Study and Optimization of Effective Parameters in The Occurrence of Blush Defect in The Plastic Injection Molding Process by Analysis of Variance

Document Type : Research Article

Authors

1 Mechanical Engineering, Yazd University, yazd, Iran

2 Mechanical Engineering, Yazd University, Yazd, Iran

Abstract

Plastic injection is one of the most important and common processes in plastic parts production. During this process, many defects can take place that affects products quality. So trying to remove these defects is very vital for the plastic industry. This research focuses on removing or decreasing one of these defects, called Blush. For this purpose, eight parameters with the probability of affecting the occurrence of this defect, which are material temperature, injection speed, mold temperature, holding pressure, runner diameter, gate diameter, gate angle, and included angle have been considered to be investigated. To study the effect or lack of effect, the extent, and the manner of the effect of these parameters on the Blush defect, a 1/8 Fractional factorial design of experiment with eight factors and two levels was performed by Minitab software. Then after finite element analysis in MoldFlow software and validation of analysis with experimental tests, the area of defect that occurred in each case was calculated by geometric methods. After analysis of variance of the data, it was found that the parameters of runner diameter, holding pressure, flow rate, and melt temperature respectively, have the most significant effects on this defect. Then, for the four factors mentioned, an experimental design of composite cube design was performed and after performing finite element analysis and analysis of variance on the data, it was found that all four parameters have a significant impact. It was also found that by increasing melt temperature, and holding pressure, and reducing the runner diameter and flow rate to the optimal level, the area of blush defect will be reduced by 82.2%.

Keywords

Main Subjects

References

[1] H. Oktem, T. Erzurumlu, I. Uzman, Application of Taguchi optimization technique in determining plastic injection molding process parameters for a thin-shell part, Materials & design, 28(4) (2007) 1271-1278.
[2] M. Juraeva, K. Ryu, D. Song, Gate shape optimization using design of experiment to reduce the shear rate around the gate, International Journal of Automotive Technology, 14(4) (2013) 659-666.
[3] F. Yin, H. Mao, L. Hua, W. Guo, M. Shu, Back propagation neural network modeling for warpage prediction and optimization of plastic products during injection molding, Materials & design, 32(4) (2011) 1844-1850.
[4] R. Wang, J. Zeng, X. Feng, Y. Xia, Evaluation of effect of plastic injection molding process parameters on shrinkage based on neural network simulation, Journal of Macromolecular Science, Part B, 52(1) (2013) 206-221.
[5] C.-P. Chen, M.-T. Chuang, Y.-H. Hsiao, Y.-K. Yang, C.-H. Tsai, Simulation and experimental study in determining injection molding process parameters for thin-shell plastic parts via design of experiments analysis, Expert Systems with Applications, 36(7) (2009) 10752-10759.
[6] J. Lladó, B. Sánchez, Influence of injection parameters on the formation of blush in injection moulding of PVC, Journal of materials processing technology, 204(1-3) (2008) 1-7.
[7] H.B. He, F.L. Wu, Y.M. Deng, Injection Molding Process Parameter Optimization for Warpage Minimization Based on Moldflow, in:  Applied Mechanics and Materials, Trans Tech Publ, 2012, pp. 254-257.
[8] T. Tábi, A. Suplicz, F. Szabó, N.K. Kovács, B. Zink, H. Hargitai, J.G. Kovács, The analysis of injection molding defects caused by gate vestiges, Express Polymer Letters, 9(4) (2015) 394-400.
[9] S. Kitayama, M. Yokoyama, M. Takano, S. Aiba, Multi-objective optimization of variable packing pressure profile and process parameters in plastic injection molding for minimizing warpage and cycle time, The International Journal of Advanced Manufacturing Technology, 92(9) (2017) 3991-3999.
[10] K. Li, S. Yan, Y. Zhong, W. Pan, G. Zhao, Multi-objective optimization of the fiber-reinforced composite injection molding process using Taguchi method, RSM, and NSGA-II, Simulation Modelling Practice and Theory, 91 (2019) 69-82.
[11] S. Kitayama, K. Tamada, M. Takano, S. Aiba, Numerical and experimental investigation on process parameters optimization in plastic injection molding for weldlines reduction and clamping force minimization, The International Journal of Advanced Manufacturing Technology, 97(5) (2018) 2087-2098.
[12] W. Guo, F. Deng, Z. Meng, L. Hua, H. Mao, J. Su, A hybrid back-propagation neural network and intelligent algorithm combined algorithm for optimizing microcellular foaming injection molding process parameters, Journal of Manufacturing Processes, 50 (2020) 528-538.
[13] S. Kitayama, K. Tamada, M. Takano, S. Aiba, Numerical optimization of process parameters in plastic injection molding for minimizing weldlines and clamping force using conformal cooling channel, Journal of Manufacturing Processes, 32 (2018) 782-790.
[14] S.Y. Martowibowo, A. Kaswadi, Optimization and simulation of plastic injection process using genetic algorithm and moldflow, Chinese Journal of Mechanical Engineering, 30(2) (2017) 398-406.
[15] S. Li, X. Fan, H. Huang, Y. Cao, Multi‐objective optimization of injection molding parameters, based on the Gkriging‐NSGA‐vague method, Journal of Applied Polymer Science, 137(19) (2020) 48659.
[16] S. Kitayama, S. Hashimoto, M. Takano, Y. Yamazaki, Y. Kubo, S. Aiba, Multi-objective optimization for minimizing weldline and cycle time using variable injection velocity and variable pressure profile in plastic injection molding, The International Journal of Advanced Manufacturing Technology, 107(7) (2020) 3351-3361.
[17] V. Tayal, J. Kumar, Improvement in production rate by reducing the defects of injection moulding, International Journal of Computer Science and Communication Engineering, 3(5) (2012) 1-4.
Amirkabir Journal of Mechanical Engineering
Volume 53, Issue 10
January 2022
Pages 5293-5308

Files

Share

How to cite

Statistics