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José M. Torralba - One of the best experts on this subject based on the ideXlab platform.

  • metal Injection Moulding of bronze using thermoplastic binder based on hdpe
    Powder Metallurgy, 2007
    Co-Authors: Gemma Herranz, A Varez, José M. Torralba
    Abstract:

    AbstractIn the present work, the Injection Moulding Process of a Cu–10Sn bronze has been studied. Different formulations of binders based on high density polyethylene, paraffin wax and polyethylene glycol have been used. The optimisation of the metallic load is based on torque measurements and rheological studies. The optimum powder loading was 60 vol.-%. The Moulding parameters are selected to obtain homogeneous specimens with three different geometries and without distortions. The green parts have an adequate strength for handling. The organic binder was eliminated by thermal debinding under N2/10%H2 atmosphere. The debinding Process has been designed by means of thermogravimetrical analysis of binder and feedstock and considering the maximum heating rates at which the samples do not present cracks. The specimens were sintered at temperatures between 875 and 950°C in the same reducing atmosphere.

  • metal Injection Moulding of hs12 1 5 5 high speed steel using a pw hdpe based binder
    Journal of Materials Processing Technology, 2006
    Co-Authors: L A Dobrzanski, Gemma Herranz, A Varez, G Matula, José M. Torralba
    Abstract:

    Abstract In this communication, we present the powder Injection Moulding (PIM) of HS12-1-5-5 high-speed steel parts using a wax-HDPE based binder. The Injection Moulding Process of the feedstock (68 vol.% of metal) has been optimized to obtain high quality green parts. The elimination of organic binder was carried out by thermal debinding under inert atmosphere. In order to keep carbon in the sample that could improve the sintering Process, incomplete debinding were performed between 450 and 500 °C. In this study, we have studied the effect of different atmospheres on the debinding Process. Debinding was performed under nitrogen and argon. The specimens were sintered at temperatures between 1200 and 1300 °C with steps of 10 °C in following mixture N 2 –10% H 2 atmosphere. The PIM parts present higher density than those obtained by conventional PM.

  • sintering in different atmospheres of t15 and m2 high speed steels produced by a modified metal Injection Moulding Process
    Materials Science and Engineering A-structural Materials Properties Microstructure and Processing, 2004
    Co-Authors: A Varez, José M. Torralba, G Matula, B Levenfeld, L A Dobrzanski
    Abstract:

    Abstract A study of the sintering behaviour of M2 and T15 high speed steel (HSS) parts obtained by a modified MIM Process in low and high vacuum and in N2–5%H2 atmosphere, showed that high vacuum sintering gave quasi-full densities at very low temperatures in both steels. Microhardness is in relation to the densities obtained, and can be improved by conventional heat treatment. The evolution of the microstructure during sintering was analysed by SEM and XRD. After vacuum sintering M6C and MC carbides were detected whereas sintering in nitrogen rich atmosphere makes carbonitrides appear.

  • sintering in different atmospheres of t15 and m2 high speed steels produced by a modified metal Injection Moulding Process
    Materials Science and Engineering A-structural Materials Properties Microstructure and Processing, 2004
    Co-Authors: A Varez, José M. Torralba, G Matula, L A Dobrzanski
    Abstract:

    Abstract A study of the sintering behaviour of M2 and T15 high speed steel (HSS) parts obtained by a modified MIM Process in low and high vacuum and in N2–5%H2 atmosphere, showed that high vacuum sintering gave quasi-full densities at very low temperatures in both steels. Microhardness is in relation to the densities obtained, and can be improved by conventional heat treatment. The evolution of the microstructure during sintering was analysed by SEM and XRD. After vacuum sintering M6C and MC carbides were detected whereas sintering in nitrogen rich atmosphere makes carbonitrides appear.

