Abstract
Injection molding technology is known as the most widely used method in mass production of plastic products. To meet the quality requirements, a lot of methods were applied in optimization of injection molding process parameter. In this study the optimization based on Taguchi orthogonal array and Grey relational analysis (GRA) is used to optimize the injection molding process parameters on a LED lens. The four process parameters are: packing pressure, injection speed, melt temperature and mold temperature. The multi-response quality characteristics are total displacement, volumetric shrinkage, and thermal residual stress. The optimal molding parameters are packing pressure (90 MPa), injection speed (300 mm/sec), melt temperature (270 °C) and mold temperature (90 °C). The luminous uniformity of the LED is 92.61 % and the viewing angle of the LED is 124.76°. Among the four factors, packing pressure plays the key role in reducing total displacement, volumetric shrinkage, and thermal residual stress.
Highlights
Nowadays plastic parts become more popular and critical in modern engineering applications, the demand for plastics product quality has increased as well
In this study the optimization based on Taguchi orthogonal array and Grey relational analysis (GRA) is used to optimize the injection molding process parameters on a LED lens
Among the four factors, packing pressure plays the key role in reducing total displacement, volumetric shrinkage, and thermal residual stress
Summary
Nowadays plastic parts become more popular and critical in modern engineering applications, the demand for plastics product quality has increased as well. Injection molding is one of the most effective techniques used in the manufacturing for mass production of plastics parts. Molten polymer is injected through runner system into a closed mold cavity. The requirements of molding products compose of many quality facets such as mechanical properties, dimension accuracy, surface quality, optical properties etc. To meet the demand of product quality, it is necessary to consider factors such as plastic materials, part and mold design, mold machining, machine performance and molding process. In these factors, injection molding process has a significant influence on the part's productivity, quality and cost
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