Effect of Injection Moulding Machine Parameters on the Warpage by Applying Taguchi Method

Abstract:

The application of Taguchi method to reduce warpage in an injection moulding process is studied. The objective of this paper is to analyze the effect of injection moulding parameters, i.e., injection time, packing time, melt temperature and mould temperature, on the warpage defect in dumbbell plastics part. Optical comparator horizontal type was used to measure the difference of warpage value on each part. L9 orthogonal array with 3 replications was done with 27 totals of specimens. The result collected was optimized using Taguchi method and percentage of contribution was calculated using analysis of variance (ANOVA). According to the analysis, it is found that the significant factors affected warpage are injection time (32.01%), packing time (29.73%), mould temperature (24.39%) and melt temperature (13.87%). The optimum parameters for minimizing the warpage were injection time (1s), packing time (5s), melt temperature (270 °C) and the mould temperature (21 °C). By using Taguchi method and ANOVA analysis, optimum parameters and the percentage of contribution of parameters can be obtained. Thus, it shows that design of experiment method is the good quality tools to get the best quality for production.

• Periodical: Applied Mechanics and Materials (Volume 699)
• Pages: 20-25
• DOI: https://doi.org/10.4028/www.scientific.net/AMM.699.20
• Online since: November 2014
• Authors: Mohd Amran*, Siti Salmah, Abdul Faiz, Raja Izamshah, Mohd Hadzley, Bukhari Manshoor, Mohd Shahir, Mohd Amri
• Keywords: Injection Moulding, Injection Moulding Parameters, Polypropylene (PP), Taguchi Method, Warpage

References

[1] M.N. Subramaniam, The basics of troubleshooting in plastics processing: an introductory practical guide., Scrivener Publishing LLC, New York, (2011).

[2] Z. Shayfull, M.F. Ghazali, M. Azaman, S.M. Nasir, N.A. Faris, Effect of differences core and cavity temperature on injection molded part and reducing the warpage by taguchi method, Int. J. Eng. Technol. 10 (2000) 133–140.

[3] Y. Gao, X. Wang, Surrogate-based process optimization for reducing warpage in injection molding, J. Mater. Process. Technol. 9 (2008) 1302–1309.

DOI: 10.1016/j.jmatprotec.2008.03.048

[4] S.H. Tang, Y.J. Tan, S.M. Sapuan, S. Sulaiman, N. Ismail, R. Samin, The use of taguchi method in injection moulding for reducing warpage, J. Mater. Process. Technol. 182 (2007) 418–426.

DOI: 10.1016/j.jmatprotec.2006.08.025

[5] B. Ozcelik, T. Erzurumlu, Comparison of the warpage optimization in the plastic injection molding using anova, neural network model and genetic algorithm, J. Mater. Process. Technol. 171 (2006) 437–445.

DOI: 10.1016/j.jmatprotec.2005.04.120

[6] P.K. Bharti, M.I. Khan, H. Singh, Recent methods for optimization of plastic injection molding process – a retrospective and literature review, Int. J. Eng. Sci. Technol. 2 (2010) 4540–4554.

[7] B. Min, A study on quality monitoring of injection-molded parts, J. Mater. Process. Technol. 136 (2003) 1–6.

[8] M.A. Mohd Amran, M. Hadzley, S. Amri, R. Izamshah, A. Hassan, S. Samsi, K. Shahir, Optimization of gate, runner and sprue in two-plate family plastic injection mould, AIP Conference Proceeding, (2010) 309-313.

DOI: 10.1063/1.3377834

[9] M. Amran, K. Okamoto, M. Yamaguchi, T. Kasai, A. Koshirai, Rheological properties for polypropylene modified by polytetrafluoroethylene, J. Polym. Sci., Part B: Polym. Phys. 4 (2009) 2008-(2014).

DOI: 10.1002/polb.21799

[10] S. Rajalingam, A. Bono, J. Sulaiman, Identifying the critical moulding machine parameters affecting injection moulding process by basic statistical process control tools, Int. J. Eng. Phys. Sci. 6 (2012) 358–364.

[11] R. Pareek, J. Bhamniya, Optimization of injection moulding process using taguchi and anova, Int. J. Sci. Eng. Res. 4 (2013) 1–6.

[12] M. Amran, S. Salmah, M. Zaki, R. Izamshah, M. Hadzley, S. Sivarao, M. Shahir, M. Amri, The Effect of Pressure on Warpage of Dumbbell Plastic Part in Injection Moulding Machine, Advanced Materials Research. 903 (2014) 61-66.

DOI: 10.4028/www.scientific.net/amr.903.61

[13] M.S. Mohd Sazali, A.G. Jaharah, K. Mohd Shahir, T. Siti Haryani, C.H. Che Hassan, Comparison between taguchi method and response surface methodology (RSM) in optimizing machining condition, Int. Conf. Robust Qual. Eng. (2013) 60–64.

[14] Othman, M. Hilmi, M. Amin, S. Yulis, Optimising injection moulding parameters that satisfies part qualities by using taguchi method, Bus. Eng. Ind. App. Colloquium. (2012) 307–312.

DOI: 10.1109/beiac.2012.6226072

[15] M.V. Kavade, S.D. Kadam, Parameter optimization of injection moulding of polypropylene by using taguchi method, J. Mech. Civil Eng. (2012) 49-58.

[16] H. Radhwan, S.M. Rozaimi, H. Razaidi, An optimization of plastic injection molding parameters using taguchi optimization method. (2012) 75-80.

[17] A.J. Yadav, S.V. Dravid, V.D. Rajput, Taguchi technique in optimization of injection molding process parameters for manufacturing plastic parts, Third Biennal Conference on Nascent Technologies. (2012) 1-8.

[18] V. Goodship, Practical Guide to Injection Moulding, 1st ed., Rapra Technology Limited and ARBURG Limited, (2004).