Optimization of the Reduction of Shrinkage and Warpage for Plastic Parts in the Injection Molding Process by Extended Adaptive Weighted Summation Method

Abstract

The consumer market has changed drastically in recent times. Consumers are becoming more demanding, and many companies are competing to be market leaders. Therefore, companies must reduce rejects and minimize their operating costs. One problem that arises in producing plastic parts is controlling deformation, mainly in the form of shrinkage due to the material and warpage associated with the geometry of the parts. This work presents a novel extended adaptive weighted sum method (EAAWSM: Extended Adaptive Weighted Summation Method) integrated into a Pareto front model. The performance of this model is evaluated against three other conventional optimization methods—Taguchi–Gray (TG), Technique for Order of Preference by Similarity to Ideal Solution (TOPSIS), and Model Optimization by Genetic Algorithm (MOGA)—and compared with EAAWSM. Two response variables and three input factors are considered to be analyzed: material melting temperature, mold temperature, and filling time. Subsequently, the performance is compared and its behavior observed using Moldflow® simulation. The results show that with the EAAWSM method, the shrinkage is 15.75% and the warpage is 3.847 mm, regarding the manufacturing process parameters of a plastic part. This proposed deterministic model is easy to use to optimize two or more output variables, and its results are straightforward and reliable.

The Influence of the Processing Conditions on Changes in Physical and Structural Properties of Injection Moulded Parts Made of Polypropylene

“…the values of shrinkage are smaller in the case of higher MFr. the shrinkage sensitivity on different processing parameters makes the prediction of the final part dimensions very complex and that's why the optimization of processing parameters can be used to identify the shrinkage dependence on the parameters' values and to minimize the shrinkage as well [27][28][29].…”

Study on Cavitation, Warpage Deformation, and Moisture Diffusion of Sop-8 Devices during Molding Process

“…An optimization method is proposed to improve the reliability of plastic packaging devices, which can comprehensively consider various influencing factors. This method uses Moldflow and ANSYS (ANSYS_2020R2) and other software; adopts an orthogonal experimental design method, range analysis method, comprehensive weighted analysis method, and other methods; puts forward better technological parameters and structural parameters in the plastic packaging process; and analyzes the influence degree of various factors [18][19][20][21][22]. This method is a universal method that can effectively select the optimal scheme and solve the same kind of problems.…”