Rejection Rate Reduction of the Automotive Thermoplastic Parts in Injection Moulding Using Response Surface Methodology

2020 ◽  
Vol 841 ◽  
pp. 225-231
Author(s):  
Huei Ruey Ong ◽  
Ifwat Mohd Shah ◽  
Wan Mohd Eqhwan Iskandar ◽  
Md. Maksudur Rahman Khan ◽  
Chi Shein Hong ◽  
...  
Keyword(s):  
Response Surface Methodology ◽  
Response Surface ◽  
Process Parameters ◽  
Injection Moulding ◽  
Injection Pressure ◽  
Acrylonitrile Butadiene Styrene ◽  
Rejection Rate ◽  
Mould Temperature ◽  
Melt Temperature ◽  
Rsm Model

Plastic injection moulding is widely used for manufacturing due to variety of plastic product. In this study, plastic part defects such as air bubble and gas mark defect are commonly occurs in thermoplastic part, specifically acrylonitrile butadiene styrene (ABS). In order to optimize the process parameters of injection moulding, design of experiment (DOE) with Response Surface Methodology (RSM) model was used. Process parameters such as melt temperature, mould temperature and injection pressure were selected for the DOE development. The experiments were conducted with melt temperature range from 200 °C to 240 °C, mould temperature from 60 °C to 80 °C and injection pressure from 90 to 99%. The result indicates that, all the selected parameters were significantly influence the rejection rate of the automotive ABS part. The optimum melt temperature, mould temperature and injection pressure were 220 °C, 70 °C and 98% respectively, in obtaining minimum rejection rate.

Application of Grey Taguchi based Response Surface Methodology (GT-RSM) in Injection Moulding of Polypropylene/E-glass Composite

2015 ◽  
Vol 5 (1) ◽  
pp. 35-48 ◽  
Author(s):  
M. Santhanakumar ◽  
R. Adalarasan
Keyword(s):  
Response Surface Methodology ◽  
Response Surface ◽  
Injection Moulding ◽  
Statistical Significance ◽  
Rheological Behaviour ◽  
Quality Characteristics ◽  
Melt Temperature ◽  
Glass Composites ◽  
Packing Pressure ◽  
Grey Taguchi

Strong non-linearity combined with the complicated rheological behaviour of polymers makes the quality characteristics of products unpredictable in plastic injection moulding. The purpose of this work is to study the mechanical properties of injection moulded polypropylene/E-glass composites. The process parameters like the melt temperature, injection pressure, packing pressure and cooling time were found to influence the quality characteristics of the produced parts. These four parameters were varied at three levels and a L18 orthogonal array was used for designing and conducting the experiments. Tensile and impact strength (Charpy-notched) were observed as the responses and a new integrated technique of grey Taguchi based response surface methodology (GT-RSM) was disclosed to predict the optimal operating condition. A confirmation test was conducted to demonstrate the accuracy of GT-RSM approach. Injection and packing pressure were found to have statistical significance in influencing the strength of injection moulded polypropylene/E-glass composites.

Influence of Injection and Cavity Pressure on the Demoulding Force in Micro-Injection Moulding

2014 ◽  
Vol 136 (3) ◽  
Author(s):  
C. A. Griffiths ◽  
S. S. Dimov ◽  
S. G. Scholz ◽  
G. Tosello ◽  
A. Rees
Keyword(s):  
Experimental Study ◽  
Process Parameters ◽  
Design Of Experiment ◽  
Injection Moulding ◽  
Processing Conditions ◽  
Cavity Pressure ◽  
Mould Temperature ◽  
Melt Temperature ◽  
Injection Speed ◽  
Micro Injection Moulding

The paper reports an experimental study that investigates part demoulding behavior in micro-injection moulding with a focus on the effects of pressure and temperature on the demoulding forces. In particular, the demoulding performance of a representative microfluidics part was studied as a function of four process parameters, melt temperature, mould temperature, holding pressure, and injection speed, employing the design of experiment approach. In addition, the results obtained using different combinations of process parameters were analyzed to identify the best processing conditions in regards to demoulding behavior of microparts when utilizing a COC polymer to mould them.

Study of the Parameters in Electro-Discharge Diamond Face Grinding through Response Surface Methodology Approach

2011 ◽  
Vol 110-116 ◽  
pp. 847-855
Author(s):  
Gyanendra Kumar Singh ◽  
Vinod Yadava ◽  
Raghuvir Kumar
Keyword(s):  
Response Surface Methodology ◽  
Response Surface ◽  
Process Parameters ◽  
Removal Rate ◽  
Experimental Models ◽  
Duty Factor ◽  
Predicted Values ◽  
Rsm Model ◽  
Pulse On Time ◽  
Face Grinding

The present study investigates the relationship of process parameters in electro-discharge diamond face grinding (EDDFG) of tungsten carbide and cobalt composite (WC-Co). The central composite rotatable design had been utilized to plan the experiments and response surface methodology (RSM) was employed for developing experimental models. Analysis on machining characteristics of EDDFG was made based on the developed models. In this study, wheel RPM, current, pulse on-time, and duty factor are considered as input process parameters. The process performances such as material removal rate (MRR) and average surface roughness (Ra) were evaluated. Analysis of variance test had also been carried out to check the adequacy of the developed regression models. The observed optimal process parameter settings are wheel RPM of 1500, current of 6.9029 A, pulse on-time of 137. 8208 µs, and duty factor of 0.79 for achieving maximum MRR and minimum Ra; finally, the results were experimentally verified. A good agreement is observed between the results based on the RSM model and the actual experimental observations. The error between experimental and predicted values at the optimal combination of parameter settings for MRR and Ra lie within 6.18% and 12.33%, respectively.

