Injection Machine Research Articles

On-Line Quality Control in the Injection Molding Machine for the Process Statistic of Thermoplastics Material

In this paper, the on-line quality control feature of the injection molding machine based on the statistical process of thermoplastics product has been developed. The optimal process begins with collecting data and setting up the parameter of the injection machine according to the design of experiment. Four control parameters are set up on Demag Ergotech 200-840 Dragon. A series of tests using a body-outdoor led lamp has been conducted by means of both approaches simulation-based and experimental-based by which is injected using two-cavity injection mold. In simulation mode, clamping force and total weight were assigned as final responses, while total weight only is used as a response in experiment mode. The molded-parts were validated using thirty samples that are divided into a three-batch production process. The application of the on-line statistical quality check feature in the injection molding machine can be used as a quality control method by setting up barrel temperature, screw-back position, injection speed, and injection pressure.

Modify the Injection Machine Mechanism to Enhance the Recycling of Plastic Waste Mixed with MHD Nanoparticles

Recycling plastic waste (RPW) benefits the ecological footprint. Therefore, the authors test its mixing by magnetic hydrodynamic MHD nanofluid materials such as alumina in two sizes (βcore, βskin) prepared into a new device called the incubator installed in the desktop injection machine to enhance its solubility by taking advantage of the mixture’s heat via defining the oblique stagnation-point slip flow (OSPSF) of a nanofluid in two dimensions. The paper has been innovative in mathematically identifying the operating parameters’ values for the injection flow mechanism (IFM) via controlling in Riga magnetic field and piston orifice pressure using a meta-heuristic algorithm called WSA. The proposed (IFM) is used to experimentally enhance the mixture properties via parameters’ control to meet the output quality and predict the control equation for the Riga plate. IFM controls the amount of pushed nanoparticles in the mixture with a ratio of plastic to aluminum approximate by 96.1%: 3.9%. The defects were reduced by approximately 23.21%, with an increasing system performance of 70.98%.

INFLUENCE OF INDIVIDUAL CHARACTERISTICS, BEHAVIOR AND NOISE INTENSITY ON BLOOD PRESSURE IN PONOROGO PLASTIC INDUSTRY’S WORKERS

Background: Noise is an unwanted sound that can be caused by any human activity. Continuous use of machines that produce noise in the work environment will have a negative impact on workers, for example is increasing blood pressure. Purpose: This study aimed to analyze the influence of individual characteristics, behavior and noise intensity on increasing blood pressure in workers in the Ponorogo’s plastic industry. Methods: The study used prospective cohort design. The sample of the study was 32 respondents who received continuous noise exposure from injection machine for 8 hours/ day. The variables include individual characteristics, behavior, noise intensity, and increased blood pressure. The data were analyzed using SPSS with paired sample t-test and multiple linear regression. Results: The result showed that the average increase in systolic and diastolic blood pressure before and after working is 5.75 mmHg and 5.31 mmHg. If analyzed by statistical paired t-test, the significance value of p = 0.00 < α = 0.05 is obtained. Furthermore, multiple linear regression test is used for variables of individual characteristics, behavior and noise intensity on increasing blood pressure showing a significance value of 0.00 <0.05 and F count (6.79 and 6.32) > F table (2.49). Conclusion: Individual characteristics, behavior and noise intensity have an effect on increasing blood pressure in workers in the Ponorogo’s plastic industry. Medical checkup and ear protection equipment are needed for workers.

The Effect of Heating and Cooling Media Temperature on Injection Molding Products Shrinkage

Injection molding is the process of molding products with various shapes and sizes from plastic materials. The problem that often arises is the presence of product defects due to shrinkage. In this regard, the effect of water cooling on product size shrinkage in the injection molding process of making acetabular cups with polypropylene plastic and metal steel mold materials will be investigated through experimental investigations. The test begins with the manufacture of molds and injection machines, then the PP liquid plastic is injected twice into the mold, the first with cooling and the second without cooling. Both products are compared for depreciation by measurement. Shrinkage analysis is done by measuring the height and diameter of the product which is then compared with the size of the mold, so that final conclusions can be drawn. Measurement of shrinkage on the outside of the product is taken from three directions, namely the height of the X-axis product (dx), the outside diameter of the Y-axis product (dy), and the outside diameter of the Z-axis product (hz). For the inside of the product with a hemispherical shape, the shrinkage measurement is calculated by calculating the volume which can then be found the average radius. The results showed that the average shrinkage of the cooling test on the X axis = 1.224 %, on the Y axis = 1.857 %, on the Z axis = 1.83%, and on the radius r = 0.825 %. The average shrinkage of the test without cooling on the X axis = 1,591 %, on the Y axis = 2,32%, on the Z axis = 2,369 %, and on the radius r = 1,267 %.
 Keywords: Injection Molding, Shrinkage, Heating Cooling Temperature

