Response surface modeling and optimization of single axis automatic application of automotive polyurethane coatings on plastic components

Abstract

The present paper discusses response surface methodology (RSM) as an efficient system for building a mathematical model and optimization of the process of polyurethane coating on acrylonitrile butadiene styrene using a single axis robotic applicator. In this work, RSM is used to optimize the process inputs such as part—applicator distance, paint flow rate, and paint viscosity to obtain the optimal values of process outputs; dry film thickness (DFT), rating value (R), and distinctness of image (DOI). The optimization was done to achieve high values of R and DOI with minimal DFT to reduce overall process cost. A 23 full factorial central composite design experimental design was employed. ANOVA showed satisfactory levels of coefficient of determination values (R2) for all three responses. The optimized results were validated experimentally. Under optimal value of process parameters high rating value (7.76) and high distinctness of image (93.137) was achieved with low dry film thickness of 29.99 μm.