Parameter Optimization of Injection Molding Ti-6Al-4V Powder and Palm Stearin Binder System for Highest Green Density Using Taguchi Method

2010 ◽  
Vol 443 ◽  
pp. 69-74 ◽  
Author(s):  
Nor Hafiez Mohamad Nor ◽  
Norhamidi Muhamad ◽  
Sufizar Ahmad ◽  
Mohd Halim Irwan Ibrahim ◽  
Mohd Ruzi Harun ◽  
...  
Keyword(s):  
Injection Molding ◽  
Taguchi Method ◽  
Injection Pressure ◽  
Palm Stearin ◽  
Quality Characteristic ◽  
Metal Injection Molding ◽  
Green Density ◽  
Injection Speed ◽  
Pressure Injection ◽  
Injection Temperature

In this paper, the titanium alloy powder of Ti-6Al-4V is mixed with binder 60wt% of palm stearin and 40wt% of polyethylene for metal injection molding (MIM) process. Injection molding parameters has been optimized using Taguchi method of L27 (313) orthogonal array. Highest green density has been identified as the green part quality characteristic or as an output for this study. Parameters optimized are the injection pressure, injection temperature, powder loading, mold temperature, holding pressure and injection speed. Besides those, interaction of the injection pressure, injection temperature and powder loading were studied. The analysis of variance (ANOVA) is employed to determine the significant levels (α) and contributions of the variables to the green density. Results show that the injection pressure has highest significant percentage followed by injection temperature, powder loading and holding pressure.

Optimization of Micro Metal Injection Molding SS 316L for the Highest Green Strength by Using Taguchi Method

2011 ◽  
Vol 264-265 ◽  
pp. 135-140 ◽  
Author(s):  
Mohd Halim Irwan Ibrahim ◽  
Norhamidi Muhamad ◽  
Abu Bakar Sulong ◽  
Khairur Rijal Jamaludin ◽  
Nor Hafiez Mohamad Nor ◽  
...  
Keyword(s):  
Injection Molding ◽  
Taguchi Method ◽  
Injection Pressure ◽  
Rheological Characteristic ◽  
Mold Temperature ◽  
Metal Injection Molding ◽  
Small Scale ◽  
Injection Time ◽  
Green Strength ◽  
Injection Temperature

Micro metal injection molding which is a new develop technology has attract most researcher where it becomes among the promising method in powder metallurgy research to produce small-scale intricate part at an effective process and competitive cost for mass production. Due to highly stringent characteristics of micro MIM feedstock,the study has been emphasized in investigating the optimization of highest green strength which plays an important characteristic in determining the successful of micro MIM. Stainless steel SS 316L with D50 = 5.96μm was used with composite binder, which consists of PEG, PMMA and Stearic Acid. From rheological characteristic and highly significant parameter through screening experiment, feedstock with 61.5% with several injection parameters were optimized 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 Taguchi’s orthogonal array. Analysis of variance (ANOVA) in terms of signal-to-noise ratio (S/N-larger is better) for green strength was also presented in this paper. Result shows that interaction between injection temperature and mold temperature(BxC) give highest significant factor followed by interaction between injection pressure and injection temperature(AxB). Single factor that also contributes to significant optimization are mold temperature(C), injection time(D) and injection pressure(A). This study shows that Taguchi method would be among the best method to solve the problem with minimum number of trials.

scholarly journals Study on Stability of a Novel Binder System Based on Palm Stearin in Metal Injection Moulding Application

2007 ◽  
Vol 4 (2) ◽  
pp. 1
Author(s):  
Muhammad Hussain Ismail ◽  
Norhamidi Muhamad ◽  
Aidah Jumahat ◽  
Istikamah Subuki ◽  
Mohd Afian Omar
Keyword(s):  
Injection Molding ◽  
Flow Characteristics ◽  
Injection Pressure ◽  
Palm Stearin ◽  
Steel Powder ◽  
Metal Injection Molding ◽  
Injection Molding Process ◽  
Binder System ◽  
Molding Process ◽  
Flow Activation Energy

Metal Injection Molding (MIM) is a wellestablished technology for manufacturing a variety of complex and small precision parts. In this paper, fundamental rheological characteristics of MIM feedstock using palm stearin are theoretically analyzed and presented. The feedstock consisted of gas atomized 316L stainless steel powder at three different particle size distributions and the binder system of palm stearin (PS) and polyethylene (PE). The powder loading used was 60vol % for all samples (monosize 16 µm, monosize 45 µm, and bimodal 16 µm + 45 µm) and the binder system of 40vol %(PS/PE = 40/60). The viscosity of MIM feedstock at different temperatures and shear rates was measured and evaluated. Results showed that, the feedstock containing palm stearin exhibited suitable rheological properties by increasing the fluidity of feedstock in MIM process. The rheological results also showed a pseudoplastic flow characteristics, which poses higher value of shear sensitivity (n) and lower value of flow activation energy (E), that are both favourable for injection molding process. The green parts were successfully injected and exhibited adequate strength for handling by optimizing the injection pressure and temperature.

