Simulation-Based Optimization of Plastic Injection Molding Parameter for Aircraft Part Fabrication Using Response Surface Methodology (RSM)

Abstract

The small size and thin part characteristics of the honeycomb floor panel for the aircraft part product may cause problems in injection molding fabrication process. The objectives of this study is to find the most appropriate parameter in injection molding process for honeycomb floor panel by simulation using MoldFlow software and optimize the quality of injection molding process parameter by using Response Surface Methodology (RSM) as to obtain an optimal response and meets the requirement specification in the aviation scope. The crucial responses are shrinkage and warpage. Melt temperature, filling pressure and injection time are selected as the most influential factor for shrinkage and warpage. Model response was fitted by quadratic model. As the results, the optimum value suggested by the software were melt temperature of 360.02c, 60 MPa filling pressure and 4.70s injection time. With small differences error value between solution and simulation, 0.3% for shrinkage and 0.6% for warpage, the results was acceptable.