DESIGN AND SIMULATION OF PLASTIC INJECTION MACHINE FOR PET (POLYETHYLENE TEREPHTHALATE)

PET (Polyethylene Terephthalate) material is widely used for several industries, especially the electronics industry. This study conducted a design and simulation for the manufacture of cases for smartphones using plastic injection machines for the manufacturing process. On the simulation results, it is found that the filling process, temperature and pressure have similarities, namely the distribution starting from the filling center point to the end of the casing design. Defects in manufacturing results are one of the failures of the production process and in this study, it is very rare to find research results that analyze predictions of defects in the smartphone case manufacturing process. On this simulation, defects were able to be detected in the simulation results of the casing design such as line defects and defects due to air bubbles. This research has succeeded in making an overview of the filling process, temperature, pressure, and early detection of defects in the injection process.

Improvement in reproducibility of large-scale perovskite solar cells using automatic liquid injection in antisolvent method

Perovskite solar cells are the most promising technology for highly efficient and cost-effective light-to-electricity conversion devices. To achieve high-quality and reproducible perovskite photo-absorbers in these devices, a great variety of deposition methods has been introduced. The widely used antisolvent approach is an efficient way for producing a homogeneous and dense perovskite films. However, the reproducibility of the obtained perovskite films is low due to uncontrollable parameters during the antisolvent dripping. In this work, an automatic liquid injection machine was used for controlling the antisolvent dripping parameters and enhancing the reproducibility of large-scale (>1 cm2) perovskite solar cells. Additionally, when compared to a manual liquid dropping, the automatic liquid injection improved the precision and consistency of liquid droplets. Our proposed method could reduce manual production tolerances and improve the reproducibility and accuracy for fabricating large-scale perovskite solar cells. Finally, it enhances manufacturing capacity and reduces the amount of waste produced during production.

Retracted: Application of Expert Adjustable Fuzzy Control Algorithm in Temperature Control System of Injection Machines.

[This retracts the article DOI: 10.1155/2022/3616814.].

Prediksi Persediaan Material Menggunakan Metode Single Exponential Smoothing

Material is an important material in manufacturing companies that make components of an item. Used to make various components which are then processed on injection machines. This of course makes warehouse and Production Planing Inventory Control (PPIC) employees have to see and ensure that the availability of materials can be fulfilled for several days or months, then make planning for spending or using materials if the existing materials have reached the availability limit. , and also inconsistent data such as lack of material. The purpose of this study is to find out how much material inventory is for the next 1 period. The method used is Single Exponential Smoothing with a constant of 0.9. Provision of constants for calculations from the High Impact Polystyrene (HIPS) 495F NATURAL material data sample which is applied to 3 other types of materials. The result of this research is that for PBT DURANEX 3300 NATURAL, the result is 777.01 with MSE 2880745.72, MAD 489.96 and MAPE 0.074%. ABS material type TOYOLAC T500-322 NATURAL got 2813.18 results with MSE 342161.98, MAD 168.85, and MAPE 0.092%. Material Type AS STYLAC 769 6A-X8113 IVORY got 663.46 results with MSE 222210.16, MAD 136.07, and MAPE 0.092%.

RANCANG BANGUN CETAKAN PLASTIK SARINGAN PEMBUANGAN AIR KAMAR MANDI

The main purpose of the design of plastic molding molds is to participate in advancing the world of the machining industry and can help the mold industry to simplify and shorten the time in doing a work of making molds, especially plastic molding molds. The design of this plastic molding mold by designing the shape of the injection machine then calculates the volume in the injection machine, the volume of this bathroom drain filter mold is 26838,475 mm3. Calculations on the design of this bathroom drain filter mold use references from the book by Scharcus, Edward and Herman Jutjz, "Westerman table for the metal Trade", Willestern Limited, new Delhi, 1985. The result of this plastic molding design is a filter. disposal of water using materials from PVC (Polyvinyl Chloride) seeds with an injection molding work system in the Sriwijaya State Polytechnic Mechanical Engineering laboratory.

