Plastic Injection Process Research Articles

Line Stop Time Reduction through Dandori Evaluation in Plastic Injection Process Production

Line Stop Time Reduction through Dandori Evaluation in Plastic Injection Process Production

Analisis Konsistensi Volume Output Pada Nozzle Barrel Mesin Mini Injeksi V-Line Menggunakan Material Plastik Polypropylene ExxonMobil AP03B

One of the processes commonly used in making plastic goods is the injection molding process. Every process in injection molding has a very important role. A less-than-perfect process will result in defects or failure in the product. To reduce product defects, one of the processes that must be researched is the barrel purging process. The purging volume on the mini injection machine using the V-line method is inconsistent, as evidenced by the fact that if the purging waste, or what is usually called an avalanche is weighed, it will produce a non-uniform mass. This research uses a mini injection machine with the V-line method which has 2 main steps to carry out the plastic injection process; dosing and injecting. Unlike injection engines in general, this engine does not have a check-ring to withstand back pressure. This machine uses a shut-off system as a replacement for the check-ring role. This machine has never been subjected to a purging volume consistency testing process. The consistency of the purging volume greatly influences the product uniformity results. The research method used in this final assignment is direct. Data collection and test specimen collection will be taken directly on the mini injection machine using the V-line method. The steps taken in this research are planning, taking data, taking test specimens, processing test specimen data, and comparing test specimen data to obtain analysis results. The research results show that the mini V-line injection machine cannot support mass production, because increasing the screw rotation speed will affect the consistency of the volume of plastic that will be produced in the barrel, causing production to not run quickly and precisely.

Effects of Plastic Injection Moulding Process Parameters on Material Elastic Modulus on Complex Geometry and Parameter Optimization for Getting Maximum Stiffness

Plastic injection is widely used in white goods sector in case of highly production rates, low transformation costs and recyclability of products. There are many parameters affecting on the quality, dimensional stability and mechanical strength in plastic injection process. In washing machine tubs which are exposed to dynamic loads during spinning, it is necessary to optimize process parameters. In this research; packing pressure, packing transition point, packing time and injection time is optimized by using Box Behnken methodology via Moldlfow elastic modulus outputs and structural analyses results. Optimum process parameters are obtained to achieve best material orientation.

APLICAÇÃO DO MAPEAMENTO DO FLUXO DE VALOR EM UM PROCESSO DE AUTOCONTROLE DA INJEÇÃO PLÁSTICA

Product quality and customer satisfaction are directly related. For the business to function properly, the customer must be satisfied. There are currently several methods for controlling product quality, one of which is self-control. This research applied Value Stream Mapping to analyze self-control in the plastic injection process in the chosen company, seeking to prove the efficiency of the decision to apply selfcontrol compared to the period without using it in the process. A qualitative research was carried out based on a case study in a consumer goods company with medium size, having in part of its production, the plastic injection process. To reach the final objective, the data prior to the implementation of selfcontrol in the plastic injection process, the quality, productivity and scrap indicators referring to six months of production were evaluated in order to have a solid base of information, and consequently using the mapping of value stream for before and after analysis. With this research, it was demonstrated that the implemented self-control method was a correct decision by the engineering sector, implying the improvement of the process and early retention of problems with non-conforming parts that could generate a bad experience for the customer.

Economical and Statistical Optimization of the Maintenance in the Production Process

The article presents a comprehensive example that demonstrates the control of a plastic injection process in practice. It includes measurement and analysis of the production process, its control using a control diagram to bring the production process to a state under statistical control by applying tests of non-random clusters and subsequent evaluation of process capability. The last part of the article gives an example of the maintenance of economical statistical optimization for four scenarios.

