Analysis of the Pressure and Shrinkage in the Mould for PLA and PLLA

2018 ◽  
Vol 919 ◽  
pp. 128-135
Author(s):  
Monika Kučerová ◽  
Petr Lenfeld
Keyword(s):  
Taguchi Method ◽  
Injection Moulding ◽  
Injection Pressure ◽  
Biodegradable Materials ◽  
Technological Parameters ◽  
Injection Mould

Paper is focused on analysis of a local shrinkage and injection pressure of the biodegradable materials PLLA and PLA. Analysed products were prepared with thickness of 4 mm in the patent injection mould. The technological parameters of the injection moulding were established by the Taguchi method. In this article, the influence of these main technological parameters on the local shrinkage and injection pressure is evaluated.

Optimization of Injection Moulding Process Parameters for Manufacturing Plastic Components (PBT) Using Taguchi Method (TM)

2019 ◽  
Vol 969 ◽  
pp. 775-780
Author(s):  
Rajendra Khavekar ◽  
Hari Vasudevan ◽  
Gosar Vimal
Keyword(s):  
Taguchi Method ◽  
Process Parameters ◽  
Injection Moulding ◽  
Injection Pressure ◽  
Injection Time ◽  
Time Zone ◽  
Polybutylene Terephthalate ◽  
Influence Of Process Parameters ◽  
Pressure Injection ◽  
Injection Moulding Process

In this Paper, the application of Taguchi Method (TM) on the process parameters of Injection Moulding of Polybutylene Terephthalate (PBT) is presented. The influence of process parameters, such as Injection Pressure, Suckback Pressure, Injection Time, Cooling Time, Zone 1 Temperature & Zone 2 Temperature (Barrel Temperatures) on Dark Spots and Short Shots (defects) were investigated using the Orthogonal Array L16 of Taguchi Method for 6 factors at 2 levels each with the response being percent defectives. It was found that Injection Pressure, Injection Time & Zone 1 Temperature had a major effect on the response. After the application of Taguchi Method, the rejection rate dropped down to 5.84% from 11.33%, which is a 48.45% reduction.

Optimization of 67% Powder Loading Co-30Cr-6Mo µMIM Part by Taguchi Method

2014 ◽  
Vol 68 (4) ◽  
Author(s):  
Azizah Wahi ◽  
Norhamidi Muhamad ◽  
Hafizawati Zakaria
Keyword(s):  
Taguchi Method ◽  
Injection Moulding ◽  
Injection Pressure ◽  
Palm Stearin ◽  
Mold Temperature ◽  
Powder Injection ◽  
Injection Time ◽  
Powder Injection Moulding ◽  
Micro Parts ◽  
Injection Temperature

This research studies the effect of injection moulding parameters on the density of green body of Cobalt-30Chromium-6Molybdenum (Co-30Cr-6Mo) for powder injection moulding (PIM) feedstock. In this paper 20 micron Co-Cr-Mo powder was mixed with a palm stearin and polyethylene binder system. L18 orthogonal array by Taguchi Method was used to optimize and predict the future performance. Several injection parameters were optimized such as injection temperature, holding pressure, injection temperature, and mould temperature and injection time. The result shows that the optimum combination of these parameters will produce higher density micro parts. The optimum parameters for 67% powder loading of 20µm Co-30Cr-6Mo powder is 180oC injection temperature, while injection pressure, mold temperature, packing time and injection time are 10 bar, 100oC, 5 s and 7 s respectively.

scholarly journals Selective laser melting for improving quality characteristics of a prism shaped topology injection mould tool insert for the automotive industry

2021 ◽  
pp. 095440622198938
Author(s):  
Mennatallah F El Kashouty ◽  
Allan EW Rennie ◽  
Mootaz Ghazy ◽  
Ahmed Abd El Aziz
Keyword(s):  
Surface Roughness ◽  
Selective Laser Melting ◽  
Automotive Industry ◽  
Injection Moulding ◽  
Dimensional Accuracy ◽  
Quality Characteristics ◽  
Surface Topology ◽  
Laser Melting ◽  
Injection Mould ◽  
Tool Insert

