Optimization of injection molding parameter for 80:20 virgin-regrind polypropylene (PP) plastic material

Salim, Mohammad Zulhakimi (2021) Optimization of injection molding parameter for 80:20 virgin-regrind polypropylene (PP) plastic material. Project Report. Melaka, Malaysia, Universiti Teknikal Malaysia Melaka. (Submitted)

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Abstract

Plastic has been a widely used as the material for most of the products in the human life. However, the rate of plastic product waste is much faster than the rate of the plastic recycling which is resulting the plastic pollution to the world environment. Plastic recycling is a common raw material used in plastic industry especially for environment preservation purposed and more importantly due to cost saving. Polypropylene (PP) is one of commonly plastic type used for bottle caps, packaging tape, cereal liners, straw and as the material of filament for 3D printings, household products such as kitchen appliances and pipes, due to its toughness and high impact resistance. Injection molding is the most common plastic shaping process for PP thermoplastic material. To optimize the injection molding parameter in 80:20 virgin regrind blended Polypropylene (PP) plastic material, five (5) process control parameters namely cooling time, packing time, injection speed, mold temperature and packing pressure each at two levels is tabulated using the L'18 orthogonal array as recommended in Taguchi Design of Experiment method. Type I specimen according to STM D638-14 speciment industry standard is produced by using the injection molding machine. Eight (8) experiments were conducted according to OA table. Three (3) speciments of each experiment trial were collected and tested to obtain the ultimate tensile strength.In total there are (24) have been tested for tensile strength reading. The results were analyzed using the S/N ratio and ANOVA approched method. Significant factors and the optimum combination of process factors setting for achieving the optimum UTS of the Polypropylene (PP) blends 80:20 virgin-regrind material were determined. There are no factors that have the most significant effect on tensile strength. Cooling time at 10 second, packing time at 5 second, injection speed at 50mm/s, mold temperature at 50°C and packing pressure at 50 MPa have resulted the optimum combination factors level according to Taguchi analysis result. The predicted tensile strength based on this optimum value is 33.94 MPa which is not much different compared to virgin 100% material tensile strength 35 MPa. As a conclusion Polypropylene (PP) 80:20 virgin-regrind material is highly recommended to be used for replacing virgin material for material cost saving project.

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