THE APPLICATION OF SIX SIGMA TO IMPROVE THE YIELD OF PLASTIC INJECTION MOLDING

Plastic injection molding has complex process parameters. The Six Sigma improvement method mainly uses quality control and statistical methods to improve product quality, so as to reduce the cost and waste caused by defective products. Taiwan is the world leader for original equipment manufacturing in the laptop industry, and related peripheral accessories are also a major concern of customers. The subject of this study was a professional supplier of laptop batteries. Through the collection of customer complaint data, it was found that battery case deformation was the most important problem for customers. Therefore, in order to remain competitive, the battery case deformation problem needed to be overcome first. Enterprises need to improve their existing processes to reduce the rate of product defects, improve output efficiency and product quality, and reduce production costs, so as to improve their competitiveness in the industry.This study took a Taiwanese company as an example to improve the plastic injection process through the improvement steps of Six Sigma. In this process, two key process factors, namely the injection speed and the cooling time, were identified by analytical tools. After calculating customers’ daily product demand, the most suitable parameters were found using the ‘design of experiments’ method. The results showed that the process capacity and product yield could be significantly improved. The key to the success of this Six Sigma project was the project implementer’s design of the experiment.

Optimization of Injection Molding Process by using different types of Conformal Cooling Channels

This paper objects to deliver a brief summary on different types of Conformal cooling channel designs available for injection molding process, Also, the conformal cooling channel plays very important role in plastic injection process of injection molding by improving its efficiency and quality thus, reducing the whole cycle time of production. A comparative study of different conformal cooling channels like Series and parallel Conformal cooling channel, square section conformal cooling channel (SSCCC), Spiral cooling channel, Scaffold conformal cooling channel, array of baffle conformal cooling channel, micro cooling channel and their effects on injection molding based manufacturing process are shown. Study related to the performance analysis of different conformal cooling channels is done by using “Autodesk moldflow Advisor”. This paper presents a succinct review of recent progress in Conformal cooling channels.

ARTIFICIAL NEURAL NETWORKS FOR PREDICTING THE GENERATION OF ACETALDEHYDE IN PET RESIN IN THE PROCESS OF INJECTION OF PLASTIC PACKAGES

The industrial production of preforms for the manufacture of PET bottles, during the plastic injection process, is essential to regulate the drying temperature of the PET resin, to control the generation of Acetaldehyde (ACH), which alters the flavor of carbonated or non-carbonated drinks, giving the drink a citrus flavor and putting in doubt the quality of packaged products. In this work, an Artificial Neural Network (ANN) of the Backpropagation type (Cascadeforwardnet) is specified to support the decision-making process in controlling the ideal drying temperature of the PET resin, allowing specialists to make the necessary temperature regulation decisions for the best performance by decreasing ACH levels. The materials and methods were applied according to the manufacturer's characteristics on the moisture in the PET resin grain, which may contain between 50 ppm and 100 ppm of ACH. Data were collected for the method analysis, according to temperatures and residence times used in the blow injection process in the manufacture of the bottle preform, the generation of ACH from the PET bottle after solid post-condensation stage reached residual ACH levels below (3-4) ppm, according to the desired specification, reaching levels below 1 ppm. The results found through the Computational Intelligence (IC) techniques applied by the ANNs, where they allowed the prediction of the ACH levels generated in the plastic injection process of the bottle packaging preform, allowing an effective management of the parameters of production, assisting in strategic decision making regarding the use of temperature control during the drying process of PET resin.

Optimizing Plastic Injection Process Using Whale Optimization Algorithm in Automotive Lighting Parts Manufacturing

In this study, using the whale optimization algorithm (WOA), one of the recent optimization algorithms inspired by nature, the plastic injection process parameters of an automotive sub-industry company were tried to be optimized. For this purpose, we tried to provide the maximum weight criterion for the “356 MCA Plastic Housing” (which is an automotive lighting part) produced by plastic injection method. The decrease in the weight of the product indicates that the material injected into the mold is missing and naturally indicates that there will be quality problems. In order to achieve this aim, the best factor levels were tried to be determined for the mold temperature (°C), injection speed (m/s), injection pressure (bar), holding time (s), and injection time (s), which are the controllable parameters of injection process. Factors and factor levels addressed using WOA have not been studied for this type of problem before and this is the novelty aspect of this research. Experiments performed to confirm the findings for optimum process parameters proved that the WOA method can be successfully applied to improve plastic injection process parameters. This study contains information for practicing researchers in terms of showing how the nature-inspired algorithm WOA can be applied in practical field studies.