Manufacturing process constraints and design complexities are the main challenges that face the aftermarket automotive industry. For that reason, recently, selective laser melting (SLM) is being recognised as a viable approach in the fabrication of injection moulding tool inserts. Due to its versatility, SLM technology is capable of producing freeform designs. For the first reported time, in this study SLM is recognized for its novel application in overcoming fabrication complexities for prism shaped topology of a vehicle headlamp’s reflector injection moulding tool insert. Henceforth, performance measures of the SLM-fabricated injection mould tool insert is assessed in comparison to a CNC-milled counterpart to improve quality characteristics. Tests executed and detailed in this paper are divided into two stages; the first stage assesses both fabricated tool inserts in terms of manufacturability; the second stage assesses the functionality of the end-products by measuring the surface roughness, dimensional accuracy and light reflectivity from the vehicle reflectors. The results obtained show that employing SLM technology can offer an effective and efficient alternative to subtractive manufacturing, successfully producing tool inserts with complex surface topology. Significant benefits in terms of surface roughness, dimensional accuracy and product functionality were achieved through the use of SLM technology. it was concluded that the SLM-fabricated inserts products proved to have relatively lower values of surface roughness in comparison to their CNC counterparts.

Semisolid Die-Casting Process of Mg-20Al-0.8Zn Magnesium Alloy

2011 ◽  
Vol 306-307 ◽  
pp. 539-543
Author(s):  
Feng Yun Yan ◽  
Xiao Feng Huang ◽  
Bo Li ◽  
Ying Ma
Keyword(s):  
Tensile Strength ◽  
Die Casting ◽  
Injection Pressure ◽  
Casting Process ◽  
Elongation Rate ◽  
Isothermal Heat Treatment ◽  
Technological Parameters ◽  
Injection Speed ◽  
Die Casting Process ◽  
Spherical Grains

Based on microstructure evolution of Mg-20Al-0.8Zn magnesium alloys realized by semisolid isothermal heat-treatment (SSIT), we obtained the non-dendrite or spherical grains microstructure under the suitable technological parameters that isothermal temperature is 495 °C and holding time is 120 min. With the help of special experimental equipment, the semisolid die-casting process has been studied and the specimens have been analyzed. The effects of different parameters as injection speed and pressure on tensile strength, elongation rate, hardness, etc have been investigated. The results indicate that tensile strength was improved along with increasing injection speed and pressure. However, excessive speed will involve gas, which formed defects and reduced the mechanical properties. When the injection pressure is 40MPa and injection speed is 4m/s, the tensile strength and elongation rate can reach maximal 220MPa and 5.63% respectively. Its fracture mechanism was intercrystalline cracking.

scholarly journals Multiobjective Optimization of Injection Moulding Process Parameters on Mechanical Properties Using Taguchi Method and Grey Relational Analysis

2018 ◽  
Vol 7 (3.7) ◽  
pp. 14 ◽  
Author(s):  
Mohd Amran Md Ali ◽  
Noorfa Idayu ◽  
Raja Izamshah ◽  
Mohd Shahir Kasim ◽  
Mohd Shukor Salleh ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Taguchi Method ◽  
Grey Relational Analysis ◽  
Injection Moulding ◽  
Cooling Time ◽  
Mould Temperature ◽  
Plastic Part ◽  
Melt Temperature ◽  
Relational Analysis ◽  
Grey Relational

This study presents an optimization of injection moulding parameters on mechanical properties of plastic part using Taguchi method and Grey Relational Analysis (GRA) approach. The orthogonal array with L9 was used as the experimental design. Grey relational analysis for ultimate tensile strength, modulus and percentage of elongation from the Taguchi method can convert optimization of the multiple performance characteristics into optimization of a single performance characteristic called the grey relational grade (GRG). It is found that mould temperature of 62oC, melt temperature of 280oC, injection time of 0.70s and cooling time 15.4s are found as the optimum process setting. Furthermore, ANOVA result shows that the cooling time is the most influenced factor that affects the mechanical properties of plastic part followed by mould temperature and melt temperature.  

scholarly journals A methodology for setting the injection moulding process parameters for polymer rapid tooling inserts

2019 ◽  
Vol 25 (9) ◽  
pp. 1493-1505 ◽  
Author(s):  
Anurag Bagalkot ◽  
Dirk Pons ◽  
Don Clucas ◽  
Digby Symons
Keyword(s):  
Tool Life ◽  
Process Parameters ◽  
Injection Moulding ◽  
Injection Pressure ◽  
Rapid Tooling ◽  
Fine Tuning ◽  
Content Type ◽  
High Injection ◽  
Start Up ◽  
Injection Moulding Process

