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.

scholarly journals Hybrid Integration of Taguchi Parametric Design, Grey Relational Analysis, and Principal Component Analysis Optimization for Plastic Gear Production

2014 ◽  
Vol 2014 ◽  
pp. 1-11 ◽  
Author(s):  
Nik Mizamzul Mehat ◽  
Shahrul Kamaruddin ◽  
Abdul Rahim Othman
Keyword(s):  
Principal Component Analysis ◽  
Process Parameters ◽  
Injection Moulding ◽  
Principal Component ◽  
Optimization Method ◽  
Processing Parameters ◽  
Hybrid Optimization ◽  
Relational Analysis ◽  
Shrinkage Behaviour ◽  
Grey Relational

The identification of optimal processing parameters is an important practice in the plastic injection moulding industry because of the significant effect of such parameters on plastic part quality and cost. However, the optimization design of injection moulding process parameters can be difficult because more than one quality characteristic is used in the evaluation. This study systematically develops a hybrid optimization method for multiple quality characteristics by integrating the Taguchi parameter design, grey relational analysis, and principal component analysis. A plastic gear is used to demonstrate the efficiency and validity of the proposed hybrid optimization method in controlling all influential injection moulding processing parameters during plastic gear manufacturing. To minimize the shrinkage behaviour in tooth thickness, addendum circle, and dedendum circle of moulded gear, the optimal combination of different process parameters is determined. The case study demonstrates that the proposed optimization method can produce plastic-moulded gear with minimum shrinkage behaviour of 1.8%, 1.53%, and 2.42% in tooth thickness, addendum circle, and dedendum circle, respectively; these values are less than the values in the main experiment. Therefore, shrinkage-related defects that lead to severe failure in plastic gears can be effectively minimized while satisfying the demand of the global plastic gear industry.

Multi-Response Parameters Optimisation for Energy-Efficient Injection Moulding Process via Dynamic Shainin DOE Method

2013 ◽  
Vol 554-557 ◽  
pp. 1669-1682 ◽  
Author(s):  
Kam Hoe Yin ◽  
Hui Leng Choo ◽  
Dunant Halim ◽  
Chris Rudd
Keyword(s):  
Energy Consumption ◽  
Process Parameters ◽  
Injection Moulding ◽  
Shop Floor ◽  
Operational Experience ◽  
Moulding Process ◽  
Part Quality ◽  
Control Factors ◽  
Injection Moulding Process ◽  
Signal Response

Process parameters optimisation has been identified as a potential approach to realise a greener injection moulding process. However, reduction in the process energy consumption does not necessarily imply a good part quality. An effective multi-response optimisation process can be demanding and often relies on extensive operational experience from human operators. Therefore, this research focuses on an attempt to develop a more user-friendly approach which could simultaneously deal with the requirements of energy efficiency and part quality. This research proposes a novel approach using a dynamic Shainin Design of Experiment (DOE) methodology to determine an optimal combination of process parameters used in the injection moulding process. The Shainin DOE method is adopted to pinpoint the most important factors on energy consumption and the targeted part quality whereas the ‘dynamic’ term refers to the signal-response system. The effectiveness of the proposed approach was illustrated by investigating the influence of various dominant parameters on the specific energy consumption (SEC) and the Charpy impact strength (CIS) of polypropylene (PP) material after being injection-moulded into impact test specimens. From the experimental results, barrel temperature was identified as the signal factor while mould temperature and cooling time were used as control factors in the full factorial experiments. Then, response function modelling (RFM) was built to characterise the signal-response relationship as a function of the control factors. Finally, RFM led to a trade-off solution where reducing part-to-part variation for CIS resulted in an increase of SEC. Therefore, the research outcomes have demonstrated that the proposed methodology can be practically applied at the factory shop floor to achieve different performance output targets specified by the customer or the manufacturer’s intent.

Modelling for Injection Moulding Process Based on Principal Component Regression Method

2011 ◽  
Author(s):  
Nong Gu. ◽  
Dougas Creighton ◽  
Saeid Nahavandi ◽  
Francisco Chinesta ◽  
Yvan Chastel ◽  
...  
Keyword(s):  
Injection Moulding ◽  
Principal Component Regression ◽  
Principal Component ◽  
Regression Method ◽  
Moulding Process ◽  
Injection Moulding Process

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.

Injection Moulding Simulation Analysis of Handle Shell

2013 ◽  
Vol 798-799 ◽  
pp. 286-289
Author(s):  
Wei Li
Keyword(s):  
Process Parameters ◽  
Injection Moulding ◽  
Simulation Analysis ◽  
Final Analysis ◽  
Moulding Process ◽  
Technical Requirements ◽  
Injection Moulding Process ◽  
Moulding Machine ◽  
Final Analysis Result

This thesis first made an introduction to the functional and technical requirements of this product, and then determined its moulding process. After that, the injection moulding process parameters of the selected injection moulding machine were set, besides, it applied Moldflow software to make simulation analysis to multiple schemes of injection moulding process, and finally, the best mold structure was determined according to the final analysis result.

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