Thermal and Mechanical Assessments of the 3D-Printed Conformal Cooling Channels: Computational Analysis and Multi-objective Optimization

Conformal cooling is an additive manufacturing-based solution and it is a rapidly developing method for reducing the cooling time of the plastic injection process. The present study investigates the thermal and mechanical performances of the 3D-printed conformal cooling channels using computational analyses and multi-objective optimization. For a real injection mold product, two different conformal cooling channel profiles, which are circular and elongated, are analyzed individually. Their cooling time, temperature non-uniformity, and pressure drop are assessed. Compared to the traditional channels, the cooling time of designed CCCs is reduced in the range of 30-60%. The cooling and fatigue life performances of the elongated channel are analyzed for different channel pathways and cross section areas. As for the circular channel, the coolant temperature, volume flow rate, and channel diameter are selected as the parameters within the ranges of 288.0-298.0 K, 1.0-10.0 L/min, and 2.1-2.5 mm, respectively. According to these parameters, the multi-objective optimization study is performed and the best trade-off point is found at the channel diameter of 2.5 mm, coolant temperature of 297 K, and the flow rate of 1 L/min when all the objectives have equal weights in the optimization problem.

Industrial Decarbonization by a New Energy-Baseline Methodology. Case Study

The main target of climate change policies in the majority of industrialized countries is to reduce energy consumption in their facilities, which would reduce the carbon emissions that are generated. Through this idea, energy management plans are developed, energy reduction targets are established, and energy-efficient technologies are applied to achieve high energy savings, which are environmentally compatible. In order to evaluate the impact of their operations and investments, companies promote measures of performance in their energy management plans. An integral part of measuring energy performance is the establishment of energy baselines applicable to the complete facility that provide a basis for evaluating energy efficiency improvements and incorporating energy performance indicators. The implementation of energy management systems in accordance with the requirements of ISO Standard 50001 is a contribution to the aim and strategies for improving cleaner production in industries. This involves an option for the industry to establish energy benchmarks to evaluate performance, predict energy consumption, and align production with the lowest possible consumption of primary and secondary forms of energy. Ultimately, this goal should lead to the manufacturing of cleaner products that are environmentally friendly, energy efficient, and are in accordance with the global environmental targets of cleaner manufacturing. This paper discusses an alternative for establishing energy baselines for the industrial sector in which several products are produced from a single raw material, and we determined the energy consumption of each product and its impact on the overall efficiency of the industry at the same time. The method is applied to the plastic injection process and the result is an energy baseline (EBL) in accordance with the requirements of ISO 50001, which serves as a reference for determining energy savings. The EBL facilitates a reduction in energy consumption and greenhouse gas emissions in sectors such as plastics, a sector which accounts for 15% of Colombia’s manufacturing GDP.