Purpose Polymer rapid tooling (PRT) inserts can be used as injection moulding (IM) cavities for prototyping and low volume production but lack the robustness of metal inserts. Metal inserts can withstand high injection pressure and temperature required, whereas PRT inserts may fail under similar parameters. The current method of parameter setting starts with using the highest pressure setting on the machine and then fine-tuning to optimize the process parameters. This method needs modification, as high injection pressures and temperatures can damage the PRT inserts. There is a need for a methodical process to determine the upper limits of moulding parameters that can be used without damaging the PRT inserts. Design/methodology/approach A case study analysis was performed to investigate the causes of failure in a PRT insert. From this, a candidate set-up process was developed to avoid start-up failure and possibly prolong tool life. This was then tested on a second mould, which successfully avoided start-up failure and moulded 54 parts before becoming unusable due to safety issues. Findings Process parameters that are critical for tool life are identified as mould temperature, injection pressure, injection speed, hold pressure and cooling time. Originality/value This paper presents a novel method for setting IM process parameters for PRT inserts. This has the potential to prevent failure at start up when using PRT inserts and possibly extend the operating life of the PRT inserts.

Integration of CAD CAM Techniques in the Development of an Injection Mould for Automotive Parts

2014 ◽  
Vol 216 ◽  
pp. 322-325 ◽  
Author(s):  
Andrei Adam ◽  
Cristian Cosma ◽  
Adrian Ilie Dume ◽  
Sorin Jadaneantu
Keyword(s):  
Injection Moulding ◽  
Unit Cost ◽  
Value Added ◽  
Injection Mould ◽  
Moulding Process ◽  
Global Competitiveness ◽  
Plastic Materials ◽  
Injection Moulding Process ◽  
Cad Cam ◽  
Automotive Parts

Processing by injection is the technological process by that the thermoplastics material is injected, under pressure, in the cavity of a mould, where it cools down and solidifies. This process is the most common method for obtaining plastic materials. Injection moulding of thermoplastics has emerged as the premier vehicle for delivering high quality, value added commercial products. Continued global competitiveness has increased standards for product capability and quality while requiring reduced product development time and unit cost. Despite advanced design methods and new process technologies, it is becoming apparent that the injection moulding process is neither flexible nor robust. This paper presents a design process using CAD-CAM software applied to an injection mould for manufacturing a plastic component that is used in the automotive industry. The component was analyzed, measured and subjected to simulations that will certify the quality of the final product.

scholarly journals Investigation of an inverse thermal injection mould design methodology in dependence of the part geometry

2021 ◽  
Author(s):  
C. Hopmann ◽  
J. Gerads ◽  
T. Hohlweck
Keyword(s):  
Wall Thickness ◽  
Injection Moulding ◽  
Thermal Design ◽  
Internal Stresses ◽  
Cooling Channel ◽  
Injection Mould ◽  
Compression Moulding ◽  
Compression Pressure ◽  
Injection Moulding Process ◽  
Thin Walled

AbstractThe production of injection moulded components with low shrinkage and warpage is a constant challenge for manufacturers. The thermal design of the injection mould plays an important role for the achievable quality, especially the placement of the cooling channels. This design is usually based on empirical knowledge of the mould designers. The construction is supported iteratively by injection moulding simulations. In the case of thick-walled plastic optics with big wall thickness jumps, the shrinkage is compensated by injection compression moulding. In this process, the thin-walled areas freeze earlier and the necessary compression pressure introduces stresses into these areas which reduces the optical performance. An adapted cooling channel design can reduce these problems. At the IKV, Institute for Plastics Processing in Industry and Crafts at the RWTH Aachen University, a methodology was developed which inversely calculates the cooling requirement of the moulded part A demand-oriented cooling channel system is derived based on the computed results. The aim of the research projects is to minimise displacement and internal stresses by temperature control of the moulded parts according to the demand. In this paper, the methodology is applied to three different geometries, representing three classical parts for the injection moulding process. Three different quality areas in the mould for the inverse optimisation are defined and investigated. For each geometry the cooling channel designs are then validated in injection moulding simulations based on the results from the thermal optimisation. It can be shown that for different component geometries and thicknesses, different quality areas are advantageous and decrease the maximum warpage of the parts. For thin-walled ribbed components, a 2D approach leads to a 15% smaller displacement, for components with wall thickness jumps, all investigated quality ranges show no differences in displacement, but a surface in the middle of the part is preferred due to a 3 °C lower standard deviation of the temperature distribution.

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