Fast Prediction of Injection Pressure and Minimal Front Temperature for Injection Moulding

2011 ◽  
Vol 26 (1) ◽  
pp. 21-29 ◽  
Author(s):  
P. Zhao ◽  
J. Fu ◽  
H. Zhou ◽  
B. Yan
Keyword(s):  
Injection Moulding ◽  
Injection Pressure ◽  
Fast Prediction ◽  
Front Temperature

scholarly journals A methodology for setting the injection moulding process parameters for polymer rapid tooling inserts

2019 ◽  
Vol 25 (9) ◽  
pp. 1493-1505 ◽  
Author(s):  
Anurag Bagalkot ◽  
Dirk Pons ◽  
Don Clucas ◽  
Digby Symons
Keyword(s):  
Tool Life ◽  
Process Parameters ◽  
Injection Moulding ◽  
Injection Pressure ◽  
Rapid Tooling ◽  
Fine Tuning ◽  
Content Type ◽  
High Injection ◽  
Start Up ◽  
Injection Moulding Process

Purpose Polymer rapid tooling (PRT) inserts can be used as injection moulding (IM) cavities for prototyping and low volume production but lack the robustness of metal inserts. Metal inserts can withstand high injection pressure and temperature required, whereas PRT inserts may fail under similar parameters. The current method of parameter setting starts with using the highest pressure setting on the machine and then fine-tuning to optimize the process parameters. This method needs modification, as high injection pressures and temperatures can damage the PRT inserts. There is a need for a methodical process to determine the upper limits of moulding parameters that can be used without damaging the PRT inserts. Design/methodology/approach A case study analysis was performed to investigate the causes of failure in a PRT insert. From this, a candidate set-up process was developed to avoid start-up failure and possibly prolong tool life. This was then tested on a second mould, which successfully avoided start-up failure and moulded 54 parts before becoming unusable due to safety issues. Findings Process parameters that are critical for tool life are identified as mould temperature, injection pressure, injection speed, hold pressure and cooling time. Originality/value This paper presents a novel method for setting IM process parameters for PRT inserts. This has the potential to prevent failure at start up when using PRT inserts and possibly extend the operating life of the PRT inserts.

Optimization of Injection Moulding Process Parameters for Manufacturing Plastic Components (PBT) Using Taguchi Method (TM)

2019 ◽  
Vol 969 ◽  
pp. 775-780
Author(s):  
Rajendra Khavekar ◽  
Hari Vasudevan ◽  
Gosar Vimal
Keyword(s):  
Taguchi Method ◽  
Process Parameters ◽  
Injection Moulding ◽  
Injection Pressure ◽  
Injection Time ◽  
Time Zone ◽  
Polybutylene Terephthalate ◽  
Influence Of Process Parameters ◽  
Pressure Injection ◽  
Injection Moulding Process

In this Paper, the application of Taguchi Method (TM) on the process parameters of Injection Moulding of Polybutylene Terephthalate (PBT) is presented. The influence of process parameters, such as Injection Pressure, Suckback Pressure, Injection Time, Cooling Time, Zone 1 Temperature & Zone 2 Temperature (Barrel Temperatures) on Dark Spots and Short Shots (defects) were investigated using the Orthogonal Array L16 of Taguchi Method for 6 factors at 2 levels each with the response being percent defectives. It was found that Injection Pressure, Injection Time & Zone 1 Temperature had a major effect on the response. After the application of Taguchi Method, the rejection rate dropped down to 5.84% from 11.33%, which is a 48.45% reduction.

Product Quality Improvement Using Simulation Tools

2014 ◽  
Vol 718 ◽  
pp. 77-82 ◽  
Author(s):  
Slavomir Hric ◽  
Alena Vagaska ◽  
Svetlana Radchenko ◽  
Filip Murgas ◽  
Milan Micko
Keyword(s):  
Wall Thickness ◽  
Injection Moulding ◽  
Production Efficiency ◽  
Injection Pressure ◽  
Simulation Tools ◽  
Geometry Design ◽  
Technological Practice ◽  
Sink Marks ◽  
Proposed Modification

The article deals with the basic technological aspects of injection moulding, pointing to the importance of correct product geometry design. Large differences in the wall thickness of the mould result in uneven cooling, material shrinkage, and the formation of internal stress. This ultimately may give rise to deformations, such as those in form sink marks, and may affect the required quality of the mould. The article describes the application of a specific example of one of the ways of correction of the mould wall thickness used in technological practice of the injection moulding technology. This is a case of employing the method of the so-called relief pins. After the introduction of the proposed modification of the form, the mould quality has improved, thereby increasing the production efficiency in the process of shape optimization of manufacturing the product called Installation Box Series S-BOX 106 made of polyamide PA 66. In addressing the issue, simulation of cooling plastic and injection pressure in Cadmold 3D-f software was employed.

