Optimization Of Injection Molding Process On Name Tag Plastic Product

Lim, Cui Fen (2016) Optimization Of Injection Molding Process On Name Tag Plastic Product. Project Report. UTeM, Melaka, Malaysia. (Submitted)

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Abstract

Injection moulding is a widely used process for manufacturing complex shaped polymer products. An injection moulding process consists of four main stages: plastification, injection, pack & hold, and ejection. After ejection, noticed that the dimension of the part is different from the desired mould dimension, the part size becomes smaller. Shrinkage is a phenomenon which occurs during the solidification of molten plastic material, but it can also be a main problem that often faced by the plastic industry if it is excessive due to the process parameter factors without optimization. This study was developed to determine the significant factor affecting the part shrinkage, and also to optimize the process parameter factors for name tag product. The factors which involved in this study were Injection Pressure, Holding Pressure, Holding Time and Cooling Time. The selected material for this study was Acrylonitrile Butadiene Styrene (ABS) plastic material. The experiments were designed by using Taguchi method, a structured approach which commonly used for determining the “best” combination of inputs to produce a plastic product. After determining the operating conditions for each parameter and levels (minimum, current and maximum), a proper Orthogonal Array (OA) was selected to create the minimum number of trials to estimate the main effects. The 9 trials were conducted and 10 samples were collected from each trial. The dimension inspection were done by using Coordinate Measuring Machine (CMM), in order to obtain the average value accurately in order to calculate the shrinkage value. The shrinkage values were used to find the Signal-to-Noise (SN) ratios using Minitab software, the main effect plots for means and SN ratios were observed. The results showed the relationship between the SN ratios and the shrinkage value (means). A set of optimized process parameter factors were obtained at the end of study.

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