Optimization of warpage on plastic part by using response surface methodology (RSM)

Hidayah, Malikhatul; Shayfull, Z.; Noriman, N. Z.; Fathullah, M.; Norshahira, R.; Miza, A. T. N. A.

doi:10.1063/1.5066796

Cited by 5 publications

(3 citation statements)

References 17 publications

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“…The most conventional strategy is to reduce the warpage by optimising the process parameters, the idea being that process parameters impact the magnitude of the warpage and the shape of the warped part. The literature [4,6,11,14,15,29] identifies the following parameters as the most influential: melt temperature, injection and cooling time, and injection packing pressure. Changing the value of these process parameters causes a change in the material state during the moulding process, e.g., temperature and pressure field distribution in the material.…”

Section: Introductionmentioning

confidence: 99%

“…The strategies used to determine the optimal combination of the process parameters employ different optimisation methods, e.g. Response Surface Method [11], Dual Response Surface Method [5], Glowworm Swarm Optimisation [28], the Kriging model [9,10], genetic algorithms [29] and others [4]. Most of them succeed in reducing warpage by up to 50%.…”

Section: Introductionmentioning

confidence: 99%

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Correction of mould cavity geometry for warpage compensation

Kastelic

Starman²,

Cafuta³

et al. 2022

Int J Adv Manuf Technol

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Warpage is one of the most challenging defects occurring in plastic injection moulded parts. Various approaches to overcome this issue have been proposed in the literature, but they all provide only partial solutions to the problem. This paper proposes a new method for the compensation and minimisation of warpage. The method is based on Mould Cavity (MC) correction. In contrast to other similar methods, here the MC correction is accomplished through a direct comparison of the local deviations of the warped part's geometry to the desired geometry of the part. Modifying the MC shape accordingly yields parts with a lower shape discrepancy from the desired geometry compared to the nonadjusted shape. The key novelty of the paper is the development of software that iteratively adjusts the MC shape to minimise local deviations. In every iteration, the warped part is compared to the desired geometry and the MC geometry is adjusted accordingly. A curved thin-walled plate part case study demonstrates the method's capabilities. We show that the maximum warpage value of 0.005 mm (0.7% of the initial maximum warpage) was reached after three iterations of MC geometry correction and remained stable afterwards.

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Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Correction of mould cavity geometry for warpage compensation

Kastelic

Starman²,

Cafuta³

et al. 2022

Int J Adv Manuf Technol

View full text Add to dashboard Cite

show abstract

“…Two combinations of factors are statistically significant on warpage: melt temperature and packing time and packing pressure and packing time. Hidayah et al [13] used response surface methodology combined the AMI software as the optimization approach in order to obtain the initial setting of process parameters in injection molding that may lead to the minimization of warpage. From ANOVA result, melt temperature is the most significant factor that give influenced to the formation of warpage.…”

Section: Introductionmentioning

confidence: 99%

Experimental and Numerical Study Determining the Warpage Phenomenon of Thin-Wall Injection Molding

Huang

Peng

et al. 2020

Advances in Polymer Technology

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This study emphasizes the warpage phenomenon of thin-walled parts using acrylonitrile-butadiene styrene (ABS) plus polycarbonate (PC) plastics for optimal processing by thin-wall injection molding. The authors first employed the Moldflow software to analyze the runner’s balance on multicavities for thin-walled parts and to simulate the warpage of thin-walled parts with thin-wall injection molding. Then, this study used those data to fabricate a real mold by computer numerical control machining. For this study, the authors fabricated thin-walled parts and measured their warpage using various process parameters (injection speed, injection pressure, mold temperature, packing time, and melt temperature) with thin-walled injection molding. Finally, the authors found that the most important processing parameter was the packing time for warpage phenomenon of thin-walled parts by thin-wall injection molding.

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Optimization of the Working Parameters with Digital Jidoka Twin by Hybridizing the WSPA and HS Methods to Keep Products Within Standard Specifications

Abed

Arjani

Seddek

2023

J. Adv. Manuf. Syst.

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The manufactured products that rely on molten Acrylonitrile Butadiene Styrene (ABS) via Tederic machine (450[Formula: see text]t) suffer from some types of defects such as black dots, shrinkage, and bubbles, which weaken the competitiveness. Therefore, this work proposes the Jidoka recruit’s network system (JRNS) to set optimal operating parameters to reduce the processes’ output variations and cut down on total process wastage autonomously. The suggested JRNS consists of two sequential stages. The first stage in front propagation relies on response surface methodology (RSM) in classifying the significant operating parameters from 15 candidates experimentally (DOE) to identify the most crucial one. The second stage predicts the processes’ deviation by integrating two meta-heuristic methods called harmony search (HS) and weighted superposition attraction (WSPA) in the backpropagation to automatically reset the operating parameters to keep the product within the standard specification to avoid 11 defect chances. JRNS is innovative and has been used to upgrade autonomous control for enhancing the Tederic machine (450[Formula: see text]t) process to reduce 70.98% of molding defects. The JRNS (RSM, [Formula: see text]) increases the operation efficiency from 94% to 100% and reduces the defects per million opportunity to the six sigma scale.

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Optimization of warpage on plastic part by using response surface methodology (RSM)

Cited by 5 publications

References 17 publications

Correction of mould cavity geometry for warpage compensation

Correction of mould cavity geometry for warpage compensation

Experimental and Numerical Study Determining the Warpage Phenomenon of Thin-Wall Injection Molding

Optimization of the Working Parameters with Digital Jidoka Twin by Hybridizing the WSPA and HS Methods to Keep Products Within Standard Specifications

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