Simulation Based Optimization of Thin Wall Injection Molding Parameter Using Response Surface Methodology

Improper mold design or processing parameter setting could make a bad impact on the appearance of molded part. It becomes more challenging if the ratio of the part size compared with its wall thickness is greater. Process parameters such as mold and melt temperature, injection temperature including...

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Bibliographic Details
Published in:IOP conference series. Materials Science and Engineering 2020-06, Vol.864 (1), p.12193
Main Authors: Rosli, M. U., Ahmad Termizi, S. N. A., Khor, C. Y., Nawi, M. A. M., Akmal Omar, Ahmad, Ikman Ishak, Muhammad
Format: Article
Language:English
Subjects:
Design parameters
Design specifications
Injection molding
Layouts
Melt temperature
Molds
Optimization
Polyurethane resins
Process parameters
Product design
Response surface methodology
Shrinkage
Thin walls
Wall thickness
Warpage
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Summary:Improper mold design or processing parameter setting could make a bad impact on the appearance of molded part. It becomes more challenging if the ratio of the part size compared with its wall thickness is greater. Process parameters such as mold and melt temperature, injection temperature including the cavity layout directly affect product quality and cost. It is a complex and difficult task to improve these multi parameters. The objective of this research is to determine optimum settings for processing parameters for a thin walled product by using Response Surface Methodology. Melting temperature, mold temperature, injection pressure and cavity layout are selected as processing parameters and Polyurethane material is selected for this research. Volumetric shrinkage and warpage are selected as the main quality criteria to be controlled respected with the product design specifications. As the result, optimum process parameter settings were mold temperature of 29.89°C, melting temperature of 220°C, and 181.30MPa injection pressure with 'H' branching cavity layout. With small differences error value between solution and simulation, 0.31% for volumetric shrinkage and 0.126% for warpage, the result was acceptable.
ISSN:1757-8981
1757-899X
DOI:10.1088/1757-899X/864/1/012193