Optimisation of warpage on plastic injection moulding part with MGSS conformal cooling channels moulds using response surface methodology (RSM)

Hazwan, M. H. M.; Shayfull, Z.; Sharif, Safian; Zainal, Nurezayana; Nasir, S. M.

doi:10.1063/1.4981860

Cited by 10 publications

(4 citation statements)

References 14 publications

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“…Their findings showed that RSM sufficed in warpage optimization of both SCC and CCC. Full factorial DoE was used to optimize the warpage resulting from a milled groove CCC with a square CS [17]. They found out that warpage was affected by the cooling time more than the temperature of the molten plastic and packing pressure.…”

Section: Sensitivity-based Design Attempts To Understand the Relation...mentioning

confidence: 99%

Simultaneous Optimization of Product Quality and Productivity for Multi-Factor designs of Circular Cross-Section Conformal Cooling Channels in Injection Molds

Simiyu

Mutua²,

Muiruri³

et al. 2023

Preprint

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The widespread use and demand for plastic products worldwide have caused manufacturers to covet high productivity and product quality. Most plastic products are produced using the injection molding technique. This technique is characterized by long cooling times, which affect the production cycle and product quality. According to the literature, cooling during the injection molding process can be significantly affected by the design of the cooling channels. This study is, therefore focused on multi-factor design optimization of circular cross-section conformal cooling channels for multiple responses. The Taguchi design-of-experiments approach was adopted in this study. The key variables of conformal cooling channels that were studied involved diameters, depths, and pitches. Solidworks® was used for 3D design and numerical simulation to determine the cooling time, volumetric shrinkage, warpage, and sink marks. Multi-response optimization was then conducted using the Taguchi-Grey Relational Analysis technique. Results show that the optimal cooling channel design has a minimum; diameter of 8 mm, a depth of 12 mm, and a pitch of 16 mm. Additionally, Analysis of Variance (ANOVA) revealed that the diameter is the significant cooling channel design parameter contributing to all the responses concurrently, with the most significant percentage of 80.26%. Comparing the conformal and straight cooling channel designs, superior performance was noted for the former against the latter, with the optimal design recording an improvement of 29.35%, 5.99%, 19.77%, and 38.85% in the cooling time, volumetric shrinkage, warpage, and depth of sink marks, respectively.

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Section: Sensitivity-based Design Attempts To Understand the Relation...mentioning

confidence: 99%

Simultaneous Optimization of Product Quality and Productivity for Multi-Factor designs of Circular Cross-Section Conformal Cooling Channels in Injection Molds

Simiyu

Mutua²,

Muiruri³

et al. 2023

Preprint

View full text Add to dashboard Cite

show abstract

“…ese include the injection speed, injection pressure, cooling time, packing pressure, mold temperature, packing time, and melt temperature. e injection speed and injection pressure have been identified in [30,31], whereas the cooling time, packing pressure, mold temperature, packing time, and melt temperature have been identified in [3,[31][32][33][34][35][36] as having an effect on the product quality. e experiments in this work were conducted on an injection molding unit known as the Arburg Allrounder 420 C [37], and a simple mold with product dimensions depicted in Figure 2 was used.…”

Section: Injection Molding Experimentsmentioning

confidence: 99%

Experimental-Based Optimization of Injection Molding Process Parameters for Short Product Cycle Time

Mukras

2020

Advances in Polymer Technology

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This paper presents a framework for optimizing injection molding process parameters for minimum product cycle time subjected to constraints on the product defects. Two product defects, namely, volumetric shrinkage and warpage, as well as seven process parameters including injection speed, injection pressure, cooling time, packing pressure, mold temperature, packing time, and melt temperature, were considered. Injection molding experiments were conducted on specifically chosen test points and results were used to compute the volumetric shrinkage and warpage (at each test point). Thereafter, three relationships between the product cycle time (one relationship), the two product defects (two relationships), and the injection molding parameters were constructed using the kriging technique. An optimization problem to minimize the product cycle time (described by the first relationship) subject to constraints on the product defects (described by the latter two relationships) was then formulated. A combination set of points between the lower and upper extreme values of acceptable product defect was generated to serve as constraints for the two product defects. The optimization problem was then solved using the Fmincon function, available in the Matlab optimization toolbox. A plot of the optimization results revealed an appreciable tradeoff between the cycle time and the two product defects. To validate the optimization, an additional injection molding experiment was conducted for one of the optimization results. Results from the additional experiment showed reasonably close agreement with simulation optimization results differing in the cycle time, the warpage and volumetric shrinkage by 6.7%, 3.2%, and 8%, respectively.

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“…Lowered cycle time translates to an increase in production rate. Previous research shows that reduction in cycle time can lead to a pro t income [13,14]. This makes the application of CCC very attractive, and it has been made possible by the application of 3D manufacturing.…”

Section: Introductionmentioning

confidence: 99%

“…Their ndings showed that RSM su ced in warpage optimization of both SCC and CCC. Full factorial DoE was used to optimize the warpage resulting from a milled groove CCC with a square CS (Hazwan, Shayfull, Sharif, Zainal, et al, 2017). They found out that warpage was affected by the cooling time more than the temperature of the molten plastic and packing pressure.…”

Section: Introductionmentioning

confidence: 99%

Multi-objective Optimization of Conformal Cooling Channel Design in Injection Molds Using Taguchi Grey Relational analysis

Simiyu

Mutua²,

Muiruri³

et al. 2023

Preprint

View full text Add to dashboard Cite

The widespread use and demand for plastic products worldwide have caused manufacturers to covet high productivity and product quality. Most plastic products are produced using the injection molding technique. This technique is characterized by long cooling times, which affect the production cycle and product quality. Literature reveals that cooling in injection molding can be significantly affected by the design of the cooling channels. This study is, therefore focused on design optimization of circular cross-section conformal cooling channels. The Taguchi design of experiments approach was adopted in this study. The key variables of conformal cooling channels that were studied involved diameters, depths, and pitches. Solidworks® was used for 3D design, and for numerical simulation to determine the cooling time, volumetric shrinkage, warpage, and sink marks. Multi-response optimization was then conducted using the Taguchi-Grey Relational Analysis technique. Results show that the optimal cooling channel design has a minimum; diameter of 8 mm, depth of 12 mm and pitch of 16 mm. Additionally, Analysis of Variance (ANOVA) revealed that the diameter is the significant cooling channel design parameter that contributes to all the responses concurrently with the largest percentage of 80.26%. Comparing the conformal with straight cooling channel designs, superior performance was noted for the former against the later with optimal design recording an improvement of 29.35%, 5.99%, 19.77%, and 38.85% in the cooling time, volumetric shrinkage, warpage, and depth of sink marks respectively.

show abstract

Optimisation of warpage on plastic injection moulding part with MGSS conformal cooling channels moulds using response surface methodology (RSM)

Cited by 10 publications

References 14 publications

Simultaneous Optimization of Product Quality and Productivity for Multi-Factor designs of Circular Cross-Section Conformal Cooling Channels in Injection Molds

Simultaneous Optimization of Product Quality and Productivity for Multi-Factor designs of Circular Cross-Section Conformal Cooling Channels in Injection Molds

Experimental-Based Optimization of Injection Molding Process Parameters for Short Product Cycle Time

Multi-objective Optimization of Conformal Cooling Channel Design in Injection Molds Using Taguchi Grey Relational analysis

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