Comparison between Single and Multi Gates for Minimization of Warpage Using Taguchi Method in Injection Molding Process for ABS Material

Abstract

In this study, a mold is designed in single and dual type of gate in order to investigate the deflection of warpage for thick component in injection molding process. Autodesk Moldflow Insight software was used as a medium for experimental tested. Nessei NEX 1000 injection molding machine and P20 mold material details were entered in this study to get more accurate data on top of Acrylonitrile Butadiene Styrene (ABS) as a molded thermoplastic material. Taguchi orthogonal array, analysis of Signal to Noise (S/N) ratio and Analysis of Variance (ANOVA) were implemented to get the best combination of parameter and significant factor that affect the warpage problem for both types of gates. Coolant inlet temperature, melt temperature, packing pressure and packing time are the selected parameter that used in this study. A conformation test is conducted to verify the combination parameters optimized. From the result, multi gates used was founded that can decrease the deflection of warpage for thick product. From ANOVA, the most significant factor is melt temperature for single gate, and coolant inlet temperature for multi gate. Packing pressure and packing time were slightly influence on warpage problem for both studies.

The influence of the type of polypropylene and the length of the flow path on the structure and properties of injection molded parts with the weld lines

“…They are therefore forced to look for new technological solutions. A certain solution to the problem of weld lines in parts is the use of unconventional injection molding methods, such as push–pull injection molding , cascade , vibration , and injection molding with variable temperature . However, each of these methods involves higher costs of moldings production, associated with a more complicated mold design and the need to ensure proper control of the injection molding machine.…”

Sisal-glass fiber hybrid biocomposite: Optimization of injection molding parameters using Taguchi method for reducing shrinkage

“…The S/N ratio measures sensitivity of shrinkage due to controlled factors versus the noise factors [25]. Higher S/N ratio value suggests smaller variance around the target value and less likelihood of random effects of the noise factors [17]. Calcula-tion of average S/N ratio for each level has been illustrated by Tang et al [31].…”

“…With cooling time as the least significant factor for shrinkage, it is likely that flow-induced stresses during filling and packing stage of IM process had a dominant role in the formation of residual stress leading to shrinkage defects [15]. In addition, Nasir et al [17] found that melt temperature was also a significant contributing factor for shrinkage and warpage defects on both single Table 6 ANOVA analysis of shrinkage in flow and x-flow direction for SF10GF20.…”

The Thermal Effect of Variate Cross-Sectional Profile on Conformal Cooling Channels in Plastic Injection Moulding

“…The straight drilled cooling channels in simple shapes such round profile is fabricated by drilling straight line holes. These conventional cooling channel will lead to non-uniform mould cooling that will increase the cooling time and lead to the imperfection of the molded part such warpage, sink mark and differential shrinkage [1][2][3] The performance of cooling channels system, in term of heat dissipation rate was significantly affect by the design configuration of cooling system itself [4]. Time and cost are the most important relation in PIM process.…”