  • mechanical properties and pitting corrosion behaviour of 316l stainless steel parts obtained by a modified metal Injection Moulding Process
    Journal of Materials Processing Technology, 2003
    Co-Authors: L Castro, A Varez, S Merino, José M. Torralba
    Abstract:

    Abstract Stainless steel AISI 316L parts have been obtained by a modified metal Injection Moulding (MIM) Process using two different thermosetting polymers: commercial acrylic resin and cyclohexyl methacrylate (CHMA). The first resin polymerises at 90 °C while the later cures between 20 and 80 °C. Different mixtures of metal and polymer were investigated and the optimum one was 60 vol.% of metal, for both resins. Due to the fact that the corrosion properties in this type of steel decrease with the carbon content, the debinding cycle has been optimised on the basis of a thermogravimetric study. Sintering was carried out under vacuum atmosphere between 1200 and 1350 °C for 1 h. Mechanical properties were evaluated by means of tensile tests and a good agreement between mechanical properties and sintering curves has been found. Pitting corrosion has been studied through pitting potentials in different chloride environments and at several temperatures. The behaviour of this material has been compared to a wrought 316L and to a conventional powder metallurgy 316L, pressed at 750 MPa and sintered at 1350 °C. The results have been studied on the basis of the carbon content determined by LECO analysis. Pits have also been examined through optical microscopy, to obtain more information about the pitting Process.

A Varez - One of the best experts on this subject based on the ideXlab platform.

  • metal Injection Moulding of bronze using thermoplastic binder based on hdpe
    Powder Metallurgy, 2007
    Co-Authors: Gemma Herranz, A Varez, José M. Torralba
    Abstract:

    AbstractIn the present work, the Injection Moulding Process of a Cu–10Sn bronze has been studied. Different formulations of binders based on high density polyethylene, paraffin wax and polyethylene glycol have been used. The optimisation of the metallic load is based on torque measurements and rheological studies. The optimum powder loading was 60 vol.-%. The Moulding parameters are selected to obtain homogeneous specimens with three different geometries and without distortions. The green parts have an adequate strength for handling. The organic binder was eliminated by thermal debinding under N2/10%H2 atmosphere. The debinding Process has been designed by means of thermogravimetrical analysis of binder and feedstock and considering the maximum heating rates at which the samples do not present cracks. The specimens were sintered at temperatures between 875 and 950°C in the same reducing atmosphere.

  • metal Injection Moulding of hs12 1 5 5 high speed steel using a pw hdpe based binder
    Journal of Materials Processing Technology, 2006
    Co-Authors: L A Dobrzanski, Gemma Herranz, A Varez, G Matula, José M. Torralba
    Abstract:

    Abstract In this communication, we present the powder Injection Moulding (PIM) of HS12-1-5-5 high-speed steel parts using a wax-HDPE based binder. The Injection Moulding Process of the feedstock (68 vol.% of metal) has been optimized to obtain high quality green parts. The elimination of organic binder was carried out by thermal debinding under inert atmosphere. In order to keep carbon in the sample that could improve the sintering Process, incomplete debinding were performed between 450 and 500 °C. In this study, we have studied the effect of different atmospheres on the debinding Process. Debinding was performed under nitrogen and argon. The specimens were sintered at temperatures between 1200 and 1300 °C with steps of 10 °C in following mixture N 2 –10% H 2 atmosphere. The PIM parts present higher density than those obtained by conventional PM.

  • sintering in different atmospheres of t15 and m2 high speed steels produced by a modified metal Injection Moulding Process
    Materials Science and Engineering A-structural Materials Properties Microstructure and Processing, 2004
    Co-Authors: A Varez, José M. Torralba, G Matula, B Levenfeld, L A Dobrzanski
    Abstract:

    Abstract A study of the sintering behaviour of M2 and T15 high speed steel (HSS) parts obtained by a modified MIM Process in low and high vacuum and in N2–5%H2 atmosphere, showed that high vacuum sintering gave quasi-full densities at very low temperatures in both steels. Microhardness is in relation to the densities obtained, and can be improved by conventional heat treatment. The evolution of the microstructure during sintering was analysed by SEM and XRD. After vacuum sintering M6C and MC carbides were detected whereas sintering in nitrogen rich atmosphere makes carbonitrides appear.

  • sintering in different atmospheres of t15 and m2 high speed steels produced by a modified metal Injection Moulding Process
    Materials Science and Engineering A-structural Materials Properties Microstructure and Processing, 2004
    Co-Authors: A Varez, José M. Torralba, G Matula, L A Dobrzanski
    Abstract:

    Abstract A study of the sintering behaviour of M2 and T15 high speed steel (HSS) parts obtained by a modified MIM Process in low and high vacuum and in N2–5%H2 atmosphere, showed that high vacuum sintering gave quasi-full densities at very low temperatures in both steels. Microhardness is in relation to the densities obtained, and can be improved by conventional heat treatment. The evolution of the microstructure during sintering was analysed by SEM and XRD. After vacuum sintering M6C and MC carbides were detected whereas sintering in nitrogen rich atmosphere makes carbonitrides appear.