ANALISIS PARAMETER INJECTION MOLDING TERHADAP WAKTU SIKLUS DAN CACAT FLASH PRODUK TUTUP BOTOL 180 ML MENGGUNAKAN METODE TAGUCHI

ROTOR ◽  
2017 ◽  
Vol 10 (1) ◽  
pp. 45
Author(s):  
Andika Wahyu Prasanko ◽  
Dwi Djumhariyanto ◽  
Agus Triono
Keyword(s):  
Injection Molding ◽  
Taguchi Method ◽  
Cycle Time ◽  
Human Life ◽  
Injection Pressure ◽  
Injection Speed ◽  
Beverage Industry ◽  
Food And Beverage Industry ◽  
Food And Beverage ◽  
Nozzle Temperature

At present plastic becomes inseparable from human life especially in the food and beverage industry. One of the methods used in the manufacturing process of plastic products is injection molding. Injection molding is one of manufacturing technique that consists of a series of cyclical processes and is used to produce thermoplastic materials. The effect of the combination of process parameters impact on the product results such as the quantity and quality of the product, the non-conformity of the parameters causes the production to be not optimal. One method that can be used for optimization is the taguchi method. The taguchi method is a set of special matrices called orthoghonal arrays that are used as reference in the determination combination of parameters and level values. The purpose of this research is to determine the optimal cycle time and net of the product on the process of making 180 ml bottle cap but by minimizing flash defects. The method used in this phase is ANOVA, and the calculation of taguchi method by using minitab 16 software. From the result of the research, the result of optimal condition is combination injection pressure 1320 bar, injection speed 50 mm/s, holding pressure 300 bar, and nozzle temperature 255oC produces a cycle time value of 15.72 seconds and netto 3.56 grams. This result is better than the setting of the company that produces 16.66 seconds cycle time and entered in the net range of 4 ± 0.5 grams resulting in an increase in production of 5.97%. While with combination of injection pressure 1280 bar, injection speed 50 mm / s, holding pressure 300 bar, and nozzle temperature 245oC resulted in fewer number of flash defects compared to company setting that is 12 units from 80 units of sample. Keywords: flash deffect, injection molding, taguchi method, cycle time

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.

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).

Dynamic Response Optimization for Cemented Carbide Injection Molding

2014 ◽  
Vol 68 (4) ◽  
Author(s):  
Sri Yulis M. Amin ◽  
Norhamidi Muhamad ◽  
Khairur Rijal Jamaludin
Keyword(s):  
Injection Molding ◽  
Palm Stearin ◽  
Processing Parameters ◽  
Cemented Carbide ◽  
Metal Injection Molding ◽  
Injection Molding Process ◽  
Molding Process ◽  
Response Optimization ◽  
Injection Molded ◽  
Injection Temperature

The need to optimize the injection molding parameters for producing cemented carbide parts via Metal Injection Molding process is crucial to ensure the system’s robustness towards manufacturer and customer’s satisfactions. Defect free product with best density can be produced while reducing time and cost in manufacturing. In this work, the feedstock consisting of WC-Co powders, mixed with palm stearin and polyethylene binder system was injection molded to produce green parts. Several processing variables, namely powder loading, injection temperature, holding pressure and flowrate, were optimized towards the density of the green body, as the response factor. By considering humidity level at morning and evening conditions as the noise factor, the results show the optimum combination of injection molding parameters that produces best green density. The green part exhibited best density by following this optimum processing parameters, A2B3C1D1, that are flowrate at 20 ccm/s, powder loading at 63% vol., injection temperature at 140°C, and holding pressure at 1700 bar.

scholarly journals Study on Stability of a Novel Binder System Based on Palm Stearin in Metal Injection Moulding Application

2007 ◽  
Vol 4 (2) ◽  
pp. 1 ◽  
Author(s):  
Muhammad Hussain Ismail ◽  
Norhamidi Muhamad ◽  
Aidah Jumahat ◽  
Istikamah Subuki ◽  
Mohd Afian Omar
Keyword(s):  
Injection Molding ◽  
Flow Characteristics ◽  
Injection Pressure ◽  
Palm Stearin ◽  
Steel Powder ◽  
Metal Injection Molding ◽  
Injection Molding Process ◽  
Binder System ◽  
Molding Process ◽  
Flow Activation Energy

Metal Injection Molding (MIM) is a wellestablished technology for manufacturing a variety of complex and small precision parts. In this paper, fundamental rheological characteristics of MIM feedstock using palm stearin are theoretically analyzed and presented. The feedstock consisted of gas atomized 316L stainless steel powder at three different particle size distributions and the binder system of palm stearin (PS) and polyethylene (PE). The powder loading used was 60vol % for all samples (monosize 16 µm, monosize 45 µm, and bimodal 16 µm + 45 µm) and the binder system of 40vol %(PS/PE = 40/60). The viscosity of MIM feedstock at different temperatures and shear rates was measured and evaluated. Results showed that, the feedstock containing palm stearin exhibited suitable rheological properties by increasing the fluidity of feedstock in MIM process. The rheological results also showed a pseudoplastic flow characteristics, which poses higher value of shear sensitivity (n) and lower value of flow activation energy (E), that are both favourable for injection molding process. The green parts were successfully injected and exhibited adequate strength for handling by optimizing the injection pressure and temperature.

