Abstract
Injection molding is one of the most important forming processes for thermoplastic polymers. Setting the injection molding parameter such as injection pressure, injection speed, cooling time and packing pressure plays a very important role in controlling the quality of the products forming by injection molding process. Taguchi approach is a widely used technique for optimizing the molding process parameters. This paper presents a simple and efficient way to study the influence of injection molding parameters on defects percentage. Using Design of experiments and Taguchi approach, the significant parameters are optimized to minimize the defects percentage of the most common defects (inverted label and incomplete plastic filling) that appeared in thin walled containers for food packaging. The results of the experimental study indicate that Injection speed and Injection pressure are the dominant factors determining the quality. The injection speed of 300 CCm/Sec give lower inverted label defect and the injection pressure of 2000 bar give lower incomplete filling defect.
Highlights
Injection molding is ideally suited for manufacturing large quantities of mass produced plastic parts of complex shapes and sizes, Over 30% of all the plastic parts are manufactured by the injection molding process [1]
The injection molding process starts with the feeding of a polymer through hopper to barrel which is heated with the sufficient temperature to make it flow, The molten plastic which was melted is injected under high pressure into the mold, As shown in Figure 1 injection pressure is applied to both platens of the injection molding machine in order to hold the mold tool together
It is it is observed that, Injection Speed is the significant factor affecting on the inverted label defect and finding the optimum value of Injection Speed will minimize this defect as proved in S/N ratio in Table 3, Analysis of Variance (ANOVA) Table 4 and Figure 4
Summary
Injection molding is ideally suited for manufacturing large quantities of mass produced plastic parts of complex shapes and sizes, Over 30% of all the plastic parts are manufactured by the injection molding process [1]. It is capable of producing an infinite variety of part designs containing an infinite variety of details such as threads, springs, and hinges, and all in a single molding operation. The molded product is ejected or removed from the mold [2]
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