YAKLAŞIK ÇÖZÜM TEKNİKLERİNİ KULLANARAK PLASTİK ENJEKSİYON PROSESİNİN TASARIM METODOLOJİSİ

Bu çalışmada, istatistiksel deney tasarım yöntemleri kullanılarak hazırlanan deney setine uygun olarak yapılan akış analizleri ile enjeksiyon parametreleri optimize edilmiştir. Elde edilen sonuçları değerlendirmek için, ilk olarak istatistiksel deney yazılımı olan MiniTab vasıtası ile uygun bir regresyon modeli oluşturulmuştur, model katsayılarının doğruluğunu saptamak için F testi, parametrelerin sonuçlar üzerindeki etkisini saptamak için ANOVA testi uygulanmıştır. İkinci olarak süreç, bir hipoteze dayanan değişken yaratılarak, Monte Carlo simülasyonu ile optimize edilmiştir. Monte Carlo simülasyonu, analitik olarak belirsiz durumlarda varsayımlara dayanan hesaplamaları yapmak için kullanılır. Kalıp sıcaklığı, soğutma suyu sıcaklığı, enjeksiyon basıncı gibi işlem parametreleri sabit değildir. Bu belirsizliği gidermek için süreç hipoteze dayalı değişken üretmek suretiyle optimize edilmiştir. Son aşamada farklı optimizasyon yöntemleri kullanılarak elde edilen sonuçlar karşılaştırılarak, hangi yöntemin daha doğru sonuç verdiği değerlendirilmiştir. Sonuç olarak Monte Carlo simülasyonu ile minimum çarpılma değeri elde edilmiştir. Sonuç bölümünde yer alan Tablo 7 ve Grafik 1 üzerinden bu sonuç daha net anlaşılmaktadır. Plastik enjeksiyon işlemi gibi birçok parametrenin sonuç üzerinde etkin olduğu üretim yöntemleri için yapılacak optimizasyon çalışmalarında, belirsizlikleri gidermek için hipoteze dayalı rastsal parametre değerleri ile çalışmak avantaj sağlamaktadır.

Minimum Warpage Prediction in Plastic Injection Process using Taguchi Method and Simulation

Plastic materials are used in automobile, electrical and electronic applications, agricultural utilization, household and furniture products, and medical equipments. Among various plastic manufacturing process, injection molding is one of the most commonly used and common methods applied for forming plastic products in the industry. The process requires a molten polymer being injected into a cavity of a mold, which is cooled and the product ejected from the mold. During the Plastic Injection Molding (PIM) process, various defects, such as volumetric shrinkage, warpage, weld line and sink mark can occur. This paper presents a method to minimizing warpage defect on PolyPropylene AZ564 via PIM simulation using Moldflow software. The approach was based on Taguchi method.Through the effectiveness of this proposed method, it is confirmed using simulation by Moldflow software. The effect of the process parameters on the warpage of a motorcycle number plate bracket, is studied using analysis of variance (ANOVA). From the ANOVA, the significant parameters affecting the process are holding time, holding pressure and injection pressure. The result of the Taguchi prediction shown that minimum warpage is 1.078 mm, which is 7.14% and 9.09% different from the simulation result and experiment, respectively.

Multi-objective and many objective design of plastic injection molding process

Plastic injection molding is one of the most used manufacturing processes capable of producing flexible and economical parts at a large scale. Since this is a highly complex process, it is a natural consequence that there are many conflicting objectives that are worth considering in the design of such process. Problems where more than three objectives are being considered at the same time are termed many objective problems (MaOPs) in literature. Unlike for multi-objective problems (MOPs, problems with two or three objectives), there is no consensus of how to find ideal solutions for general MaOPs. In this paper, the multi-objective and many objective design of a plastic injection molding process is addressed. To accomplish this task, the two main contributions of this work are as follows: first, a new optimization model that contains up to seven objectives is proposed. That is, for the first time, it is considered the many objective design of a plastic injection process. Second, the usefulness of the Pareto Explorer, a global/local exploration tool for MaOPs, in the current context is demonstrated. For this, the complete seven-objective optimization problem on several selected scenarios related to the hypothetical decision making of a plastic gear is considered.

Injection process design for manufacturing of bicycle plastic bottle holder using CAx tools

Abstract The purpose of the paper is to present the design of new bicycle plastic bottle holder and injection process simulation. The model of plastic bottle holder was designed and simulated to determine injection parameters in SolidWorks environment. Based on main part’s 3D m0del the mold tool was created. From the virtual testing the most suitable injection point location, material temperature as well as fill time and required injection pressure have been specified.

