Influence of Injection Moulding Process Parameters on High-Density Polyethylene Surface Hardness

2020 ◽  
Vol 994 ◽  
pp. 189-196
Author(s):  
Aleš Mizera ◽  
Tomáš Fiala ◽  
Miroslav Manas ◽  
Pavel Stoklásek ◽  
Martin Ovsik
Keyword(s):  
Mechanical Properties ◽  
Process Parameters ◽  
Injection Moulding ◽  
High Density Polyethylene ◽  
Surface Hardness ◽  
High Density ◽  
Mould Temperature ◽  
Depth Sensing ◽  
Moulding Process ◽  
Injection Moulding Process

Commodity polymers are a common part of everyday life. They consist mainly of polyolefins such as polyethylene, polypropylene. They are primarily used for ease of processing, cost and especially chemical resistance. The disadvantages of these polymers are low mechanical properties as well as temperature resistance. Any improvement in the mechanical properties can extend the application possibilities of the commodity polymers to the areas reserved for the construction polymers. This paper deals with changing two injection moulding process parameters - melt and mould temperature to high-density polyethylene (HDPE) surface hardness. HDPE hardness was measured using the method of Depth-Sensing Indentation (DSI) on three different instruments (ultranano-, nanoand micro-hardness tester). It has been found that as the melt and mould temperature increases, the hardness slightly increases.

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.

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.

Polymeric Micro-Filter Fabrication Using a Micro Injection Moulding Process

2015 ◽  
Author(s):  
Rossella Surace ◽  
Vincenzo Bellantone ◽  
Irene Fassi
Keyword(s):  
Injection Moulding ◽  
Electrical Discharge Machining ◽  
Polymeric Materials ◽  
Machining Process ◽  
Injection Velocity ◽  
Mould Temperature ◽  
Moulding Process ◽  
Micro Injection Moulding ◽  
Injection Moulding Process ◽  
Incomplete Filling

This paper reports on fabrication and characterization of a micro-filter for hearing aid, dialysis media and inhaler. The micro-feature specifications consist in a diameter of 2.3 mm, a thickness of 0.2 mm and it is composed by a mesh with grid of 80 μm and ribs with width of 70 μm. The proposed micro-filter is fabricated by micro injection moulding process adopting a steel mould manufactured by micro Electrical Discharge Machining process (micro EDM). Different polymeric materials (POM, HDPE, LCP), particularly indicated for the injection moulding applications due to their flowability and stability, are tested and evaluated in relation to the process replication capability. Since the polymer micro-filter is made of a complex grid of micro-ribs, the injection moulding process must ensure complete filling of the micro-parts, preventing any defects (i.e. premature solidification, incomplete filling, flash and air traps). To this aim, different system parameters configurations (melt and mould temperature, injection velocity, holding time and pressure, cooling time, pressure limit) are tested for obtaining acceptable part in all polymers grade. Finally, the component is dimensionally characterized by confocal microscopy and its filtration capacity is then verified. Although the feature complexity was high, the results showed that the object could be successfully replicated by filling completely the micro cavities with two of them: POM and HDPE. The most significant parameters influencing the part filling were the mould temperature and the injection velocity. These findings allow to further optimize the micro-injection process parameters to obtain a high quality product.

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