Multiple Performance Optimization for the Best Injection Molding Process of Ti-6Al-4V Green Compact

2010 ◽  
Vol 44-47 ◽  
pp. 2707-2711 ◽  
Author(s):  
Norhamidi Muhamad ◽  
Nor Hafiez Mohamad Nor ◽  
Sufizar Ahmad ◽  
Mohd Halim Irwan Ibrahim ◽  
Mohd Ruzi Harun
Keyword(s):  
Injection Molding ◽  
Confidence Level ◽  
Performance Optimization ◽  
Injection Pressure ◽  
Mold Temperature ◽  
Powder Injection ◽  
Injection Molding Process ◽  
Pressure Injection ◽  
Injection Temperature ◽  
Grey Relational

The L27 (313) Taguchi orthogonal array is used in the experiment while the injection pressure, injection temperature, powder loading, mold temperature, holding pressure and injection speed are optimized in this study. A grey relational grade (GRG) obtained from the grey relational analysis (GRA) is used to solve the titanium alloy powder injection molding operations with the multiple performance characteristics such as strength and density. From the analysis of variance (ANOVA), the injection temperature has the highest contribution at confidence level 90% to the quality of green part followed by powder loading. The others factor such as mold temperature, holding pressure, injection pressure and injection rate and all the interactions are not significant even though it give contribution during injection molding but the confidence level are less than 90%.

Fabrication of Supports for Solid Oxide Fuel Cells by Powder Injection Molding

2011 ◽  
Author(s):  
Ali Keshavarz Panahi ◽  
Hadi Miyanaji ◽  
Moein Taheri ◽  
Milad Janbakhsh
Keyword(s):  
Injection Molding ◽  
Weld Line ◽  
Injection Pressure ◽  
Mold Temperature ◽  
Injection Rate ◽  
Powder Injection ◽  
Pressure Injection ◽  
Packing Pressure ◽  
Molded Parts ◽  
Short Shot

In this paper the processing steps for producing SOFC (Solid Oxide Fuel Cell) supports by means of PIM (Powder Injection Molding) technique were investigated. Injection molding parameters in this study were divided into pressure-related (injection pressure and packing pressure), temperature-related (nozzle temperature and mold temperature), and time-related (injection rate and holding time) parameters. Keeping the other parameters (pressure-related, temperature-related and time-related parameters) constant at an optimized value, the effects of each of the molding parameters above were investigated. The results show that the short shot, warpage, weld line and void are the most common defects in molded parts. According to the results the short shot could be seen in low values of injection pressure, injection rate, nozzle and mold temperature. Also, warpage could be seen in high values of mold temperature, injection and packing pressure. Poor weld line was another defect that could be seen in low values of injection pressure, injection rate, nozzle and mold temperature. Also the void was one of the most common defects that could be seen in high values of injection rate and nozzle temperatures. Finally, using optimized molding parameters, the molded parts underwent debinding and sintering processes. Based on the results of thermal shock tests and the porosity measurements of the sintered parts, these molded parts possessed relatively desirable characteristics.

scholarly journals Optimization of Process Parameters for Vertical-Faced Polypropylene Bottle Injection Molding

2018 ◽  
Vol 2018 ◽  
pp. 1-9 ◽  
Author(s):  
Youmin Wang ◽  
Zhichao Yan ◽  
Xuejun Shan
Keyword(s):  
Injection Molding ◽  
Process Parameters ◽  
Dwell Time ◽  
Optimization Problem ◽  
Injection Pressure ◽  
Mold Temperature ◽  
Orthogonal Test ◽  
Injection Molding Process ◽  
Injection Time ◽  
Melt Temperature