Analisis Efektivitas Mesin Injection 2500 Ton di Bagian Produksi PT.XYZ Menggunakan Metode Overall Equipment Effectiveness

PT. XYZ is an industrial company that focuses on manufacturing automotive components. The company also has many branches in various countries such as in the USA, India, China, Japan, Vietnam, Thailand and Malaysia. The machine used in this company is an injection molding machine. PT. XYZ focuses its company on manufacturing car interior components. Many activities are carried out in it such as the injection process, painting to assembly. Data for the injection engine of 2500 TON experienced downtime or damage for the last three months (January-March 2022) which was 10,055 minutes, where the highest injection engine downtime data occurred in January 2022 of 3685 minutes. It is necessary to evaluate the injection machine to be able to determine the effectiveness of the injection machine using the Overall Equipment Effectiveness (OEE) method by looking for values from availability, performance to quality. Based on the results obtained in these three months, it does not meet international standards at an OEE score of 85%.

A Novel Method of Fault Diagnosis for Injection Molding Systems Based on Improved VGG16 and Machine Vision

Artificial intelligence technology has enabled the manufacturing industry and actively guided its transformation and promotion for the past few decades. Injection molding technology is a crucial procedure in mechanical engineering and manufacturing due to its adaptability and dimensional stability. An essential step in the injection molding process is quality inspection and manual visual inspection is still used in conventional quality control, but this open-loop working method has issues with subjectivity and real-time monitoring capacity. This paper proposes an integrated “processing–matching–classification–diagnosis” concept based on machine vision and deep learning that allows for efficient and intelligent diagnosis of injection molding in complex scenarios. Based on eight categories of failure images of plastic components, this paper summarizes the theoretical method of processing fault categorization and identifies the various causes of defects from injection machines and molds. A template matching mechanism based on a new concept—arbitration function Jψij—provided in this paper, matches the edge features to achieve the initial classification of plastic components images. A conventional VGG16 network is innovatively upgraded in this work in order to further classify the unqualified plastic components. The classification accuracy of this improved VGG16 reaches 96.67%, which is better than the 53.33% of the traditional network. The accuracy, responsiveness, and resilience of the quality inspection are all improved in this paper. This work enhances production safety while promoting automation and intelligence of fault diagnosis in injection molding systems. Similar technical routes can be generalized to other industrial scenarios for quality inspection problems.

Biologizacja procesów wytwórczych Stan zagadnienia, zasady i trendy rozwojowe

In this paper, a survey of new achievements in the area of biologically inspired design and manufacturing and fundamental rules of biological transformation in manufacturing – also in relation to mechanical engineering – is provided. Some possible scenarios and several examples of the applications of biological transformation in manufacturing are presented. Some new trends, for instance, the way so-called Living Manufacturing Systems, which are based on advanced AI techniques, are discussed. Finally, some examples of a successful biologicalisation of manufacturing tools, i.e. injection moulds, machine tools, manufacturing processes, and systems are provided. This paper can motivate Polish engineers and researchers to undertake this topic in Poland.

Mold Design and Analysis for Multi-Component Plastic Injection Parts with Contrasting Functional Features: Case Study

The classical plastic injection method is based on the principle of injecting a single color of a single polymeric material into the mold cavity under high pressure. In cases where the products are expected to have contrasted functional features and different colors, the classic injection process and the conventional injection molds are not sufficient. This paper proposes a new design approach for multi-component injection molds required by products containing different polymeric materials or different colors of the same polymeric material at the same time. It also presents a case study including the design of the hot runner, electromechanical rotary-cross, cooling, and ejection systems of a two-component, eight-cavity toothbrush mold. The polymeric materials are polypropylene for the first component, and styrene based thermoplastic elastomer for the second component, which exhibit good bonding properties with each other. In addition, an analysis study covering the filling parameters and production defect generations is also provided. The adopted design approach provides a production rate of 1600 parts per hour, corresponding to 18 s cycle time and 200 cycles per hour, and makes it sufficient to rotate only the 80 kg core plate instead of 1120 kg entire core side. Compared to existing methods, the results show that the proposed multi-component injection mold design method eliminates the need for particular injection machines and robotic systems, shortens the cycle time, and reduces energy consumption.

