Study on the influence of injection molding parameters on the warpage using simulation and Taguchi method

Abstract

Injection moulding (IM) is a processing technique produced from polymeric products. Warpage defect (WD) is the defect that generally occurs during the IM process due to the inappropriate processing parameters of the melt temperature, mould surface temperature, packing pressure, injection pressure, and packing pressure time. This paper investigates the IM parameters that influence product warpage by combining the simulation, analysis of variance, signal-to-noise analysis, and Taguchi method. The simulation process was performed by Moldflow software. The product material is high-density polyethylene. The WD has been predicted and optimized to enhance product quality. Melt temperature and packing pressure time are the factors that acrimoniously influenced the warpage of the product. The results show that the packing pressure time and melt temperature have the highest effects on the WD by the contributions of 48.94% and 37.48%, respectively. The optimal IM parameters are scanned again with the WD abated at about 1.2%. The mathematical formula has been constructed to predict the WD with the reflection of acceptable values of 86.29%. The research hopes that the results have been applied to designing and fabricating the plastic product in the near future.