Development of ultrasonic assisted compression moulding mould

Jamaludin, Muhammad Izzul (2017) Development of ultrasonic assisted compression moulding mould. Project Report. Universiti Teknikal Malaysia Melaka, Melaka, Malaysia. (Submitted)

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Abstract

In general, most of the rubber articles are produced by moulding, a process in which uncured rubber is cured under pressure in a mold. There are three moulding techniques that are generally employed namely compression, transfer and injection moulding. From those three techniques, compression moulding are preferable in terms of reliability and productivity. In compression moulding, a pre-weighed, generally preformed piece is placed in the mould; the mould is closed, with the rubber under pressure, as it vulcanizes. However, the compression moulding process can be disturbed by the curing process that cause shrinkage, bubble, poor strength and crosslink. Thus, enhancing the capability of the compression moulding process are necessary aim to increase the rubber part performances. One of the possible technique are by employing the ultrasonic vibration at the mould known as UACM during the curing stage aim to enhanced the pressure concentration and uniformity on the rubber. This thesis deals with the development of ultrasonic assisted compression moulding process for Natural rubber/ethylene propylene diene monomer (NR/EPDM) material. The effectiveness of the UACM technique are evaluate based on the part strength and crosslinking density factor. In addition, a statistical Response Surface Methodology are employed as the design of experiment to assess the significance of the compression moulding parameter i.e. temperature, pressure, time and ultrasonic power on the responses. From the conducted investigation, it shows that UACM are capable to increased the part performances compared to the conventional mould. The presence of the ultrasonic vibration enhanced the pressure concentration and uniformity on the rubber during the curing stage which significantly improved the rubber part. In addition, from the statistical results indicated that pressure and time significantly affect the part performances. Multi-objectives optimization is performed through numerical optimisation and the predicted result are validated with 90% agreements.

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