In order to obtain the optimal combination of process parameters for vertical-faced polypropylene bottle injection molding, with UG, the model of the bottle was drawn, and then, one module and sixteen-cavity injection molding system was established and analyzed using Moldflow. For filling and maintaining pressure during the process of infusion bottle injection molding, the orthogonal test table L25 (56) using CAE was designed for injection molding of the bottle, with six parameters such as melt temperature, mold temperature, injection pressure, injection time, dwell pressure, and dwell time as orthogonal test factors. By finding the best combination of process parameters, the orthogonal experiment was completed, the results were analyzed by range analysis, and the order of influence of each process parameter on each direction of optimization was obtained. The prediction dates of the infusion bottle were gained under various parameters, a comprehensive quality evaluation index of the bottle was formulated, and the multiobjective optimization problem of injection molding process was transformed into a single-objective optimization problem by the integrated weighted score method. The bottle parameters were optimized by analyzing the range date of the weighted scoring method, and the best parameter combination such as melt temperature 200°C, mold temperature 80°C, injection pressure 40 MPa, injection time 2.1 S, dwell pressure 40 MPa, and dwell time 40 S was gained.

Optimizing Injection Parameters of Kenaf Filler Polypropylene Composite by Taguchi Method

2017 ◽  
Vol 894 ◽  
pp. 81-84 ◽  
Author(s):  
Mohd Khairul Fadzly Md Radzi ◽  
Norhamidi Muhamad ◽  
Abu Bakar Sulong ◽  
Zakaria Razak
Keyword(s):  
Injection Molding ◽  
Taguchi Method ◽  
Process Condition ◽  
Injection Pressure ◽  
Poor Quality ◽  
Injection Molding Process ◽  
Molding Process ◽  
Injection Parameters ◽  
Pp Composites ◽  
Injection Temperature

Optimization of injection molding parameters provided a solution to achieve strength improvement of kenaf filler polypropylene composites. Since, molded polymers composites possibility being effected by machine parameters and other process condition that may cause poor quality of composites product. Thus in this study, composite of kenal filler reinforced with thermoplastic polypropylene (PP) were prepared using a sigma blade mixer, followed by an injection molding process. To determine the optimal processing of injection parameters, Taguchi method with L27 orthogonal array was used on statistical analysis of tensile properties of kenaf/PP composites. The results obtained the optimum parameters which were injection temperature 190°C, injection pressure 1300 bar, holding pressure 1900 bar and injection rate 20cm3/s. From the analysis of variance (ANOVA), both flow rate and injection temperature give highest contribution factor to the mechanical properties of the kenaf/PP composites.

Numerical and Experimental Study on the Injection Moulding of a Thin-Wall Complex Part

2008 ◽  
Author(s):  
Catalin Fetecau ◽  
Ion Postolache ◽  
Felicia Stan
Keyword(s):  
Injection Molding ◽  
Injection Pressure ◽  
Mold Temperature ◽  
Processing Parameters ◽  
Injection Molding Process ◽  
Thin Wall ◽  
Molding Process ◽  
Complex Part ◽  
Filling Time ◽  
Wall Injection

The research presented in this paper involves numerical and experimental efforts to investigate the relative thin-wall injection molding process in order to obtain high dimensional quality complex parts. To better understand the effects of various processing parameters (the filling time, injection pressure, the melting temperature, the mold temperature) on the injection molding of a thin-wall complex part, the molding experiments are regenerated into the computer model using the Moldflow Plastics Insight (MPI) 6.1 software. The computer visualization of the filling phase allows accurate prediction of the location of the flow front, welding lines and air traps. Furthermore, in order to optimize the injection molding process, the effects of the geometry of the runner system on the filling and packing phases are also investigated. It is shown that computational modeling could be used to help the process and mold designer to produce accurate parts.

Characterization of Micro Metal Injection Molding by Using PMMA & PEG

2013 ◽  
Vol 315 ◽  
pp. 992-996
Author(s):  
Mohd Halim Irwan Ibrahim ◽  
Norhamidi Muhamad ◽  
A.B. Sulong
Keyword(s):  
Stainless Steel ◽  
Injection Molding ◽  
Injection Pressure ◽  
Steel Powder ◽  
Mold Temperature ◽  
Point Of View ◽  
Metal Injection Molding ◽  
Volume Percentage ◽  
Shape Retention ◽  
Injection Temperature

