Parts ◽  
Manufacturing Accuracy ◽  
Injection Molded

With the improvement of accuracy requirements for industrial products, the precise injection molding is replacing the traditional injection molding quickly and widely. Many factors influence the quality of injection-molded parts greatly, such as the property of the plastics, mold structure and the manufacturing accuracy, injecting machine and the injecting process parameters. In this paper, the work is emphasized for the influence of mold structure on the quality of injection-molded parts. Eight portions of injection mold are analyzed, including the cavities and cores, the guide components, the runner system, the ejection system, the side-core pulling mechanism, the temperature balance system, the venting system and the supporting parts. The structural characteristics of the above eight portions are presented.

scholarly journals Simulation of Polymer Injection Molding: A New Practical Approach to Improve Computation Accuracy

2016 ◽  
Vol 7 (3) ◽  
pp. 25-28 ◽  
Author(s):  
Przemysław Narowski ◽  
Krzysztof Wilczyński
Keyword(s):  
Injection Molding ◽  
Input Data ◽  
Polymeric Materials ◽  
Engineering Problem ◽  
Injection Mold ◽  
Polymer Injection ◽  
Simple Tool ◽  
Cavity Filling ◽  
Polymer Injection Molding

Simulation of injection molding of polymeric materials is still a series scientific and engineering problem. The quality of the input data is crucial for computation accuracy. The original, relatively simple tool has been designed to validate simulations. This allows a fast identification of the critical input data, and next their proper adjustment to computations. FEM simulations have been compared with directly registered pictures of cavity filling process in a special injection mold with a sight-glass.

Research Progress of Improving Surface Quality of Microcellular Foam Injection Parts

2011 ◽  
Vol 66-68 ◽  
pp. 2010-2016 ◽  
Author(s):  
Yue Wang ◽  
Guang Hong Hu
Keyword(s):  
Injection Molding ◽  
Surface Quality ◽  
Dimensional Stability ◽  
Surface Defects ◽  
Research Progress ◽  
Microcellular Foam ◽  
Counter Pressure ◽  
Foam Injection Molding ◽  
Application Scope

Microcellular foam injection parts have many advantages such as saving material and energy, reducing cycle time, and processing excellent dimensional stability. Despite these advantages, the low surface quality problems limit its application scope seriously. In this study, the microcellular foam injection molding principle and some surface defects were introduced, and the technologies to improve surface quality, such as Gas Counter Pressure (GCP), Rapid Heat Cycle Molding (RHCM), and Film Insulation were summarized in detail. Finally, the prospect of CAE technologies about microcellular foam injection molding was proposed.

Welding Parameter Optimization of Surface Quality by Taguchi Method

2014 ◽  
Vol 660 ◽  
pp. 109-113
Author(s):  
Chuan Huat Ng ◽  
Mohd Khairulamzari Hamjah
Keyword(s):  
Taguchi Method ◽  
Surface Quality ◽  
Weld Pool ◽  
Welding Current ◽  
Droplet Formation ◽  
Welding Parameter ◽  
Welding Parameters ◽  
Weld Parameters ◽  
Selection Of

An experimental study of GTAW was conducted to determine the optimization of weld parameters on the droplet formation in the surface quality of weld pools. These optimization investigations consisted of welding current, welding speed and feed rate. The strength and surface quality of weld pool were measured for each specimen after the welding parameter optimizations and the effect of these parameters on droplet formation were researched. To consider these quality characteristics together in the selection of welding parameters, the Orthogonal Array of Taguchi method is adopted to analyze the effect of each welding parameter on the weld pool quality, and then to determine the welding parameters with the optimal weld pool quality.

scholarly journals Study of Advanced Manufacturing Technologies for Active Parts of Injection Molds

2018 ◽  
Vol 8 (1) ◽  
pp. 89-94
Author(s):  
Noémi Rita Soós ◽  
Ödön János Soós
Keyword(s):  
Surface Quality ◽  
High Speed ◽  
Advanced Manufacturing ◽  
Injection Mold ◽  
High Speed Machining ◽  
Active Components ◽  
Advanced Manufacturing Technologies ◽  
Manufacturing Technologies

Abstract The main objective of this paper is to show the advantages of advanced manufacturing, such as high speed machining (HSM), for the active plates of injection molds. The goal of the experiment is to push the machine and the tools to the limit without reducing the surface quality of the manufactured part. The parts that are machined in this experiment are the active components of bucket injection mold. The mold core and nest is composed of several plates that have to form a whole when mounted together.

Optimization Design of Hot Runner Injection Molding for Thin Shell Parts Based on Moldflow

2014 ◽  
Vol 599-601 ◽  
pp. 564-567
Author(s):  
Xu Xia Zhu ◽  
Hai Xiao Zheng
Keyword(s):  
Injection Molding ◽  
Cycle Time ◽  
Thin Shell ◽  
Optimization Design ◽  
Design Parameters ◽  
Injection Molding Process ◽  
Injection Mold ◽  
Molding Process ◽  
Shell Part

In this paper, based on the characteristics of shell part, the application of hot runner system for the shell parts injection molding process was analyzed by Moldflow. According to this research, design parameters obtained were optimized. The result shows that hot runner system enables injection mold cooling faster , shortens the molding cycle time , and also improves the quality of the shell part.

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