Numerical investigation of warpage in insert injection-molded lightweight hybrid products

Nguyen, Trieu Khoa; Hwang, Chul Jin; Lee, Dong-Weon

doi:10.1007/s12541-017-0024-5

Cited by 23 publications

(13 citation statements)

References 18 publications

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“…Additionally, an orthogonal array is implemented to characterize the influences of certain factors on the process by just conducting a minimal and optimized number of experiments. Therefore, the Taguchi method is a hugely efficient method and is employed in many fields due to its advantage of identifying the importance of each factor influencing product quality [36].…”

Section: 2mentioning

confidence: 99%

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Development and Characterization of a Thermoforming Apparatus Using Axiomatic Design Theory and Taguchi Method

Nguyen

Pham

Chau

et al. 2020

Preprint

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In this study, an experimental investigation of the development of a thermoforming apparatus and the thickness uniformity of its samples was performed based on the axiomatic design theory in conjunction with the Taguchi method. Thermoforming is a powerful tool for both consumer product needs and packaging industry. Such traditional technology has been investigated in many aspects for a long time ago. However, there are still needs for the development and characterization of thermoforming devices aiming at shorter construction time and less cost involved. Therefore, an experimental analysis was performed to systematically realize all the functional structures of the device using axiomatic design theory. The combination of orthogonal array (OA) and analysis of variance revealed the influences of the relatival processing factors, showing that the thickness of the plastic sheet and areal draw ratio had crucial roles to play. Furthermore, an optimization process using the Taguchi method was utilized to determine all accurate and optimum processing parameters. The outcomes obviously verified that the present combination method can overcome the current development and optimization method’s limitation and also conclusively give accurate optimal outcomes without using complicated algorithms and software solutions. Therefore, it promises a simple and powerful tool for engineers on-site in medium or small scale manufactories.

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Section: 2mentioning

confidence: 99%

“…where y is the observation, n is the number of experiments. The effects of processing conditions can also be analysed using an ANOVA study [38], which determines the percentage that each parameter contributes [36]. The total sum of squared deviations SS T from the total mean S/N ratio, is described below:…”

Section: 2mentioning

confidence: 99%

Development and Characterization of a Thermoforming Apparatus Using Axiomatic Design Theory and Taguchi Method

Nguyen

Pham

Chau

et al. 2020

Preprint

Self Cite

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show abstract

“…Nguyen et al. 16 investigated the insert injection molding (IIM) process using Taguchi methods-based RSM and employed the double optimization technique to optimize the process parameters for minimizing warpage of plastic-metal hybrid products. Chen et al.…”

Section: Literature Reviewmentioning

confidence: 99%

Multi-objective optimization for multi-stage sequential plastic injection molding with plating process using RSM and PCA-based weighted-GRA

Sreedharan

Jeevanantham

Ananthanarayanan

2019

Proceedings of the Institution of Mechanical Engineers, Part C:

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The multi-stage sequential process with multi-objective is a complex problem to address as the decision made at a particular stage influences the subsequent stage and vice versa. In this article, the effects of input variables of plastic injection, mold, and different plating stages were investigated on different output responses, namely weldline, warpage, length, and various metal plating thicknesses. This paper investigates a real-time industrial data of manufacturing an automotive exterior part made of ABS material. A D-optimal experimental layout with 55 experiments was generated for eight input factors each at three levels. Nine different output responses in each experiment were normalized into a weighted grey relational grade using grey relational analysis coupled with principal component analysis. The solutions obtained by the analysis of variance on weighted grey relational grade, and by the desirability analysis of D-optimal were compared and validated. The confirmation experiments recorded an average improvement in cumulative process outputs as 40.56% by grey relational analysis and 38.50% by desirability analysis.

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“…The prediction of warpage by computer will solve the issue of universality. Some methods have been introduced and developed to predict the warpage of CIM parts [ 18 , 19 , 20 ], and some of them have been introduced into commercial software, such as Moldflow and Moldex 3D. The large warpage is considered as the main defect of RHCM parts [ 21 ].…”

Section: Introductionmentioning

confidence: 99%

Warpage Prediction of RHCM Crystalline Parts Based on Multi-Layers

Bei

Liu

et al. 2021

Polymers

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Warpage is a typical defect for injection-molded parts, especially for crystalline parts molded by rapid heat cycle molding (RHCM). In this paper, a prediction method is proposed for predicting the warpage of crystalline parts molded by the RHCM process. Multi-layer models were established to predict warpage with the same thicknesses as the skin-core structures in the molded parts. Warpages were defined as the deformations calculated by the multi-layer models. The deformations were solved using the classical laminated plate theory by Abaqus. A model was introduced to describe the elastic modulus with the influence of temperature and crystallinity. The simulation process was divided into two procedures, before ejection and after ejection. Thermal stresses and thermal strains were simulated, respectively, in the procedure before ejection and after ejection. The prediction results were compared with the experimental results, which showed that the average errors between predicted warpage and average experimental warpage are, respectively, 7.0%, 3.5%, and 4.4% in conventional injection molding (CIM), in RHCM under a 60 °C heating mold (RHCM60), and in RHCM under a 90 °C heating mold (RHCM90).

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Numerical investigation of warpage in insert injection-molded lightweight hybrid products

Cited by 23 publications

References 18 publications

Development and Characterization of a Thermoforming Apparatus Using Axiomatic Design Theory and Taguchi Method

Development and Characterization of a Thermoforming Apparatus Using Axiomatic Design Theory and Taguchi Method

Multi-objective optimization for multi-stage sequential plastic injection molding with plating process using RSM and PCA-based weighted-GRA

Warpage Prediction of RHCM Crystalline Parts Based on Multi-Layers

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