Analysis and modeling of effective parameters for dimension shrinkage variation of injection molded part with thin shell feature using response surface methodology

Abstract

The injection molded housing part with thin shell feature could be produced to increase the internal space for packing more components. In this study, injection velocity, packing pressure, mold temperature, and melt temperature were selected as effective parameters for injection molding process. For the purpose of reducing dimension shrinkage variation of thin shell molded part, the response surface methodology was utilized to determine the relationship between input parameters and responses. Then the optimization condition was obtained according to the desirability function. Results show that melt temperature is the most significant factor on dimension shrinkage variation in transverse direction, followed by packing pressure, mold temperature, and injection velocity. However, in the longitudinal direction, packing pressure has the greatest influence on the dimension shrinkage variation, followed by injection velocity, melt temperature, and mold temperature. In accordance with verification experiments, the difference between the experimental data and predicted values ranges from −9.8% to 1.8%. To obtain the optimal condition, the overall desirability must be larger than 0.9. Based on analysis of variance, the proposed models look reasonably accurate.