Optimization of Plastic Filling’s Ratio into Thin Wall Injection Molded Part
Corressponding author's email:
Nho@ntt.edu.vnDOI:
https://doi.org/10.54644/jte.76.2023.1286Keywords:
Injection mold, Short shot, Thin Wall, Cavity Molding, Taguchi methodAbstract
The plastic injection molding process is very complicated and there are many defects encountered such as warping, not filling, black burning. In particular, the incomplete filling defect often occurs when pressing thin-walled plastic products. Most manufacturing engineers have used trial and error to set settings for a number of specifications, including melting temperature, injection pressure, injection velocity, and often depending on their experience. All that wastes time and does not optimize the specifications. In this study, the plastic filling rate of thin-walled injection molds was determined by simulation using SolidWorks software. The Taguchi method is used to predict the filling rate of resin in the cavity of the mold. The SolidWork simulation results show that the plastic filling rate in the thin-walled plastic injection mold is strongly influenced by design variables. This result is also determined by signal/noise analysis, analysis of variance, and regression analysis. The optimal value of the plastic filling ratio into the thin-walled plastic injection mold cavity is gained 0.59.
Downloads: 0
References
M. Moayyedian, K. Abhary, and R. Marian, "The analysis of short shot possibility in injection molding process," Int. J. Adv. Manuf. Technol., vol. 91, pp. 3977–3989, 2017.
S. Y. Yang, S. C. Nian, S. T. Huang, and Y. J. Weng, "A study on the micro-injection molding of multi-cavity ultra-thin parts," Polymers Advances Technologies, vol. 22, pp. 891–902, 2011.
Y. K. Shen, C. F. Huang, Y. S. Shen, S. C. Hsu, and M. W. Wu, "Analysis for microstructure of micro lens arrays on micro-injection molding by numerical simulation," International Communications in Heat and Mass Transfer, vol. 35, pp. 1097-1100, 2008.
K. F. Zhang and Z. Lu, "Analysis of morphology and performance of PP microstructures manufactured by micro injection molding," Microsyst. Technol., vol. 14, pp. 209-214, 2008.
B. Sha, S. Dimov, C. Griffiths, and M. S. Packianather, "Investigation of micro-injection moulding: Factors affecting the replication quality," Journal of Materials Processing Technology, vol. 183, pp. 284–296, 2007.
V. V. Gaddamwar and S. P. Bhosle, "Optimization of Process Parameter for ABS, Nylon, Polypropylene Material in Injection Molding using Taguchi Method," International Journal of Engineering Research & Technology (IJERT), vol. 8, no. 6, Jun. 2019.
M. Moayyedian, K. Abhary, and R. Marian, "Gate design and filling process analysis of the cavity in injection molding process," Adv. Manuf., vol. 4, pp. 123–133, 2016.
Y. K. Shen, P. H. Yeh, and J. S. Wu, "Numerical simulation for thin wall injection molding of fiber-reinforced thermoplastics," Intern. Comm. Heat Mass Transf., vol. 28, pp. 1035–1042, 2001.
M. Moayyedian, K. Abhary, and R. Marian, "Optimization of injection molding process based on fuzzy quality evaluation and Taguchi experimental design," CIRP J. Manuf. Sci. Technol., vol. 21, pp. 150–160, 2018.
M. Moayyedian, A. Dinc, and A. Mamedov, "Optimization of Injection-Molding Process for Thin-Walled Polypropylene Part Using Artificial Neural Network and Taguchi Techniques," Polymers, vol. 13, p. 4158, 2021.
S. Kamaruddin, Z. A. Khan, and S. H. Foong, "Application of Taguchi Method in the Optimization of Injection Moulding Parameters for Manufacturing Products from Plastic Blend," IACSIT International Journal of Engineering and Technology, vol. 2, no. 6, Dec. 2010, doi: 10.7763/IJET.2010.V2.184.
C. Y. Wu, C. C. Ku, and H. Y. Pai, "Injection molding optimization with weld line design constraint using distributed multi-population genetic algorithm," Int. J. Adv. Manuf. Technol., vol. 52, pp. 131–141, 2011.
M. Zhai and Y. Xie, "A study of gate location optimization of plastic injection molding using sequential linear programming," Int. J. Adv. Manuf. Technol., vol. 49, pp. 97–103, 2010.
J. K. Kim and E. S. Jeon, "Optimization of Injection Molding Process Parameters to Improve Mechanical Strength of LFT Specimen," International Journal of Applied Engineering Research, vol. 12, no. 13, pp. 3671-3676, 2017.
J. Sreedharan and A. K. Jeevanantham, "Optimization of Injection Molding Process to Minimize Weld-line and Sink-mark Defects Using Taguchi based Grey Relational Analysis," Materials Today: Proceedings, vol. 5, pp. 12615–12622, 2018.
R. Baesso, M. Salvador, and G. Lucchetta, "Filling Balance Optimization for Plastics Injection Molding," AMST’05 Advanced Manufacturing Systems and Technology, pp. 617–624, 2005.
J. H. Jung and W. T. Kwon, "Optimization of EDM process for multiple performance characteristics using Taguchi method and Grey relational analysis," Journal of Mechanical Science and Technology, vol. 24, pp. 1083-1090, 2010.
V. H. Hoang, N. T. Huynh, H. Nguyen, and S. C. Huang, "Analysis and optimal design of a new flexible hinge displacement amplifier mechanism using Finite Element Analysis based on Taguchi method," in 2019 IEEE Eurasia Conference on IoT, Communication, and Engineering (ECICE), pp. 259-262.
N. T. Huynh, S. C. Huang, and T. P. Dao, "Design variables optimization effects on acceleration and contact force of the double sliders-crank mechanism having multiple revolute clearance joints by use of the Taguchi method based on a grey relational analysis," Sādhanā, vol. 45, no. 1, pp. 1-22, 2019.
N. C. Vu, N. T. Huynh, and S. C. Huang, "Optimization of the first frequency modal shape of a tensural displacement amplifier employing flexure hinge by using Taguchi Method," Journal of Physics: Conference Series, vol. 1303, no. 1, p. 012016, 2019.
C. N. Wang, K. P. Truong, N. T. Huynh, and H. Nguyen, "Optimization on effects of design parameter on displacement amplification ratio of 2 DOF working platform employing Bridge-type compliant mechanism flexure hinge using Taguchi method," Journal of Physics: Conference Series, vol. 1303, no. 1, p. 012053, 2019.
C. N. Wang, K. P. Truong, N. T. Huynh, "Optimization effects of design parameter on the first frequency modal of a Bridge-type compliant mechanism flexure hinge by using the Taguchi method," Journal of Physics: Conference Series, vol. 1303, no. 1, p. 012063, 2019.
Q. P. Tran, N. T. Huynh, S. C. Huang, "Artificial neural network based on grey relational analysis estimate displacement of bridge-type amplifier," IOP Conference Series: Materials Science and Engineering, vol. 1113, no. 1, p. 012007, 2021.
Downloads
Published
How to Cite
Issue
Section
Categories
License
Copyright (c) 2023 Journal of Technical Education Science
This work is licensed under a Creative Commons Attribution-NonCommercial 4.0 International License.
Copyright © JTE.