A new approach to dynamic forecasting of cavity pressure and temperature throughout the injection molding process

AbstractThe injection molding process is very sensitive to ordinary environmental alterations, as the numerical simulation is limited to within one injection cycle, and it cannot predict transient regimes. The present study presents a new approach based on SARIMAX models developed to predict the temperature and pressure inside the mold cavity. The proposed approach was developed in Python language, and it can identify the behavior of the process, allowing preventive actions. Experimental data of temperature and pressure obtained in real‐time inside an injection mold were accessed to use and to validate the proposed model. The results showed its efficiency and its high accuracy for predicting variations in temperature and pressure inside the mold, even when using a small number of samples to be trained. The proposed model can be very useful for monitoring the production of mechanical parts, under an Industry 4.0 environment. For future works, the model enables a contribution toward digital twins of a molded part, considering all the alteration on the parts' properties due to the disturbance on the injection molding process. Furthermore, it lays the groundwork for a new injection machine control system architecture.

The Effect of Foaming on Mechanical and Morphological Properties of Polypropylene

The automotive industry is among the priority technology areas of our country, and the reduction of vehicle weight and fuel consumption and thus CO2 emissions without compromising safety criteria are among the priority research areas. For this reason, R&D studies on increasing the use of polymer-based materials in the automotive industry are of great importance. In order to produce “high strength and weight reduction parts” in plastic moulding technologies, advanced technologies that focus on cost reduction and efficiency are being implemented rapidly. The chemical foaming process, which provides many advantages such as reducing the consumption of plastic material used, reducing the total moulding cycle time, using less tonnage injection moulding machines, and thus reducing the energy costs, is one of the innovative technologies that have been implemented since a very recent time. In this study, chemical foaming agent were being reinforced at the rate of 1-2-3% in natural fiber-reinforced recycled composite polypropylene raw material. The samples obtained in the injection machine was be moulded in the sizes and shapes in accordance with the standards. Tensile, hardness, impact and three points bending tests would be done. By examining the test results, the mechanical, and morphological properties of natural fiber reinforced polypropylene materials at different chemical agent percentages were examined. With increasing the amount of foaming agent, mechanical properties decreased.

Vibration Extraction for Melting Plastic Hydraulic Injection System with Stick Slip Vibration Analysis

IntroductionA hydraulic power injection machine is designed to use a driving screw to inject melted plastic into a specified mold. This machine can be found at an automotive spare parts factory. The cantilever-style heavy-duty screw injector is supported by one roller and secured at the end. An obvious need for vibration analysis on the roller support is essential. A mass spring damper model is proposed for deeply investigating the friction induced vibration mechanism for this injection system to well understand and analyze its vibration behavior.PurposeA mechanical mode of two degrees-of-freedom (DOF) is designed to improve research on the dynamic features of the Plastic Hydraulic Injection System (PHIS) mechanism.Materials and methodsExperimental investigation and analysis of this mechanism are explored to obtain the instability speed and critical stick slip (SS) speed. The numerical imitation results of this work will help with the design and development of the PHIS mechanism.ConclusionThe stability of the system and SS behavior are next examined by determining the critical variability speediness and critical SS speed. A simulation study is carried out to evaluate the effect of various parameters of the system on its stability and on the behavior of the SS motion.

Dust Cleaning System on Panel PET Preform Injection Machine BM500

Dust Cleaning System on Panel Injection Machine BM500 PET preforms. The clean machine panel is essential so that performance and safety are maintained. Dust that sticks to electrical components such as contactors, servo drives, solid-state relays, PLCs, and several other components causes overheating. Dust attached to the conductors of electrical components will burn and become carbon which bridges the emergence of sparks. To reduce the risk of damage to electrical equipment on the injection machine, an automatic dust cleaning system is designed. This system uses a GP2Y1010AU0F dust sensor, a DHT 22 sensor to detect temperature and humidity, Arduino Uno microcontroller, 16x2 LCD, L298N driver, DC motor, fan, solenoid valve and utilizes high-pressure air to spray dust inside the panel which is then sucked in with a fan and collected in a dust bag. From the results of the trial installation of this system with 10 times of data collection for 4 hours 30 minutes with an interval of 30 minutes, it can be seen that the dust cleaning process runs 2 times. After the cleaning process is running the data shows that the dust density can drop to 0.16 mg/m³. Likewise, the temperature inside the engine panel, after the air circulation process runs well in the first or second conditions, the temperature inside the panel can drop below 40°C. From the test results, it can be seen that the system can work well.

