Plastic Injection Research Articles

Optimization of plastic injection molding process parameters for cowl B (L/R) sink mark defects by using Taguchi methods and ANOVA

The plastic injection molding process on Cowl B (L/R) products that have been carried out has sink mark defects. The defects that arise occur because the composition of injection molding parameter values is not optimal in the variables of melt temperature, mold temperature, packing time, packing pressure, and cooling time. The purpose of this study is to find the optimal composition of parameter values for each variable, to minimize sink mark defects in the product. The analysis process begins with the preparation of an orthogonal array matrix to determine the design parameters to be simulated on Autodesk mold flow. These results are evaluated with a signal-to-noise ratio to determine the effect of each parameter value composition on the results of the analysis process. The Analysis of Variance (ANOVA) method is used to estimate the contribution of each independent variable to all response measurements (the dependent variable). The optimization results for sink mark defects in the sink mark index value of 1.4494%, volumetric shrinkage of 0.5053%, and sink mark estimate of 0.0608 mm are found in the composition of the parameter values of melt temperature 200°C, mold temperature 80°C, packing time 30 seconds, packing pressure 80 MPa and a cooling time of 13,365 seconds. This data is used as a reference in determining parameters before production is carried out on plastic injection molding machines so that the time and cost of testing the injection molding process are optimal.

Recycling of Laser Powder Bed Fusion Scraps in Conventional Plastic Injection Systems

Recycling of Laser Powder Bed Fusion Scraps in Conventional Plastic Injection Systems

Study on injection molding parameters on PET with bio-plastic material and hot runner mold

Trend of global warming is increasingly interested for everyone who concerns on sustainability in terms of material used in production process. Plastic material is widely used in general industry. Presently, PET is used instead of common plastic together with bio-plastic that can be degradable after end of life. PET together with bio-plastic like PLA is more concerned for plastic product design particularly packaging, container, bottle and so on. However, there are rarely studied on plastic injection molding parameters and the impact on quality of preforms prior to both injection and blow molding the final products. The paper proposes simulation and design of experiment on plastic injection and blow molding parameters using PET + PLA Bio plastic material under the condition of hot runner. Case study is applied on a preform water bottle design. There are three factors which are concerned; machine, mold and plastics material. Due to rarely knowledge and information about the plastic injection molding parameters on using PET + PLA, plastic injection molding parameter is studied in this work. Simulation is on MOLDEX together with DOE of the Taguchi method. The study is investigated on controlling plastic injection molding such as melt temperature, mold temperature, packing pressure, and cooling time in each stage. Plastic flow simulation is created and tested. The results are discussed in details.

Design and development of a drip irrigation system

Nowadays agriculture is done everywhere and not just limited to farm lands. Residents of individual houses, apartments are growing wide variety of plants and many households sometimes neglect regular watering of the plants due to busy schedule and water large amounts in a single instances. This paper describes the design and development of the prototype of a small-scale drip irrigation system which is made up of three main components namely, Drip Flow regulator, Bottle holder and Ground support module which is simple to set-up with no hassle of piping systems and requires less maintenance. This product ensures the plants to be nurtured and watered on a regular basis with appropriate amounts of hydration and also allows to set-up a nutrient delivery system. The working mechanism of the flow regulator is by using a simple yet effective method of threaded nut and bolt design where the inlet of water is obstructed by the regulator when fastened and released accordingly to control the flow and drip of the water, additionally the bottle holder is designed such that, it can also incorporate non-standardized bottle sizes as well as regular beverage bottles and provides a universal fit. The potential applications of this drip irrigation component is for window plants, potted plants, garden plants, grown by individual house, apartment residents and office spaces and it has a lot of scope for use in the market and can be mass manufactured by using Plastic Injection Die methods.

Nitriding treatment for improvement of eroded surfaces by electroerosion

Surface modification of molds and dies by nitrogen diffusion processes has great application in the plastic injection industry. And electroerosion machining is a process capable of machining parts with complex and more detailed profiles and high hardness, having great application in this area. In this work, the application of the nitriding process on surfaces finished by electroerosion at different amperages was analyzed. From microhardness tests and metallographic analysis, it was found that after machining at low amperage or for roughing, it is possible to apply the superficial hardening of nitriding without the need for grinding and polishing.