Due to its versatility, micro metal injection molding has become an alternative method in powder metallurgy where it can produce small part with a minimal number of waste. The success of micro MIM is greatly influenced by feedstock characteristics. This paper investigated the characterization and optimization which both of them plays an important characteristic in determining the successful of micro MIM. In this paper, stainless steel SS 316L was used with composite binder, which consists of PEG (Polyethelena Glycol), PMMA (Polymethyl Methacrilate) and SA (Stearic Acid). The rheology properties are investigated using Shimadzu Flowtester CFT-500D capillary rheometer. The geometry of water atomised stainless steel powder are irregular shape, therefore it is expected significant changes in the rheological results that can influence the microcomponent, surface quality, shape retention and resolution capabilities. From rheological characteristics, feedstock with 61.5% shows a significant value with several injection parameters were optimized through screening experiment such as injection pressure (A), injection temperature (B), mold temperature (C), injection time (D) and holding time (E). Besides that, interaction effects between injection pressure, injection temperature and mold temperature were also considered to optimize in the Taguchis orthogonal array. Result shows that 61.5%vol contributes a significant stability over a range of temperature and the best powder loading from a critical powder volume percentage (CPVP) and rheological point of view. Furthermore interaction between injection temperature and mold temperature (BxC) give highest significant factor followed by interaction between injection pressure and mold temperature (AxC).

Optimization and Design for Parameter in Injection Molding Technology of Cell Shell of Polypropylene

2011 ◽  
Vol 189-193 ◽  
pp. 537-540
Author(s):  
Jia Min Zhang ◽  
Ming Yi Zhu ◽  
Zhao Xun Lian ◽  
Rong Zhu
Keyword(s):  
Injection Molding ◽  
Injection Pressure ◽  
Mold Temperature ◽  
Injection Molding Process ◽  
Technological Parameters ◽  
Molding Process ◽  
Melt Temperature ◽  
Injection Speed ◽  
Technical Parameters ◽  
High Degree

The use of L27 (35) orthogonal to the battery shell injection molding process is optimized. The main factors of technical parameters were determined mould temperature, melt temperature, the speed of injection, injection pressure, cooling time.On the basis of actual production, to determine the factors values of different process parameters.Combination of scrapped products in key (reduction and a high degree of tolerance deflated) tests were selected in the process parameters within the scope of the assessment. Various factors impact on the product of the total height followed by cooling time, mold temperature, melt temperature, injection pressure, injection speed from strong to weak .The best products technological parameters were determined.Good results were obtained for production.

Automotive Interior Parts Molding Process Simulation and Parameter Optimization

2013 ◽  
Vol 734-737 ◽  
pp. 2725-2729
Author(s):  
Yin Wu Tan ◽  
You Min Wang ◽  
Ge Zhou ◽  
Xiao Yang Du
Keyword(s):  
Injection Molding ◽  
Orthogonal Experiment ◽  
Injection Pressure ◽  
Mold Temperature ◽  
Injection Molding Process ◽  
Molding Process ◽  
Interior Decoration ◽  
Melt Temperature ◽  
Influence Of Process Parameters ◽  
Sink Mark

By the use of UG software，the solid model of the interior decoration board inside the automobile door was created and the molding behavior of the plastic product was simulated and analysis in the virtue of Moldflow．Based on the analysis of the effect of the mould parameter on the molding behavior ,the best gate location was achieved.We designed the L9(33) orthogonal experiment table of the parts injection molding,selected the mold temperature, melt temperature, injection pressure as the factores .Sink mark index, volume shrinkage, maximumwarping deformation and cavity residual stress are determined as the parts quality evaluation. We completed the orthogonal experiment and the range analyses of the results. We analyzed the influence of process parameters on evaluation of every optimal direction,developed evaluation for comprehensive quality of parts. Finally, we get the table showing the tendency on the assessment of the quality index influenced by various factors, which provides a foundation for the approaching research on the parameters of the injection molding process.

scholarly journals Welding lines formation in holes obtained by low pressure injection molding of ceramic parts

