Warpage deflection is one of the common pitfalls in plastic injection moulding which is always affected the quality and accuracy of the plastic products. It occurs due to the influences of mould temperature during injection moulding process and it is related to the number of cooling system existed in the mould. Therefore, this paper studies the effect of cooling channels on warpage of dumbbell plastic part having different number of cooling channel using Moldflow software. Warpage analysis was run using four and eight cooling channels. Parameters involved in this study are injection time, packing time, melt temperature and mould temperature. The result of warpage from simulation analysis was projected on the graphic having different colour which is presented the actual value of warpage. It is found from warpage simulation result that the maximum warpage for four cooling channels is 1.283mm and the maximum warpage for eight cooling channels is 1.280mm. It shows that the increasing of the number of cooling channel from four to eight channels in the injection mould reduces the warpage deflection about 0.2%. Thus, the result shows that the number of cooling system in the mould plays an important role on the quality of plastic part during injection moulding process.
The heat treatment process is important to conduct on A356 Aluminum Alloy that broadly used in an automotive application. Analysis of the effect grain refinement, eutectic silicon modification of T6 solutionizing heat treatment parameter on strength development of A356 Aluminum Alloy were performed to become an important prospect of controlling the behaviour of materials as well as duration and temperature. In this study, there are three parameters condition were conducted which is duration Time (Hour) and Temperature (°C) which is 465°C in 8 hours, 500°C in 7 hours and 535°C in 6 hours, respectively. The study generated three responses that are tensile, hardness test and microstructure analysis of the different temperature and duration time, respectively following by water-quenching. The result showed that the modification of duration time and high temperature of solutionizing heat treatment have superior mechanical properties while the microstructure analysis showed the clear formation of refinement α-Al dendrite and eutectic silicon particle.
Thixoforming is a type of semisolid metal (SSM) processing for forming alloys in the semisolid state to near net-shaped products. In the present study, the effect of a thixoforming process on the microstructure and mechanical properties of Al-6Si-3Cu aluminium alloy was investigated. Melt was poured on a cooling slope at 630oC and the samples were obtained through permanent mold casting. They were thixoformed using a hydraulic press after holding at 571oC for 5min to yield a microstructure predominantly composed of α-Al globules and inter-globular Si particles. As-cast and thixoformed samples were characterized using optical microscopy, scanning electron microscopy (SEM), energy dispersive X-ray (EDX) and X-ray diffraction (XRD) as well as hardness measurements and tensile tests. The results indicate that the mechanical properties of thixoformed alloy have improved as compared to permanent mold cast alloy. The ultimate tensile strength of as-cast sample was 210 ± 3.5 MPa and increased to 241 ±3.1 MPa in the thixoformed sample while the yield strength of as-cast alloy was 140 ±4.5 MPa and increased to 176±3.3 MPa in the thixoformed sample. The thixoformed alloy also showed an improvement in elongation to fracture as it increased from 2% in as-cast sample to 3.2% in thixoformed alloy. The fracture of as-cast sample showed a cleavage fracture, whereas in the thixoformed alloy, a combination of dimple and cleavage was observed.
The effect of mould temperature on warpage using water and oil as coolant fluid was studied using flow software analysis. Mould temperature was controlled using two types of coolants; where cold mould was controlled by water and hot mould was controlled by oil. The simulation analysis was performed using flow software analysis Moldflow Plastics Insight (MPI). Taguchi method was used to design the planning matrix and to find the optimum levels of input variables. Then, to find the percentage contribution of input variables on output variables, analysis of variance (ANOVA) was used. It is found that mould temperature controlled by water shows less warpage analysis compared to oil. The minimum and maximum percentage of warpage analysis between cold mould and hot mould are 3.1% and 7.1% respectively. In addition, ANOVA analysis shows that the most significant parameters affected the warpage analysis for both moulds using oil and water are melt temperature (255°C) followed by mould temperature (water 15°C and oil 70°C) and cooling time (water 8s and oil 6s). Thus, it shows that coolant medium used in mould cooling system contributes the quality of plastic parts.
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