Optimization of Injection Molding Process to Minimize Weld-line and Sink-mark Defects Using Taguchi based Grey Relational Analysis

Sreedharan, J; Jeevanantham, A.K.

doi:10.1016/j.matpr.2018.02.244

Cited by 18 publications

(8 citation statements)

References 12 publications

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“…4,15,62 Taguchi method is widely used for the optimization of the process parameters and conducting designs of experiments. 16,63,64 The S/N ratio formula in Equation ( 19) is explaining largerthe-better characteristics, used to get optimized process parameters to maximize weld-line strength as…”

Section: Methods Of Reducing Weld-lines and Its Effectmentioning

confidence: 99%

“…Increasing packing pressure and melt temperature will increase the strength of the weld‐line, however it is also reported after a certain level, increasing packing pressure and melt temperature, the strength of the weld‐line gets reduced therefore well balance of packing pressure and melt temperature is important 4,15,62 . Taguchi method is widely used for the optimization of the process parameters and conducting designs of experiments 16,63,64 . The S/N ratio formula in Equation (19) is explaining larger‐the‐better characteristics, used to get optimized process parameters to maximize weld‐line strength as

\frac{S}{N} = - 10 \log (\frac{1}{n} \sum_{i = 1}^{n} \frac{1}{y_{i}^{2}})

…”

Section: Methods Of Reducing Weld‐lines and Its Effectmentioning

confidence: 99%

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Weld‐lines and its strength evaluation in injection molded parts: A review

Jadhav,

Gaval,

Solanke

et al. 2023

Polymer Engineering & Sci

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Injection molding manufacturing is immensely popular nowadays because of its excellent manufacturability for complex designs produced from a wide range of different engineering plastic materials. Weld‐line is a defect that arises in injection molding when two or more flow fronts collide. The weld‐lines are undesirable from both aesthetic and functional points of view and their effect is different for varied materials, process conditions, loadings, forms of weld‐line, etc. The presence of a weld‐line weakens components locally due to insufficient intermolecular diffusion, v‐notch formation, fiber anisotropy, insufficient process conditions, and so on. When a component is under load, crack propagation usually begins with a weak weld‐line area. Therefore, the designer should anticipate the presence of weld‐lines and their strength to avoid failure of components during operation. In this article, the review of published research work on weld‐line formation during injection molding has been summarized. The review focuses on the phenomenon of weld‐line formation, the type of weld‐lines, and the importance of weld‐line evaluations. The theoretical, experimental, and computational approaches to analyzing weld‐line and its strength are covered in detail. At last, methods for reducing weld‐lines and increasing the strength of weld‐line area have been discussed. This review also gathers data on weld‐line strength with respect to different materials.Highlights Details of weld‐line formation and its types. Importance of weld‐line evaluation. Methods of weld‐line strength evaluation. Methods of reduction of the number of weld‐line and its effect. Summary of weld‐line strength for different material.

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Section: Methods Of Reducing Weld-lines and Its Effectmentioning

confidence: 99%

\frac{S}{N} = - 10 \log (\frac{1}{n} \sum_{i = 1}^{n} \frac{1}{y_{i}^{2}})

…”

Section: Methods Of Reducing Weld‐lines and Its Effectmentioning

confidence: 99%

Weld‐lines and its strength evaluation in injection molded parts: A review

Jadhav,

Gaval,

Solanke

et al. 2023

Polymer Engineering & Sci

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“…Recently, additive manufacturing (AM) has emerged as a promising manufacturing method that, in many cases, could replace traditional manufacturing methods [1][2][3]. The original material shapes for the AM method are powder or wire, and they are melted and adhered to generate the designed forms.…”

Section: Introductionmentioning

confidence: 99%

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

et al. 2023

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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.

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“…Experiments have been conducted to determine the effect of injection molding parameters on the defects of transparent injection molding parts used in air conditioners. A grey relational analysis (GRA) was generated using the Taguchi method to determine the optimal injection molding parameters [11]. Artificial neural network (ANN) and particle swarm optimization (PSO) techniques were used to predict the optimal injection molding processes for bi-aspheric lenses [12].…”

Section: Introductionmentioning

confidence: 99%

Optimization of Injection Molding of Automotive Plastic Horn Cover Part Using Taguchi Method and Reverse Engineering

Lee¹,

Cho²,

Han³

2022

Mater. Plast.

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The aim of the paper consisted in the development of an injection mold for plastic horn cover parts in commercial vehicles. Three mold types were designed in anticipation of the structure and quality of molds, and injection molding numerical analyses were conducted for the three types of molds. One mold type was selected in consideration of the resin flow patterns inside the mold, surface quality, and final deflection amount of the horn cover. To perform optimal injection molding using the selected mold, optimization of injection molding parameters was performed using the Taguchi method, one of the designs of experiment (DOE) and ANOVA methods. As a result, it was confirmed that the deflection amount of the molding under optimal molding parameters decreased by about 34.3% compared to the deflection amount before optimization of the molding parameters. Based on these encouraging results, the previously selected mold type was actually manufactured. The horn cover was molded using the obtained optimal injection molding parameters to the manufactured mold. To verify the precision of the molded horn cover, the deflection amount of the molding was measured with a 3D scanner. The deflection amount of the horn cover was estimated to be about 11% to 43% larger for each measurement position than the deflection amounts in the analysis results. The manufactured mold was revised to solve the problem that the deflection amount of the actual molding is larger than the deflection amount predicted by injection molding analysis. The dimensions and surface quality of the horn cover with a revised mold were satisfactory.

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Optimization of Injection Molding Process to Minimize Weld-line and Sink-mark Defects Using Taguchi based Grey Relational Analysis

Cited by 18 publications

References 12 publications

Weld‐lines and its strength evaluation in injection molded parts: A review

Weld‐lines and its strength evaluation in injection molded parts: A review

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

Optimization of Injection Molding of Automotive Plastic Horn Cover Part Using Taguchi Method and Reverse Engineering

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