Abstract
In the process of injection molding, a certain percentage of recycled material is usually used in order to save costs. The material properties of recycled materials can change significantly compared with raw materials, and the quality of their molded products is more difficult to control. Therefore, it is crucial to propose a method that can effectively maintain the yield of the recycled material products. In addition, the variation of clamping force during the injection molding process can be determined by measuring the tie-bar elongation of the injection molding machine. Therefore, this study proposes a real-time product quality monitoring system based on the variation of clamping force during the injection molding process for the injection molding of recycled materials for plastic bottle caps. The variation of clamping force reflects the variation of cavity pressure during the injection molding process and further maps the variation of injection parameters during the injection molding process. Therefore, this study evaluates the reliability of the proposed method for three different injection parameters (residual position, metering end point and metering time). Experiments have shown that there is a strong correlation between the quality (geometric properties) and weight of the product under different molding parameters. Moreover, the three main injection parameters have a strong influence on the weight and quality of the plastic caps. The variation of the clamping force is also highly correlated with the weight of the plastic bottle cap. This demonstrates the feasibility of applying the variation of clamping force to monitor the quality of injection molded products. Furthermore, by integrating the clamping force variation index with the calibration model of the corresponding injection parameters, it is possible to control the weight of the plastic cap within the acceptable range of the product in successive production runs.
Highlights
Injection molding is a form of mass plastic product manufacturing, which has the advantages of low cost, high efficiency, and the ability to produce precision parts, and it is widely used in the fields of electronic products, automobiles, medical devices and optical lenses
Proposing a method that enables real-time online monitoring, control and prediction of the molding quality of injection molded products made of recycled materials is a worthy research topic
In order to improve the quality of recycled material products, in 2016, GU et al [2] analyzed and evaluated recycled polypropylene (PP) composites with talc as the main filler and maleic anhydride-grafted polypropylene (MAPP) as the bulking agent, all results were analyzed using principal component analysis (PCA) and cluster analysis (CA); the results show that adding fillers can well improve the physical and mechanical properties of virgin PP composite and its recycled plastic mechanical properties
Summary
Injection molding is a form of mass plastic product manufacturing, which has the advantages of low cost, high efficiency, and the ability to produce precision parts, and it is widely used in the fields of electronic products, automobiles, medical devices and optical lenses. In the actual production process, the use of recycled materials can lead to unstable quality changes of molten plastic, resulting in unstable injection molding product quality and failure to ensure high product yield production. This is mainly because the high-precision injection molding machine only ensures the stability of parameters during the molding process and does not control the unstable changes of molten plastic quality. Proposing a method that enables real-time online monitoring, control and prediction of the molding quality of injection molded products made of recycled materials is a worthy research topic
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