scholarly journals Optimization on the Injection Molding Propypopylene Parameters Using Central Composite Design for Minimizing Defects

2020 ◽  
Vol 55 (2) ◽  
Author(s):  
Moh. Hartono ◽  
Pratikto ◽  
Purnomo B. Santoso ◽  
Sugiono
Keyword(s):  
Injection Molding ◽  
Central Composite Design ◽  
Injection Pressure ◽  
Holding Time ◽  
Clamping Force ◽  
Molding Process ◽  
Injection Speed ◽  
Injection Temperature ◽  
Central Composite ◽  
Plastic Products

This study aims to simultaneously forecast and investigate the optimization process characterization of the design of controlled parameters in the injection process of polypropylene molding including injection pressure combination, clamping force, injection temperature, injection speed, and holding time, and their interaction to produce qualified plastic by minimizing defects. The experimental methods used the central composite design of response surface method with five factors and a variety of levels. This method is more effective because it is an improvement on and a development from previous studies—especially those related to the plastic molding process. Additionally, it can simultaneously predict and optimize the obtaining of the highest quality plastic products as well as minimizing defects. The results are in the form of a combination of control level factors and interactions among the factors that generate the robust output of plastic products with minimum defects. Moreover, the optimum settings of the parameters provides a global solution at an injection temperature of 275°C, injection pressure of 75 bar, injection speed of 98%, clamping force of 88 tons, and a holding time of 8 seconds to generate a response to product probability defects by 0.0062. The benefit is that it can reveal the behavior and characteristics of parameter design and their interactions in the plastic injection molding process to produce qualified plastics and minimize product defects.

Optimization of Injection Molding Parameters by Data Mining Method in PIM Process

2012 ◽  
Vol 59 (2) ◽  
Author(s):  
Azizah Wahi ◽  
Norhamidi Muhamad ◽  
Khairur R. Jamaludin ◽  
Javad Rajabi ◽  
Abbas Madraky
Keyword(s):  
Data Mining ◽  
Injection Molding ◽  
Injection Moulding ◽  
Injection Pressure ◽  
Injection Rate ◽  
Green Density ◽  
Mould Temperature ◽  
Green Strength ◽  
Defect Score ◽  
Pressure Injection

Data Mining is a method that can be used to analyze large amount of data and produce useful information. In this study, clustering which is one of data mining tasks is used to clustered machine based on the injection moulding data. This paper is the first documented results on the optimization of Injection Moulding via Data Mining. Powder injection moulding is a process to produce near net shape with intricate part in mass production. This work focus on the optimization of injection molding process with combination of fine, coarse and bimodal water atomized SS 316L powder particles. The parameters involved in the optimization are injection pressure, injection temperature, mould temperature, holding pressure, injection rate, holding time, powder loading, cooling time and particle size. These variables are based on the defect score, green density and green strength. The key influencer report shows that the most influencing factors are injection rate, holding pressure as well as mould temperature where defect score lower than 2.4 can be achieved. The density higher than 5.34g/cm3 is also influenced most by the mould temperature. The result also shows that the optimize condition can be achieved by using bimodal particle. Injection rate and mould temperature gives the highest impact on the defect score and green strength value. While highest green density is significantly affected by powder loading and injection pressure.

Application of Taguchi Method to Improve Resistance Quality of Graphene/Polypropylene Composites

2019 ◽  
Vol 818 ◽  
pp. 118-122
Author(s):  
Ching Been Yang ◽  
Wei Chang Peng ◽  
Yan Wen Huang ◽  
Hsiu Lu Chiang
Keyword(s):  
Injection Molding ◽  
Taguchi Method ◽  
Optimal Parameter ◽  
Impact Resistance ◽  
Injection Pressure ◽  
High Impact ◽  
Polypropylene Composites ◽  
Injection Temperature ◽  
New Generation

Polypropylene is a widely used thermoplastic with high impact resistance and strong mechanical properties. Graphene has exhibited in a new generation of electronic component materials owing to its high thermal conductivity and low resistivity. In this study, a composite of graphene and polypropylene for injection molding purposes was created. In Taguchi method, an L9 orthogonal array for injection molding experiments was adopted. The process parameters included injection temperature (A), holding time (B), injection pressure (C), and graphene ratio (D). Optimal parameter combinations were determined according to resistivity, and the results were A3B2C1D3: 2956.333 MΩ by original and A1B2C1D3: 2802 MΩ Taguchi analysis, respectively, where the improvement was 5.2%.

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