Cerâmica ◽  
2018 ◽  
Vol 64 (369) ◽  
pp. 97-103 ◽  
Author(s):  
C. A. Costa ◽  
A. F. Michels ◽  
M. E. Kipper
Keyword(s):  
Injection Molding ◽  
Injection Pressure ◽  
Mold Temperature ◽  
Low Pressure ◽  
Process Conditions ◽  
Injection Mold ◽  
Extraction Temperature ◽  
Post Injection ◽  
Injection Process ◽  
Pressure Injection

Abstract This work presents a study to evaluate the process of producing internal holes in ceramic disks produced by low pressure injection molding (LPIM) process. Two process conditions defined as pre-injection and post-injection were used to test the proposition. In the first one the pin cores that produce the holes were positioned in the cavity before the injection of the feedstock; and in the second one, the pin cores were positioned in the cavity, just after the feeding phase of the injection mold. An experimental injection mold designed and manufactured to test both processes was developed to produce ceramic disk with Ø 50 x 2 mm with four holes of Ø 5 mm, equally and radially distributed through the disk. The feedstock was composed of 86 wt% alumina (Al2O3) and 14 wt% organic vehicle based on paraffin wax. Heating and cooling systems controlled by a data acquisition system were included in the mold. The results showed that there were no welding lines with the post-injection process, proving to be an option for creating holes in the ceramic parts produced by LPIM. It was observed that best results were obtained at 58 °C mold temperature. The pins extraction temperature was about 45 °C, and the injection pressure was 170 kPa.

Processability Testing of Injection Molding Rubber Compounds

1984 ◽  
Vol 57 (4) ◽  
pp. 826-842 ◽  
Author(s):  
John A. Sezna ◽  
P. J. DiMauro
Keyword(s):  
Injection Molding ◽  
Injection Pressure ◽  
Mold Temperature ◽  
Injection Molding Process ◽  
Capillary Rheometer ◽  
Excellent Correlation ◽  
Molding Process ◽  
Rubber Compounds ◽  
Using Data ◽  
And Control

Abstract A simple model of the injection molding process has been constructed using data from a capillary rheometer (MPT) and the Oscillating Disk Rheometer (ODR). For an NR and an SBR compound, the model had an excellent correlation with injection molding trials. The model successfully predicted the effects of adjusting injection pressure, mold temperature, and barrel temperature on injection times and scorch conditions. Such a model enables an injection molder to predict the effect of adjusting molding conditions, optimize his process for a given mold and compound, and control processability of his compounds batch-to-batch.

Optimization of Injection Parameters Using 16µm Stainless Steel Powder (SS316L) at 63 Vol. %, 63.5 Vol. % and 64 Vol. % Powder Loading by Taguchi Method for Metal Injection Molding

2011 ◽  
Vol 471-472 ◽  
pp. 558-562 ◽  
Author(s):  
Muhammad Ilman Hakimi Chua Abdullah ◽  
Abu Bakar Sulong ◽  
Norhamidi Muhamad ◽  
Mohd Fazuri Abdullah ◽  
Che Hassan Che Haron
Keyword(s):  
Stainless Steel ◽  
Injection Molding ◽  
Surface Quality ◽  
Injection Pressure ◽  
Steel Powder ◽  
Mold Temperature ◽  
Stainless Steel Powder ◽  
Holding Time ◽  
Metal Injection Molding ◽  
Injection Temperature

In this paper, injection molding parameters are optimized using the L18 Taguchi orthogonal array for mechanical strength and surface quality of the green part. The feedstock used consists of stainless steel powder (SS316L) with the powder loading of 63 vol. %, 63.5 vol. % & 64 vol. %. The binder compositions used are polyethelene glycol (PEG-73 wt.%), polymethyl methacrilate (PMMA-25 wt.%) and stearic acid (4 wt.%). Mould temperature, injection temperature, injection pressure, injection time, holding time and powder loading ware selected as signal factors using Taghuci’s method based on literature, where these parameters were significant in MIM. Results showed that the optimum parameters are: mold temperature at 650C, injection temperature at1450C, injection pressure at 650 bar, injection flow rate at 20 m3/s, holding time at 5 s and powder loading of 64 vol.%. Analysis of Variance (ANOVA) result shown that mold temperature is the most influence in order to produce good green part’s surface quality while powder loading give the best result for green part’s strength.

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