Application of Taguchi's method on the optimal process design of an injection molded PC/PBT automobile bumper

Chen, R.S.; Lee, H.H.; Yu, C.Y.

doi:10.1016/s0263-8223(97)00110-4

Cited by 46 publications

(25 citation statements)

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“…It employs some orthogonal arrays taking into account the number of parameters and their levels as well as the number of trials to be conducted, and subsequently determines the best combinations of parameters based on the signal to noise ratio. As an example, Taguchi L27 3 13 implies a system comprising 13 parameters each with 3 levels, which requires only 27 trial experiments, instead of 3 13 , for obtaining the desired result.…”

Section: Taguchi Methods For Design Of Experimentsmentioning

confidence: 99%

“…The application of similar procedures in injection molding are found in some other works, e.g., minimization of friction coefficient and strain [118], minimization of warpage and shrinkage [84], and minimization of shrinkage in polypropylene and polystyrene components [4]. Various forms of the Taguchi method were applied in many other works concerning with injection molding optimization, e.g., determination of the optimum parameters based on visual quality and shrinkage [111], evaluation of the process parameters by avoiding silver streak defects in injection molded automobile plastic bumpers [13], evaluation of the influence of process parameters on the dimensional variation of injection molded ceramic [109], evaluation of process parameters by minimizing warpage in thin-shell plastic products [39], identification of parameters affecting shrinkage and warpage in thin-wall cellular phone covers [66], study of the effects of design parameters on shrinkage [15], determination of the optimal values of process parameters by minimizing warpage of a rectangular plate [108], study of the effect of input parameters on optimizing mechanical properties of recycled plastic parts [76][77][78], etc. In the recent application of the Taguchi method, Kang [46] optimized input parameters by minimizing shrinkage and warpage, Wang et al [116] optimized input parameters in order to improve the compressive property of a brake booster valve body, and Karasu et al [47] reduced the number of trial runs needed before mass production.…”

Section: Taguchi Methods For Design Of Experimentsmentioning

confidence: 99%

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Process parameter optimization of plastic injection molding: a review

Kashyap

Datta

2015

Int J Plast Technol

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Over the years, injection molding has been a premier manufacturing technique in the production of intricate polymer components. Its molding efficiency rests on the shoulders of multiple process and machine parameters, which dictate the final product quality in terms of multiple output responses. It is imperative to state that a precise optimization of various input parameters is paramount for achieving the desired quality indices. In this article, a review of different techniques employed till date for optimizing various injection molding parameters is presented along with their advantages and limitations. It is found in the review that a complete intelligent technique operable without human interference is yet to be developed.

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Section: Taguchi Methods For Design Of Experimentsmentioning

confidence: 99%

Section: Taguchi Methods For Design Of Experimentsmentioning

confidence: 99%

Process parameter optimization of plastic injection molding: a review

Kashyap

Datta

2015

Int J Plast Technol

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“…Hence, the integration of numerical simulation and Taguchi method can be used to screen the significant processing parameters in injection moulding prior the optimization if numerous processing parameters are to be considered in the optimization experiment. Reference [44] utilized C-Mold and Taguchi method to find the optimum levels of processing parameters to eliminate silver streaks on the surface of an injection-moulded polycarbonate/poly(butylene terephthalate) automobile bumper. A preliminary experiment was conducted with a L 12 orthogonal array (OA) to screen the significant parameters prior the optimization experiment.…”

Section: Isrn Industrial Engineeringmentioning

confidence: 99%

Practical Applications of Taguchi Method for Optimization of Processing Parameters for Plastic Injection Moulding: A Retrospective Review

Fei

Mehat²,

Kamaruddin

2013

ISRN Industrial Engineering

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Determining the optimal processing parameter is routinely performed in the plastic injection moulding industry as it has a direct and dramatic influence on product quality and costs. In this volatile and fiercely competitive market, traditional trial-and-error is no longer sufficient to meet the challenges of globalization. This paper aims to review the research of the practical use of Taguchi method in the optimization of processing parameters for injection moulding. Taguchi method has been employed with great success in experimental designs for problems with multiple parameters due to its practicality and robustness. However, it is realized that there is no single technique that appears to be superior in solving different kinds of problem. Improvements are to be expected by integrating the practical use of the Taguchi method into other optimization approaches to enhance the efficiency of the optimization process. The review will shed light on the standalone Taguchi method and integration of Taguchi method with various approaches including numerical simulation, grey relational analysis (GRA), principal component analysis (PCA), artificial neural network (ANN), and genetic algorithm (GA). All the features, advantages, and connection of the Taguchi-based optimization approaches are discussed.

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“…Kim and Lee (1997) discussed different geometries for plastic parts to improve the parts' warpage by Taguchi's orthogonal experiment design. To avoid producing flaws of silver streaks for automobile plastic bumpers, Taguchi's optimization method is utilized to decide the optimal values for the process parameters by Chen et al (1997). The same optimization method was also used by several works (Huang and Tai 2001;Liu and Chen 2002;Liao et al 2004a, b;Oktem et al 2007) to find the optimal combinations of process parameters for different plastic products.…”

Section: Literature Review On the Optimization Of Process Parameters mentioning

confidence: 99%

Finding efficient frontier of process parameters for plastic injection molding

Chen

Huang

2013

J Ind Eng Int

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Product quality for plastic injection molding process is highly related with the settings for its process parameters. Additionally, the product quality is not simply based on a single quality index, but multiple interrelated quality indices. To find the settings for the process parameters such that the multiple quality indices can be simultaneously optimized is becoming a research issue and is now known as finding the efficient frontier of the process parameters. This study considers three quality indices in the plastic injection molding: war page, shrinkage, and volumetric shrinkage at ejection. A digital camera thin cover is taken as an investigation example to show the method of finding the efficient frontier. Solidworks and Moldflow are utilized to create the part's geometry and to simulate the injection molding process, respectively. Nine process parameters are considered in this research: injection time, injection pressure, packing time, packing pressure, cooling time, cooling temperature, mold open time, melt temperature, and mold temperature. Taguchi's orthogonal array L27 is applied to run the experiments, and analysis of variance is then used to find the significant process factors with the significant level 0.05. In the example case, four process factors are found significant. The four significant factors are further used to generate 3 4 experiments by complete experimental design. Each of the experiments is run in Moldflow. The collected experimental data with three quality indices and four process factors are further used to generate three multiple regression equations for the three quality indices, respectively. Then, the three multiple regression equations are applied to generate 1,225 theoretical datasets. Finally, data envelopment analysis is adopted to find the efficient frontier of the 1,225 theoretical datasets. The found datasets on the efficient frontier are with the optimal quality. The process parameters of the efficient frontier are further validated by Moldflow. This study demonstrates that the developed procedure has proved a useful optimization procedure that can be applied in practice to the injection molding process.

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Application of Taguchi's method on the optimal process design of an injection molded PC/PBT automobile bumper

Cited by 46 publications

References 1 publication

Process parameter optimization of plastic injection molding: a review

Process parameter optimization of plastic injection molding: a review

Practical Applications of Taguchi Method for Optimization of Processing Parameters for Plastic Injection Moulding: A Retrospective Review

Finding efficient frontier of process parameters for plastic injection molding

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