The effect of CNC and manual laser machining on electrical resistance of HDPE/MWCNT composite

In this study, electrical conductivity of high-density polyethylene (HDPE)/multi-walled carbon nanotube (MWCNT) composite was investigated after laser machining. To this end, produced using plastic injection process, nano-composite samples were laser machined with various combinations of input parameters such as feed rate (35, 45, and 55 mm/min), feed angle with injection flow direction (0°, 45°, and 90°), and MWCNT content (0.5, 1, and 1.5 wt%). The angle between laser feed and injected flow direction was set via either of two different methods: CNC programming and manual setting. The results showed that the parameters of angle between laser line and melt flow direction and feed rate were both found to have statistically significance and physical impacts on electrical resistance of the samples in manual setting. Also, maximum conductivity was seen when the angle between laser line and melt flow direction was set to 90° in manual setting, and maximum conductivity was seen at feed rate of 55 mm/min in both of CNC programming and manual setting.

Risk Assessment with Failure Mode and Effects Analysis and Grey Relational Analysis Method in Plastic Injection Process

This study aims to evaluate the risks that may arise during the production process in a plastic injection manufacturing enterprise with traditional Failure Mode and Effect Analysis (FMEA) and Grey Relational Analysis (GRA). Although it is a widely used analytical technique that helps to identify and reduce the risks of failure in a process, the Failure Mode and Effects Analysis (FMEA) has some drawbacks that the different risks can have the same risk priority values and the weight of risk factors is not take into consideration. This situation has been tried to be eliminated by integrating the FMEA with the GRA. As a result, it is seen that the order of risk priority values of the identified failure changes according to both methods.

Application of Taguchi Method-Moldflow-Particle Swarm Optimization for Plastic Injection Process Parameters Optimization

Plastic injection process is one of techniques used to manufacture plastic products. The technique is widely used due to its higher and faster production capacity and low cost. However, production process problems are often found, one of which is inappropriate process parameters settings, which may cause product defects. This paper presents a method using combination of Taguchi method, Moldflow simulation and PSO to optimize plastic injection molding process parameters. Moldflow simulations were run to obtain volumetric shrinkage values resulting from each combination of parameters setting selected by means of OA. In adopting S/N ratio technique of Taguchi method, study adhered to principle of the smaller better. The ANOVA method was also used to analyze effect of each process parameter on volumetric shrinkage and a regression analysis was used to establish equation used for application of PSO method to optimize plastic injection process parameters. This method was applied for production of number plate brackets from PP AZ564 material. The study concluded that application of combined Taguchi-Moldflow-PSO method could reduce volumetric shrinkage from 6.05% to 4.24%.

PERENCANAAN PENGGUNAAN MATERIAL PLASTIK DAUR ULANG DENGAN SISTEM MANUFAKTUR BERKELANJUTAN DI POLITEKNIK MANUFAKTUR ASTRA

One of many kinds of production processes in Politeknik Manufaktur Astra is Plastic Injection Process with ABS material. This process will produce plastic and scrap. The amount of plastic scrap that is produced by this process reaches 50% of all of the amount. To increase the efficiency of ABS material and build up the culture of Sustainable Development System so that is done a kind of research that is focused on the utilization of plastic waste material from Process of Plastic Injection by doing a recycle process and using the product of recycle as the basic additive material in Plastic Injection Process. To figure out the properness of the material of recycled plastic as the main material in Plastic Injection Process so is also done a tensile test to any composition of recycled ABS material and valuing certain mechanical properties that are similar to original ABS material. Moreover to cut the cost of ABS material providing so is done an analysis of material reservation with EOQ method to figure out the economic number of material reservation. The calculation of EOQ showed the most economic amount per reserving is 75kg/reserve. By the utilization of recycled material and usage of EOQ method on providing the ABS material so that Politeknik Manufaktur Astra can do a cost reduction for 36%.

Biodegradable Mg Strengthened Poly-Lactic Acid Composite through Interfacial Properties

High-strength magnesium alloy (AZ31) reinforced poly-lactic acid (PLA) composite rods for potential application of bone fracture fixation prepared by plastic injection process on Mg rod.Thecomposities possess improved the interfacial bonding between poly-lactic acid and Mg rod due to the micro-anchoring which lead to better mechanical performance in Simulated body fluid solution.The present results indicated that this new PLA-clad Mg composite rods show good potential for biomedical applications.