Design of experiments (DOE) of parts manufactured in 3D printers using composed filaments of PLA and Aluminum

The Department of Mechanical Metal (Mechatronic Engineering) of the Technological Institute of Nogales was one of the first national degrees to offer in its study plans the specialty of plastic injection molding (IMCEMIP-2017-01), with the eager to continue innovating and evolving in this area, we present the following research work, with which we experimented and generated knowledge to determine the mechanical properties of parts manufactured in 3D printers, with polymer composite materials (PLA) and metallic powders ( Aluminum). In the first place, the filament formed by a matrix of PLA and an ALUMINUM reinforcement was created, which was extruded in a molding machine manufactured inside in the molding laboratory of this Institute, taking as consideration that the reinforcing material in this case aluminum the following percentages will be 0% and 20%. Placing these filaments in a suitable printer for the manufacture of 3D parts with composite materials to which an analysis of experiments was performed to determine what percentage of composite material has better mechanical properties

Implementing Statistical Quality Control of refrigerator lamp cover production lines in a plastic injection molding company (Case Study: CV. ABC)

Implementing Statistical Quality Control of refrigerator lamp cover production lines in a plastic injection molding company (Case Study: CV. ABC)

Conformal Cooling Channel Design for Improving Temperature Distribution on the Cavity Surface in the Injection Molding Process

Mold heating is an essential process in plastic injection molding. Raising the temperature of the mold before injecting liquefied plastic can ease the mold-filling process. A cooling channel can be used to transport high-temperature fluids for this purpose, such as hot water or oil. This dual purpose is a cost-effective solution for heating the mold because the target temperature is easily achieved using this method. In addition, a conformal cooling channel (CCC) can provide more efficient mold heating than a straight cooling channel. This study used the response surface methodology to determine the optimum CCC shape for heat distribution in a mold, and the simulation results confirmed its optimization. The average temperature of the mold using a CCC was better than that using a straight cooling channel, and the heat zone was uniform across the mold surface.

On the low-cycle fatigue behavior of a novel high-strength mold steel

Mold steels, usually being used for dies in low-temperature die casting or in molds for plastic injection, can additionally be considered as material of choice in precision optomechatronics. In any case, these steels will suffer from cyclic loading during their service life. Thus, despite of the envisaged application, the fatigue behavior must be studied comprehensively. In the present study, microstructure and mechanical properties, especially the low-cycle fatigue behavior, of a novel high-strength mold steel were investigated focusing on two different heat treatment conditions, i.e., low- and high-temperature annealing (LTA and HTA). The mechanical behavior being elaborated by tensile tests and strain controlled fatigue tests is discussed based on microstructural insights revealed by electron backscatter diffraction and fracture surface analysis. The results obtained indicate, that a more energy- and cost-intensive HTA treatment can be avoided without pronounced loss of mechanical performance.

Investigation of erosion wear performance and mechanism of mold materials

Abstract The surface of an injection mold is prone to erosion and wear under the impact of the filler during plastics injection molding, which leads to premature failure of the mold. The mechanism of erosion and wear of a filler on the mold has not been clarified yet. A numerical technique was employed to simulate the erosion and wear process, and the influence of environmental parameters and particle characteristics, such as erosion velocity, erosion angle, temperature, and particle shape were studied. The results showed that the erosion velocity and erosion angle are important factors that affect erosion and wear. Finally, the relationship between change of particle energy and erosion and wear of the material is studied from the perspective of energy.

Comparison of Conventional and Microcellular Injection Using New Chemical Agents

ABSTRACT This study is mainly focused to obtain stable dimensions for plastic products used in manufacturing industries. A technique of microcellular foaming injection method was chosen with added chemical blowing agents to decrease the mass, clamping force, and cycle time. Mold flow analysis was run to compare the conventional plastic injection (KP) method with chemical foaming injection molding method using added TecoCell H1 (TH) and CS (TCS). The primary process conditions are considered as temperature of the mold, velocity of injection, pressure and time of holding, and cooling time. The experiments were carried under polymer material as (polypropylene) Moplen EP548P. The new chemical blowing agents TH and TCS, having different reactive material ratios (50% and 25% endothermic) and gas concentration ratios, were utilized at a rate of 1% by weight claiming to be a novel method for producing the parts with high efficiency. The results of both the flow analysis and the injection molding experiments demonstrate that, plastic samples produced by conventional plastic injection could be made approximately 7.5% lesser weight, with 33% lesser force of clamping, and a gain of cycle time nearly 15% by adding chemical blowing agents to the process. Topsis technique is carried for determining the best fabrication method. It was observed that, the injection molding method with Tecocell H1 (TH) chemical foaming agent exhibited better results in terms of less clamping force, reduced cycle time, and weight of the product. The experimental results are validated using the Topsis method and the results are satisfied. Hence, the chemical blowing agent Tecocell H1 (TH) can be applied as a foaming agent for manufacturing the plastic products and increase the efficiency of the production.

Methodology for Creating a Software for Structuring the Reconstruction Technologies by Laser Welding of Metal Moulds

Abstract Metal and plastic parts are made in moulds, in production processes such as plastic injection, metal alloy die casting and metal deformation. During operations, moulds are exposed to severe conditions: wear, impact, corrosion, thermal cycling and high mechanical stresses. Moulds reconstruction has advanced, precisely because to new technologies, such as laser welding. Laser technologies offers several benefits, including increase of work speeds, reduced thermally influenced zones and material losses and decreased additional working times for mechanical machining processes.

