Optimization of injection moulding parameters of three plate injection mould using flow analysis software

Sha'arani, Fatin Izzati (2016) Optimization of injection moulding parameters of three plate injection mould using flow analysis software. Project Report. Universiti Teknikal Malaysia Melaka, Melaka, Malaysia. (Submitted)

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Abstract

Injection moulding process have been widely used in industry as it is an automated process with high speed production of plastic parts. However, there is limitation of injection moulding process where selection of mould design may affected on output parts. Also, the input parameters of the process acted as the main characters in controlling the output response of the product. Hence, the investigation towards optimisation of injection moulding parameters is done by using Autodesk Moldflow Insight software. The objective of this study is to determine suitable input parameters of injection moulding process including the mould temperature, melt temperature, injection time and also cooling time. Second is to examine on output response of the process focusing on volumetric shrinkage, in-cavity residual stress, deflection and fill time on the final parts. Last purposes of this study is to optimize the output response by using Taguchi method and Analysis on Variance (ANOVA). The family mould model are tested which tensile test, impact test, flexural test and hardness test. These models were prepared by CATIA software before transferred into Autodesk Moldflow software. Taguchi method are used to get the total of nine runs with three levels and four factors. By using Taguchi method, the lowest output response for each response are defined along with the best combination of parameters. The lowest percentage for volumetric shrinkage is at run 1, while for in-cavity residual stress at run 3, whereas for deflection is run 6 and lowest fill time is at run 1. From S/N analysis, optimization value are determined where volumetric shrinkage at 7.67867%, in-cavity residual stress at 27.4133MPa, deflection at 0.917567mm and fill time is 0.278233 second. Then by via ANOVA, resolved that melt temperature is the significant input parameter for injection moulding process.

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