  • mechanical properties and pitting corrosion behaviour of 316l stainless steel parts obtained by a modified metal Injection Moulding Process
    Journal of Materials Processing Technology, 2003
    Co-Authors: L Castro, A Varez, S Merino, José M. Torralba
    Abstract:

    Abstract Stainless steel AISI 316L parts have been obtained by a modified metal Injection Moulding (MIM) Process using two different thermosetting polymers: commercial acrylic resin and cyclohexyl methacrylate (CHMA). The first resin polymerises at 90 °C while the later cures between 20 and 80 °C. Different mixtures of metal and polymer were investigated and the optimum one was 60 vol.% of metal, for both resins. Due to the fact that the corrosion properties in this type of steel decrease with the carbon content, the debinding cycle has been optimised on the basis of a thermogravimetric study. Sintering was carried out under vacuum atmosphere between 1200 and 1350 °C for 1 h. Mechanical properties were evaluated by means of tensile tests and a good agreement between mechanical properties and sintering curves has been found. Pitting corrosion has been studied through pitting potentials in different chloride environments and at several temperatures. The behaviour of this material has been compared to a wrought 316L and to a conventional powder metallurgy 316L, pressed at 750 MPa and sintered at 1350 °C. The results have been studied on the basis of the carbon content determined by LECO analysis. Pits have also been examined through optical microscopy, to obtain more information about the pitting Process.

L A Dobrzanski - One of the best experts on this subject based on the ideXlab platform.

  • metal Injection Moulding of hs12 1 5 5 high speed steel using a pw hdpe based binder
    Journal of Materials Processing Technology, 2006
    Co-Authors: L A Dobrzanski, Gemma Herranz, A Varez, G Matula, José M. Torralba
    Abstract:

    Abstract In this communication, we present the powder Injection Moulding (PIM) of HS12-1-5-5 high-speed steel parts using a wax-HDPE based binder. The Injection Moulding Process of the feedstock (68 vol.% of metal) has been optimized to obtain high quality green parts. The elimination of organic binder was carried out by thermal debinding under inert atmosphere. In order to keep carbon in the sample that could improve the sintering Process, incomplete debinding were performed between 450 and 500 °C. In this study, we have studied the effect of different atmospheres on the debinding Process. Debinding was performed under nitrogen and argon. The specimens were sintered at temperatures between 1200 and 1300 °C with steps of 10 °C in following mixture N 2 –10% H 2 atmosphere. The PIM parts present higher density than those obtained by conventional PM.

  • sintering in different atmospheres of t15 and m2 high speed steels produced by a modified metal Injection Moulding Process
    Materials Science and Engineering A-structural Materials Properties Microstructure and Processing, 2004
    Co-Authors: A Varez, José M. Torralba, G Matula, B Levenfeld, L A Dobrzanski
    Abstract:

    Abstract A study of the sintering behaviour of M2 and T15 high speed steel (HSS) parts obtained by a modified MIM Process in low and high vacuum and in N2–5%H2 atmosphere, showed that high vacuum sintering gave quasi-full densities at very low temperatures in both steels. Microhardness is in relation to the densities obtained, and can be improved by conventional heat treatment. The evolution of the microstructure during sintering was analysed by SEM and XRD. After vacuum sintering M6C and MC carbides were detected whereas sintering in nitrogen rich atmosphere makes carbonitrides appear.

  • sintering in different atmospheres of t15 and m2 high speed steels produced by a modified metal Injection Moulding Process
    Materials Science and Engineering A-structural Materials Properties Microstructure and Processing, 2004
    Co-Authors: A Varez, José M. Torralba, G Matula, L A Dobrzanski
    Abstract:

    Abstract A study of the sintering behaviour of M2 and T15 high speed steel (HSS) parts obtained by a modified MIM Process in low and high vacuum and in N2–5%H2 atmosphere, showed that high vacuum sintering gave quasi-full densities at very low temperatures in both steels. Microhardness is in relation to the densities obtained, and can be improved by conventional heat treatment. The evolution of the microstructure during sintering was analysed by SEM and XRD. After vacuum sintering M6C and MC carbides were detected whereas sintering in nitrogen rich atmosphere makes carbonitrides appear.