Sepiolite organic modifiers effect on pet/sepiolite nanocomposites degradation

In this paper the effect of different organosepiolites on PET matrix was evaluated through the analyses of Melt Flow Index (MFI) and Intrinsic Viscosity (IV) of the nanocomposites. PET/sepiolite nanocomposites were produced through a two-stage process. The masterbatch production was done in a melt compounding extruder, and then these were taken to an injection machine, where different specimens were obtained for characterization purposes. Two types of organomodifiers were tested, silanes in one hand and a quaternary ammonium salt on the other. Thermal analyses were done to determine thermal stability of the organomodifiers. Then, different experiments were carried out increasing the concentration of coupling agents to analyse its effect on PET matrix degradation. As results indicate a high degree of degradation of the nanocomposites matrix, pyromellitic dianhydride (PMDA) was added as chain extender to react with PET molecular chains, with the aim of increasing its molecular weight (Mw).

Development of a treated cardboard wastes injection machine into the sandy soils

This study aimed to evaluate a new prototype for an injection machine that works in sandy soils using treated cardboard waste. The tests were divided into three major categories: The first one was a performance evaluation of the new injection prototype. Secondly, study the effect of adding the treated cardboard to the sandy subsoil on reducing the irrigation levels and increasing the moisture content in the root zone of cultivated plants. As well, investigate sandy soil water storage efficiency and its impact on improving the soil’s properties. Thirdly, measurements on water-sensitive crop yields, like potatoes. The new prototype technique was designed based on using an automatic control system that is integrated to precisely control the injection discharge rate. So, the injection operation is proportionally synchronized with the tractor's forward speed. The field experiments were carried out at 0.24, 0.40, 0.57 and 0.74 m sec-1 of tractor forward speeds with 250, 350 and 450 mm of furrow openers' subsoil depths at 140 and 200 mm of injection widths and 5 and 10% concentrations of cardboard solution. The main results indicated that the maximal consumed energy was 196.08 kWh ha-1 with a field efficiency of 89.05% and an optimal field capacity of 0.281 ha h-1 using the highest variable levels. In addition, the water saving percentage was 35.80%, while the water storage efficiency was 85.85%. Furthermore, the total economic costs were reduced by 13.88% compared to the traditional silt injection method for the tested control plots.

Application of Expert Adjustable Fuzzy Control Algorithm in Temperature Control System of Injection Machines.

The stability and accuracy of temperature control of the injection molding machine is one of the keys to determine the quality and appearance of plastic parts. Due to the temperature control system of water-cooled injection molding machine has the characteristics of coupling, nonlinearity, and hysteresis, the traditional proportion-integral-derivative (PID) method to control the barrel temperature of injection molding machine will yield temperature overshoot and oscillation, affecting the product and appearance quality. In order to improve the effect of barrel temperature control, in this paper, an expert adjustable fuzzy control strategy (EAFCA) is designed to optimize the barrel temperature control system through the combination of expert control, fuzzy control, and PID control. The expert control rules are designed according to the barrel temperature deviation e and its change rate ec. The expert rules are used to adjust the mapping range of the fuzzy universe in real time for the input and output variables of the fuzzy controller and finally to realize the accurate adjustment of the PID controller parameters. In terms of control systems, the distributed control system (DCS) monitoring system of injection molding machine is designed with Siemens CPU315-2PN/DP and industrial computer as the hardware core and Step7 and windows control center (WinCC) as the software platform to complete the tool plastic production monitoring system. The DCS improves the operability, data management convenience, and plastic production efficiency of the injection molding machine monitoring system. The Simulink simulation and field test show that the EAFCA method can increase the adjustment speed by approximately 34 s and reduce the overshoot by nearly 3.1%, which significantly improves the stability and accuracy of the barrel temperature and improves the quality of plastic parts.