Effect Of Injection Moulding Parameters On Warpage Deflection

Injection moulding is a process that can be characterised as their ability to produce high production rates with accurately product size and complex part shape. Generally, there are four elements affected the quality of injection moulded parts such as machine parameters, mould design, plastic materi...

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Main Author:	Mohd Sani, Siti Salmah
Format:	Thesis
Language:	English
Published:	2015
Subjects:	T Technology (General) TP Chemical technology
Online Access:	http://eprints.utem.edu.my/id/eprint/16823/1/Effect%20Of%20Injection%20Moulding%20Parameters%20On%20Warpage%20Deflection.pdf
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id	my-utem-ep.16823
record_format	uketd_dc
institution	Universiti Teknikal Malaysia Melaka
collection	UTeM Repository
language	English
topic	T Technology (General) TP Chemical technology
spellingShingle	T Technology (General) TP Chemical technology Mohd Sani, Siti Salmah Effect Of Injection Moulding Parameters On Warpage Deflection
description	Injection moulding is a process that can be characterised as their ability to produce high production rates with accurately product size and complex part shape. Generally, there are four elements affected the quality of injection moulded parts such as machine parameters, mould design, plastic materials and operator. In order to ensure quality of injection moulding parts can be produced at minimum cost and maximum productivity, the appropriate machine setting parameters are the priority should be achieved. Variation of process parameters are unavoidable in production of injection moulding and affected the quality of part because involved enormous process parameters. The purpose of this study is to analyze the effect of injection moulding parameters that are including cavity temperature, core temperature, mould temperature, melt temperature and cooling time. The main response of this study is to investigate the warpage deflection using simulation software and actual experimental method. The experiment was performed using injection moulding machine Arburg 420C 800-250 while simulation was done using MoldflowTM Plastic Insight (MPI) software. Design of experiment (DOE) using Taguchi method was applied to design the experimental runs and it was used to analyze the significant factors that affected the warpage deflection. Three methods of investigation work were performed in this research. First investigation work was performed by compared the deviation percentage between simulation MoldflowTM software and actual experimental method using different core and cavity mould temperature gradient. Second and third investigation works focus on optimized parameters using whole cold mould and whole hot mould where both investigation works were performed using simulation MoldflowTM software. Analysis of variance (ANOVA) was used as statistical tools to get the percentage of contribution for each factor and to find the interaction between parameters involved. The average deviation percentage of warpage deflection by simulation software and actual experiment for first investigation work using different mould core and cavity temperature gradient was found 12.80%. The improvement of warpage deflection between those three investigation works shows that the warpage deflection is improved at 89.53% from 0.5716mm to 0.0599mm between first and third investigation work. Meanwhile, warpage reduction between first and second investigation is 83.52% and between second and third investigation is 35.31%. Result shows that the lower differences between core and cavity temperature contributes smaller warpage deflection. On the other hand hot mould temperature controlled contributes less warpage deflection as compared to cold mould. This study proved that with appropriate control parameters in injection moulding process can produce better plastic products quality.
format	Thesis
qualification_name	Master of Philosophy (M.Phil.)
qualification_level	Master's degree
author	Mohd Sani, Siti Salmah
author_facet	Mohd Sani, Siti Salmah
author_sort	Mohd Sani, Siti Salmah
title	Effect Of Injection Moulding Parameters On Warpage Deflection
title_short	Effect Of Injection Moulding Parameters On Warpage Deflection
title_full	Effect Of Injection Moulding Parameters On Warpage Deflection
title_fullStr	Effect Of Injection Moulding Parameters On Warpage Deflection
title_full_unstemmed	Effect Of Injection Moulding Parameters On Warpage Deflection
title_sort	effect of injection moulding parameters on warpage deflection
granting_institution	Universiti Teknikal Malaysia Melaka
granting_department	Faculty Of Manufacturing Engineering
publishDate	2015
url	http://eprints.utem.edu.my/id/eprint/16823/1/Effect%20Of%20Injection%20Moulding%20Parameters%20On%20Warpage%20Deflection.pdf
_version_	1747833897106800640
spelling	my-utem-ep.168232020-11-11T14:31:38Z Effect Of Injection Moulding Parameters On Warpage Deflection 2015 Mohd Sani, Siti Salmah T Technology (General) TP Chemical technology Injection moulding is a process that can be characterised as their ability to produce high production rates with accurately product size and complex part shape. Generally, there are four elements affected the quality of injection moulded parts such as machine parameters, mould design, plastic materials and operator. In order to ensure quality of injection moulding parts can be produced at minimum cost and maximum productivity, the appropriate machine setting parameters are the priority should be achieved. Variation of process parameters are unavoidable in production of injection moulding and affected the quality of part because involved enormous process parameters. The purpose of this study is to analyze the effect of injection moulding parameters that are including cavity temperature, core temperature, mould temperature, melt temperature and cooling time. The main response of this study is to investigate the warpage deflection using simulation software and actual experimental method. The experiment was performed using injection moulding machine Arburg 420C 800-250 while simulation was done using MoldflowTM Plastic Insight (MPI) software. Design of experiment (DOE) using Taguchi method was applied to design the experimental runs and it was used to analyze the significant factors that affected the warpage deflection. Three methods of investigation work were performed in this research. First investigation work was performed by compared the deviation percentage between simulation MoldflowTM software and actual experimental method using different core and cavity mould temperature gradient. Second and third investigation works focus on optimized parameters using whole cold mould and whole hot mould where both investigation works were performed using simulation MoldflowTM software. Analysis of variance (ANOVA) was used as statistical tools to get the percentage of contribution for each factor and to find the interaction between parameters involved. The average deviation percentage of warpage deflection by simulation software and actual experiment for first investigation work using different mould core and cavity temperature gradient was found 12.80%. The improvement of warpage deflection between those three investigation works shows that the warpage deflection is improved at 89.53% from 0.5716mm to 0.0599mm between first and third investigation work. Meanwhile, warpage reduction between first and second investigation is 83.52% and between second and third investigation is 35.31%. Result shows that the lower differences between core and cavity temperature contributes smaller warpage deflection. On the other hand hot mould temperature controlled contributes less warpage deflection as compared to cold mould. This study proved that with appropriate control parameters in injection moulding process can produce better plastic products quality. 2015 Thesis http://eprints.utem.edu.my/id/eprint/16823/ http://eprints.utem.edu.my/id/eprint/16823/1/Effect%20Of%20Injection%20Moulding%20Parameters%20On%20Warpage%20Deflection.pdf text en public http://plh.utem.edu.my/cgi-bin/koha/opac-detail.pl?biblionumber=96252 mphil masters Universiti Teknikal Malaysia Melaka Faculty Of Manufacturing Engineering 1. Aashiq, M.M., Arun, A.P., and Parthiban, M., 2013. Investigation of Process Parameters for an Injection Molding Component for Warpage and Shrinkage. International Journal of Engineering Trends and Technology, 4 (4), pp.1237-1241. 2. Abhang, L.B., and Hameedullah, M., 2012. 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