scholarly journals Influence of Process Parameters on Rapid Prototype Part Using Response Surface Methodology

2019 ◽  
Vol 1 (1) ◽  
pp. 4-7
Author(s):  
Chockalingam Palanisamy ◽  
Natarajan Chinnasamy ◽  
Karthikeyan Muthu
Keyword(s):  
Response Surface Methodology ◽  
Response Surface ◽  
Layer Thickness ◽  
Process Parameters ◽  
Rapid Prototype ◽  
Acrylonitrile Butadiene Styrene ◽  
Fused Deposition Modelling ◽  
Influence Of Process Parameters ◽  
Fused Deposition

In this research the influencing process parameters on fused deposition modelling of Acrylonitrile Butadiene Styrene (ABS) parts were studied. The two process parameters, layer thickness and model interior fill style are studied. The specimens were built, tests carried out to find out the surface roughness quality of the specimens. The results analyzed using Response Surface Methodology (RSM). The result indicates that the specimen Type 1 with the 0.254mm layer thickness and solid model interior fill style is the best specimen among the types of specimens tested.

Shrinkage and Warpage in the Permanent Shape of Sape-Memory Polyurethane Parts

2022 ◽  
Vol 58 (4) ◽  
pp. 102-113
Author(s):  
Sukran Katmer ◽  
Cetin Karatas
Keyword(s):  
Shape Memory ◽  
Injection Moulding ◽  
Flow Direction ◽  
Injection Pressure ◽  
Cooling Time ◽  
Mould Temperature ◽  
Melt Temperature ◽  
Packing Pressure ◽  
Permanent Shape ◽  
Packing Time

The shape memory effect, as the most important ability of shape memory polymers, is a working property and provides the design ability to shape memory polymer features. Shrinkage and warpage are important parameters to control the dimensional accuracy of permanent and temporary shapes of an injection moulded shape memory polyurethane (SMPU) part. In this study, the effects of injection moulding parameters on the shrinkage and warpage of the permanent shape of moulded SMPU parts were experimentally investigated. The parameters of injection pressure, melt temperature, mould temperature, packing pressure, packing time, and cooling time, were chosen as the injection moulding control factors. Taguchi�s L27 orthogonal array design table was used with six injection moulding parameters and their three levels. The results showed that the part has different shrinkage ratios in three main directions, namely, the flow direction, perpendicular to the flow direction, and the direction through the thickness. The results of the analysis of variance showed that the cooling time is the most influential parameter on both the shrinkage (except in thickness) and warpage. The shrinkage in the flow direction as well as in perpendicular to the flow direction decreased with increasing the cooling time. Warpage also decreased with increasing the cooling time. Injection pressure and melt temperature were found to be effective on shrinkage in thickness. Effects of mould temperature, packing pressure, and packing time were found to be limited. A statistically significant relationship has been noticed among shrinkage, warpage, and residual stresses during the study.

Modeling and Analysis of Process Parameters for Plastic Injection Molding of Base-Cover

2012 ◽  
Vol 602-604 ◽  
pp. 1930-1933 ◽  
Author(s):  
Yan Fang Yin
Keyword(s):  
Process Parameters ◽  
Injection Pressure ◽  
Acrylonitrile Butadiene Styrene ◽  
Analysis Data ◽  
Mold Temperature ◽  
Melt Temperature ◽  
Modeling And Analysis ◽  
Filling Time ◽  
And Performance ◽  
The Cost

The quality of the plastic part depends on the material characteristics, the mold design, and the process parameters, one of which is more important. It involves many sub-design tasks that determine the cost and performance in the early conceptual mold layout design phase. Base-Cover was injection molded with acrylonitrile–butadiene–styrene (ABS)/polycarbonate (PC) [ABS/PC] alloy resin and its process parameters was analyzed by commercial Moldflow software. The optimum gate location and melt filling time were determined, and the optimum injection temperature was obtained by analyzing the shrinkage of the product after molding. An effective regression model was developed to determine the mathematical relationship between the process parameters (mold temperature, melt temperature, injection pressure, injection time, and cooling time) and the volumetric shrinkage by utilizing the analysis data.

Experimental Study of Injection Conditions for a Thin-Walled Wax Pattern Using Response Surface Methodology

2014 ◽  
Vol 607 ◽  
pp. 185-192 ◽  
Author(s):  
Chang Hui Liu ◽  
Sun Jin ◽  
Xin Min Lai ◽  
Dong Hong Wang ◽  
Yu Lian Wang
Keyword(s):  
Response Surface Methodology ◽  
Response Surface ◽  
Process Parameters ◽  
Mold Temperature ◽  
Holding Time ◽  
Melt Temperature ◽  
Packing Pressure ◽  
Wax Pattern ◽  
Thin Walled ◽  
The Relationship

In this paper, the relationship between the shrinkage of the thin-walled wax part in the investment casting process (ICP) and the process parameters including mold temperature, melt temperature, packing pressure and holding time are investigated through a series of experiments. The relationship is successfully described by a mathematical regression model which is based on the response surface methodology (RSM). The rationality and adequacy of the mathematical model are checked via analysis of variation (ANOVA) and a sensitivity analysis for process parameters on the dimensional shrinkage variation are conducted which shows that the contribution percentages of mold temperature, melt temperature, packing pressure and holding time are 23.77%, 43.67%, 11.85% and 16.99%, respectively. Additionally, the optimal setting of the process parameters is also obtained by calculating the desirability function. The optimal combination of the mold temperature, melt temperature, packing pressure, and holding time is 74°C, 30°C 25bar, and 5 sec, respectively.

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