Optimization of a Wafer Conveyor Spool for Plastic Injection Molding Production

Optimization of a Wafer Conveyor Spool for Plastic Injection Molding Production

Extending the Lifetime of Copper-beryllium Alloys as Plastic Injection High-end Needle Valve Mold Nozzle Tips Through a Heat-treatment-based Microstructure Optimization Approach

Extending the Lifetime of Copper-beryllium Alloys as Plastic Injection High-end Needle Valve Mold Nozzle Tips Through a Heat-treatment-based Microstructure Optimization Approach

Effect of Temperature, Holding Time, and Addition of Sn on Density on Metal Injection Molding Sintering Process

Metal injection molding (MIM) is a metal forming technique that combines powder metallurgy with plastic injection molding. MIM is very efficient in manufacturing small and complex products in large quantities. The MIM process has four steps: mixing, debinding, injection molding, and sintering. This research was conducted to determine the effect of variations in Sn addition, temperature, and holding time on the density of Al-PP products after the sintering process. Density is mass per volume so to find out the volume of Al-PP products, the use of a 3D scanner was attempted along with the EinScan application and a mesh mixer. The Taguchi method was used for data processing to determine the influence of variations in Sn addition, temperature, and holding time on density. The calculation of the percentage contribution showed that variations in Sn addition, temperature, and holding time affected density by 47%, 21%, and 3%. Also, 2% Sn addition yielded a reasonably good microstructure formation compared to without Sn addition and 1% Sn addition, where many voids remained in the specimen (the more significant the voids, the lower the density).

Design Plastic Injection Mold with the Help of Modular Software Mold Wizard

The purpose of the article is to research and apply CAD/CAM theory and techniques to design a set of plastic injection molds for supporting industries, providing plastic products for the smartphone manufacturing process in Vietnam, that is, injection molds, plastic connector between the power cord and the phone's charger. This set of molds has a much lower cost when compared to imported equipment of the same type, has guaranteed quality and is commercially viable. Especially, the result of the project is a model for students to grasp about the technology of manufacturing plastic products, contributing to improving the training quality of the CAD/CAM-CNC module.
 CAE at the design stage can be performed on a computer to design modification options, conduct evaluation (Evaluate), evaluate (Verify) and optimize (Optimize), reduce testing time and cost, mold, actual mold fix, shorten actual trial and error cycle, shorten product development time and time-to-market, reduce waste, time and money in stages.

Analysis and Validation of Varied Simulation Parameters in the Context of Thermoplastic Foams and Special Injection Molding Processes.

The simulation solutions of different plastic injection molding processes are as multifaceted as the field of injection molding itself. In this study, the simulation of a special injection molding process, which generates partially foamed integral components, was parameterized and performed. This partial and physical foaming is realized by a defined volume expansion of the mold cavity. Using the injection molding simulation software Moldex 3D, this so-called Pull and Foam process was digitally reconstructed and simulated. Since the Pull and Foam process is a special injection molding technique for producing foamed components, the validity of the simulation results was analyzed and evaluated. With the use of Moldex 3D, varied settings such as different bubble growth models and mesh topologies were set, parameterized, and then analyzed, to provide differentiated numerical calculation solutions. Actual manufactured components represent the experimental part of this study and are produced for reference. Different evaluation methods were used to quantify morphological quantities such as porosities, local densities, and cell distributions. These methods are based on two-dimensional and three-dimensional imaging techniques such as optical microscopy and X-ray microtomography (µ-CT). Thus, this structural characterization of the manufactured samples serves as the validation basis for the calculated results of the simulations. According to the illustrated results, the adequate selection of bubble growth models and especially mesh topologies must be considered for valid simulation of specific core-back techniques, such as the Pull and Foam injection molding process.

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.

Efficiency comparison of conformal cooling channels produced by additive and subtractive manufacturing in automotive industry plastic injection moulds: a hybrid application

Efficiency comparison of conformal cooling channels produced by additive and subtractive manufacturing in automotive industry plastic injection moulds: a hybrid application

Development of runner reservoir and its effect on optical properties of small high-precision plastic injection molded parts

ABSTRACT Adding reservoirs as extensions to a multi-cavity runner-system to regulate cavity fill-rate within small, high-precision optical parts during filling and fill-to-pack switch-over (F/P) was studied with the aid of simulations. This work aimed for a constant melt-front velocity inside the cavities with varying geometries. Three methods of reservoir designs were considered: first, using engineering intuition, second and third, using mass balance and mass and momentum balance equations, respectively. Eight reservoirs were designed and compared to two no-reservoir cases. For each case, 27 runs covering three levels of fill-rate, F/P, and packing pressure were simulated, resulting in 270 simulation runs. The quality variables of flow and thermally induced retardation and the average and standard deviation of volumetric shrinkage were considered and for each parameter, the minimum, best cases, occurred with a reservoir case. Thus, this study offers a proof-of-concept design for using reservoirs to improve molding of small, high-precision optical parts.