Shrinkage and Warpage in the Permanent Shape of Sape-Memory Polyurethane Parts

2022 ◽  
Vol 58 (4) ◽  
pp. 102-113
Author(s):  
Sukran Katmer ◽  
Cetin Karatas
Keyword(s):  
Shape Memory ◽  
Injection Moulding ◽  
Flow Direction ◽  
Injection Pressure ◽  
Cooling Time ◽  
Mould Temperature ◽  
Melt Temperature ◽  
Packing Pressure ◽  
Permanent Shape ◽  
Packing Time

The shape memory effect, as the most important ability of shape memory polymers, is a working property and provides the design ability to shape memory polymer features. Shrinkage and warpage are important parameters to control the dimensional accuracy of permanent and temporary shapes of an injection moulded shape memory polyurethane (SMPU) part. In this study, the effects of injection moulding parameters on the shrinkage and warpage of the permanent shape of moulded SMPU parts were experimentally investigated. The parameters of injection pressure, melt temperature, mould temperature, packing pressure, packing time, and cooling time, were chosen as the injection moulding control factors. Taguchi�s L27 orthogonal array design table was used with six injection moulding parameters and their three levels. The results showed that the part has different shrinkage ratios in three main directions, namely, the flow direction, perpendicular to the flow direction, and the direction through the thickness. The results of the analysis of variance showed that the cooling time is the most influential parameter on both the shrinkage (except in thickness) and warpage. The shrinkage in the flow direction as well as in perpendicular to the flow direction decreased with increasing the cooling time. Warpage also decreased with increasing the cooling time. Injection pressure and melt temperature were found to be effective on shrinkage in thickness. Effects of mould temperature, packing pressure, and packing time were found to be limited. A statistically significant relationship has been noticed among shrinkage, warpage, and residual stresses during the study.

Optimization of Injection Molding Parameters by Data Mining Method in PIM Process

2012 ◽  
Vol 59 (2) ◽  
Author(s):  
Azizah Wahi ◽  
Norhamidi Muhamad ◽  
Khairur R. Jamaludin ◽  
Javad Rajabi ◽  
Abbas Madraky
Keyword(s):  
Data Mining ◽  
Injection Molding ◽  
Injection Moulding ◽  
Injection Pressure ◽  
Injection Rate ◽  
Green Density ◽  
Mould Temperature ◽  
Green Strength ◽  
Defect Score ◽  
Pressure Injection

Data Mining is a method that can be used to analyze large amount of data and produce useful information. In this study, clustering which is one of data mining tasks is used to clustered machine based on the injection moulding data. This paper is the first documented results on the optimization of Injection Moulding via Data Mining. Powder injection moulding is a process to produce near net shape with intricate part in mass production. This work focus on the optimization of injection molding process with combination of fine, coarse and bimodal water atomized SS 316L powder particles. The parameters involved in the optimization are injection pressure, injection temperature, mould temperature, holding pressure, injection rate, holding time, powder loading, cooling time and particle size. These variables are based on the defect score, green density and green strength. The key influencer report shows that the most influencing factors are injection rate, holding pressure as well as mould temperature where defect score lower than 2.4 can be achieved. The density higher than 5.34g/cm3 is also influenced most by the mould temperature. The result also shows that the optimize condition can be achieved by using bimodal particle. Injection rate and mould temperature gives the highest impact on the defect score and green strength value. While highest green density is significantly affected by powder loading and injection pressure.

Mixing and Moulding without Mastication

1940 ◽  
Vol 13 (3) ◽  
pp. 667-675
Author(s):  
F. H. Cotton ◽  
W. F. Hodson
Keyword(s):  
Injection Moulding ◽  
Injection Pressure ◽  
Careful Study ◽  
Uniform Heating ◽  
Rubber Powder ◽  
Rubber Particles ◽  
Mould Cavity ◽  
Delayed Action ◽  
The Individual ◽  
Low Activity

Abstract The preliminary experiments described indicate the remarkable potentialities of the injection method of moulding rubber articles, whether produced from mixes of powdered or masticated rubber. Employing rubber powder made by the Stam process, intimate mixing with vulcanizing ingredients and fillers is essential, and may conveniently be achieved with simple apparatus by ball milling the ingredients. The necessity for heavy rubber machinery of the orthodox type is eliminated. It is desirable to employ an accelerator of relatively low activity, or a delayed action ultra-accelerator. With very fast accelerators, vulcanization begins either during mixing of the powder or while being forced from the injection cylinder to the mould. Such premature vulcanization leads to serious distortion. It is believed that the stresses to which a compressed rubber powder compound is subjected during the process of injection moulding are sufficient to rupture the individual rubber particles, to ensure cohesion, and promote satisfactory dispersion of compounding ingredients. It is confidently asserted that results superior to those instanced herein could be achieved with an injection moulding device designed to facilitate uniform heating of both top and bottom of the mould cavity. It is also felt that a careful study of the effect of changing the injection pressure and the size of the injection orifice might yield valuable information. The success attending these early experiments warrants extending the investigation to new types of rubber powder (cf. Rubber Age, 19, 335 (1938)).

