A Study of Injection Moulding Optimum Parameters to Control Shrinkage and Warpage of Polypropylene-Nanoclay Hinges Samples

Abstract:

Injection moulding is one of the most efficient processes in mass production that can easily attain up to complex geometry product within a very short cycle time. To choose a suitable setting of parameter was very crucial, in controlling the quality of product with regard to their function. The main propose of this research is to optimize the injection moulding parameter for controlling the shrinkage and warpage of thermoplastics sample through practical injection moulding. The additional study for this project is to investigate the effect of nanoclay contents towards the parameter setting. In this experiment, the selected parameters were packing pressure; melt temperature, screw speed and filling time. The material that was selected for this project was a mixture of polypropylene and nanoclay with the addition of polypropylene-grafted-maleic anhydride as the compatibilizer. Three formulations were chosen, which was 0 wt%, 3 wt% and 5 wt% of Nanoclay. Each formulation was added with 15 wt% of compatibilizer. The experiment design for this project shall adopt the L₉4³ Orthogonal Array of Taguchi Method. By using the Signal to Noise Ratio responses, the optimum parameter for each formulation has been obtained. The findings of this experiment shall be useful for future manufacturing process in order to control shrinkage and warpage specifically for products made from polypropylene-nanoclay.

• Periodical: Applied Mechanics and Materials (Volumes 465-466)
• Pages: 1011-1015
• DOI: https://doi.org/10.4028/www.scientific.net/AMM.465-466.1011
• Online since: December 2013
• Authors: Wan Nur Azrina Wan Muhammad*, Mohd Hilmi Othman, Sulaiman Hasan, Muhammad Faiz Ruslee
• Keywords: Hinges, Injection Molding, Parameter Settings Polypropylene-Nanoclay

References

[1] H. Oktem, T. Erzurumlu, I. Uzman, Application of Taguchi Optimization Technique in Determining Plastic Injection Moulding Process Parameters for a Thin-shell Part, Materials & Design, 28/4 (2005)1271-1278.

DOI: 10.1016/j.matdes.2005.12.013

[2] F. Johannaber, Injection Moulding Machine, 4th Edition, Hanser Gardner Publication Inc. (2007).

[3] M.C. Huang, C. C. Tai, The effective factors in the warpage problem of an injection-molded part with a thin shell feature. Material Processing Technology 110, (2001) 1-9.

DOI: 10.1016/s0924-0136(00)00649-x

[4] M.P. Groover, Fundamentals of Modern Manufacturing - Materials, Process and System John Wiley & Sons, Inc, (2010).

[5] S.N. Bhattcharya, M.R. Kamal, R.K. Gupta, Polymeric Nanocomposites- Theory and Practice. Carl hanser Verlag: Munich. (2008).

[6] S. Sinha Ray and M. Okamoto, Polymer/layered silicate nanocomposites: a review from preparation to processing, Progress in Polymer Science, 28, /11 (1997) 1539-1641.

DOI: 10.1016/j.progpolymsci.2003.08.002

[7] N. M. Mehat, S. Kamaruddin, Quality control and design optimisation of plastic product using Taguchi method: a comprehensive review, International Journal of Plastics Technology, 16/2, (2012) 194-209.

DOI: 10.1007/s12588-012-9037-1

[8] S. Hasan, M.H. Othman, and S. Rasli, The Effect of Parameter Setting towards the Processing of Hinges Test Samples through Cadmould 3D-F Injection Moulding Simulation, Applied Mechanics and Materials, 315, (2013) 171-175.

DOI: 10.4028/www.scientific.net/amm.315.171

[9] S. Shamsudin, S. Hasan, M.H. Othman, and M.N. Abd Rahman, The Effects of Injection Moulding Processing Parameters and Mould Gate Size towards Weld Line Strength, Advanced Materials Research, 488, (2012) 801-805.

DOI: 10.4028/www.scientific.net/amr.488-489.801

[10] M.H. Othman , S. Shamsudin, and S. Hasan, The Effects of Parameter Settings on Shrinkage and Warpage in Injection Molding through Cadmould 3D-F Simulation and Taguchi Method, Applied Mechanics and Materials, 229, (2012) 2536-2540.

DOI: 10.4028/www.scientific.net/amm.229-231.2536

[11] M.H. Othman, S. Hasan, W. N. A. Wan Muhammad, and Z. Zakaria, Optimising Injection Moulding Parameter Setting in Processing Polypropylene-Clay Composites through Taguchi Method, Applied Mechanics and Materials, 271(2013) 272-276.

DOI: 10.4028/www.scientific.net/amm.271-272.272