The Development of Metal Injection Moulding for ZK60 Magnesium Alloy Using Palm Stearin Based Binder System

2011 ◽  
Vol 230-232 ◽  
pp. 1199-1203 ◽  
Author(s):  
M.R. Harun ◽  
N. Muhamad ◽  
A.B. Sulong ◽  
N.H. Mohamad Nor ◽  
K.R. Jamaludin
Keyword(s):  
Magnesium Alloy ◽  
Injection Moulding ◽  
Injection Pressure ◽  
Palm Stearin ◽  
Weight Percent ◽  
Binder System ◽  
Machine Model ◽  
Moulding Machine ◽  
Zk60 Magnesium Alloy ◽  
Good Workability

In this paper, the development of green compact of ZK60 magnesium alloy was studied in the context of MIM using screw type injection moulding machine model Battenfeld BA250CDC. The MIM feedstock used was 64 vol.% powder loading and the balance was palm stearin and low linear density polyethylene with the fraction of 60/40 by weight percent. The injection moulding parameters were then adjusted until the optimal condition of green part was accomplished. Results indicate that the feedstock exhibited good workability when injection moulded at the temperature of 190°C, injection pressure of 900kN, flow rate of 15,5cm3/s and with a very low ejection parameters. This technique provides an additional means to manufacture magnesium alloy components for a wide variety of applications.

scholarly journals Sustainable injection moulding: The impact of materials selection and gate location on part warpage and injection pressure

2015 ◽  
Vol 5 ◽  
pp. 1-8 ◽  
Author(s):  
Marton Huszar ◽  
Fawzi Belblidia ◽  
Helen M. Davies ◽  
Cris Arnold ◽  
David Bould ◽  
...  
Keyword(s):  
Injection Moulding ◽  
Injection Pressure ◽  
Materials Selection ◽  
Gate Location ◽  
The Impact

scholarly journals Green Density Optimisation with Sustainable Sewage Fat as Binder Components in SS316L Feedstock of Metal Injection Moulding Process (MIM) by Taguchi Method

2015 ◽  
Vol 773-774 ◽  
pp. 173-177 ◽  
Author(s):  
Azriszul Mohd Amin ◽  
Mohd Halim Irwan Ibrahim ◽  
Rosli Asmawi ◽  
Najwa Mustapha ◽  
Mohd Yussni Hashim
Keyword(s):  
Injection Moulding ◽  
Injection Pressure ◽  
Powder Metallurgy Method ◽  
Moulding Process ◽  
High Productivity ◽  
Optimum Density ◽  
Metal Injection Moulding ◽  
Injection Moulding Process ◽  
Experimental Base ◽  
Shape Retention

Metal injection moulding has gain much attention due to flexibility and high productivity of the plastics injection moulding with the powder metallurgy method of sintering. In order to gain better shape retention, optimum density of green part is required. This paper deals with the application of Taguchi optimisation technique on getting the optimum density for Metal Injection Moulding (MIM) components base on certain parameters in process injection. For this purposes only 3 process parameters were considered here including its interactions which are injection pressure, injection temperature and mould temperature. Since its more close to the final products these parameters were selected and other parameters will be kept constant. An orthogonal array of L16 experimental base design was conducted. Confirmation test will be done base on Signal-to-Noise (S/N) ratio and it Means.

Rejection Rate Reduction of the Automotive Thermoplastic Parts in Injection Moulding Using Response Surface Methodology

2020 ◽  
Vol 841 ◽  
pp. 225-231
Author(s):  
Huei Ruey Ong ◽  
Ifwat Mohd Shah ◽  
Wan Mohd Eqhwan Iskandar ◽  
Md. Maksudur Rahman Khan ◽  
Chi Shein Hong ◽  
...  
Keyword(s):  
Response Surface Methodology ◽  
Response Surface ◽  
Process Parameters ◽  
Injection Moulding ◽  
Injection Pressure ◽  
Acrylonitrile Butadiene Styrene ◽  
Rejection Rate ◽  
Mould Temperature ◽  
Melt Temperature ◽  
Rsm Model

Plastic injection moulding is widely used for manufacturing due to variety of plastic product. In this study, plastic part defects such as air bubble and gas mark defect are commonly occurs in thermoplastic part, specifically acrylonitrile butadiene styrene (ABS). In order to optimize the process parameters of injection moulding, design of experiment (DOE) with Response Surface Methodology (RSM) model was used. Process parameters such as melt temperature, mould temperature and injection pressure were selected for the DOE development. The experiments were conducted with melt temperature range from 200 °C to 240 °C, mould temperature from 60 °C to 80 °C and injection pressure from 90 to 99%. The result indicates that, all the selected parameters were significantly influence the rejection rate of the automotive ABS part. The optimum melt temperature, mould temperature and injection pressure were 220 °C, 70 °C and 98% respectively, in obtaining minimum rejection rate.

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