M. H. M. Hazwan - One of the best experts on this subject based on the ideXlab platform.

  • applying response surface methodology rsm in optimizing warpage of a thin Injection moulded part
    AIP Conference Proceedings, 2017
    Co-Authors: A Yasiin, M. Fathullah, Z. Shayfull, S. M. Nasir, M. H. M. Hazwan, S Shazzuan
    Abstract:

    Injection Moulding Process usually used in industry manufacturing for producing variety plastic parts. The most serious issues in manufacturing is to minimize the cost of producing product without influencing their final product quality. To produce a high quality of product, it’s important to control the parameters of Injection Moulding machine. So that, this paper presents a systematic methodology to analyse on the quality (warpage) on a top part of optical mouse using Response Surface Methodology (RSM). Acrylonitrile Butadiene Styrene (ABS) were selected as a material that used in simulation. The variable parameters were selected based on previous researches that influence the warpage and shrinkage on the moulded part which are packing pressure, packing time, melt temperature, mould temperature and cooling time. The result show that the warpage on the top part of optical mouse was improved 28.4% after the optimization Process. Mould temperature was selected as the most significant factors affects the wa...

  • warpage optimisation on the moulded part with straight drilled and mgss conformal cooling channels using response surface methodology rsm
    AIP Conference Proceedings, 2017
    Co-Authors: M. H. M. Hazwan, Z. Shayfull, S. M. Nasir, Safian Sharif, M M Rashidi
    Abstract:

    Today, there are various optimisation methods that have been explored by many researchers to find the appropriate Processing parameters setting in Injection Moulding Process. Based on previous researches, the application of optimisation work enhanced the moulded part quality. Apart from the quality, the productivity also plays an important role in the Injection Moulding Process. Thus, some researchers have introduced the application of conformal cooling channels which have been proven improved both quality and productivity of the moulded part. Nonetheless, most of the previous researches in optimisation work are only focusing on the conventional straight- drilled cooling channels and the application of optimisation work on conformal cooling channels are still lacking. Therefore in this study, the application of optimisation work to improve warpage of the front panel housing part with straight-drilled and Milled Groove Square Shape (MGSS) conformal cooling channels has been presented. By performing Response Surface Methodology (RSM) optimisation approach, warpage of the moulded part has been optimised for both cooling channels. Based on the results warpage has optimised by 47.l% for straight-drilled cooling channels. While, for MGSS conformal cooling channels warpage has optimised by 46.5%. In addition, the finding also shows that the application of optimisation work on the conformal cooling channels offers the best outcome.Today, there are various optimisation methods that have been explored by many researchers to find the appropriate Processing parameters setting in Injection Moulding Process. Based on previous researches, the application of optimisation work enhanced the moulded part quality. Apart from the quality, the productivity also plays an important role in the Injection Moulding Process. Thus, some researchers have introduced the application of conformal cooling channels which have been proven improved both quality and productivity of the moulded part. Nonetheless, most of the previous researches in optimisation work are only focusing on the conventional straight- drilled cooling channels and the application of optimisation work on conformal cooling channels are still lacking. Therefore in this study, the application of optimisation work to improve warpage of the front panel housing part with straight-drilled and Milled Groove Square Shape (MGSS) conformal cooling channels has been presented. By performing Respons...

  • warpage optimisation on the moulded part with conformal cooling channels using response surface methodology rsm and genetic algorithm ga optimisation approaches
    3rd Electronic and Green Materials International Conference 2017 EGM 2017, 2017
    Co-Authors: M. H. M. Hazwan, Z. Shayfull, S. M. Nasir, Safian Sharif, M M Rashidi
    Abstract:

    In the Injection Moulding Process, quality and productivity are important and must be controlled for each product that have been produced in Moulding industries. To control the quality of the moulded part, many researchers have introduced various of optimisation methods to get an appropriate combination of Processing parameters setting. On the other hand, to improve the productivity of Injection Moulding Process, some researchers have introduced the application of conformal cooling channels in mould fabrication which have been proven will shorten the Moulding cycle time. Thus in this paper, the application of Response Surface Methodology (RSM) with Genetic Algorithm (GA) optimisation methods on the moulded part with a conformal cooling channels moulds will be presented. A front panel housing made from ABS has been selected as a specimen and the performance of the proposed optimisation method have been applied on the Milled Groove Square Shape (MGSS) conformal cooling channels. Based on the simulation resu...

  • warpage optimisation on the moulded part with straight drilled and conformal cooling channels using response surface methodology rsm and glowworm swarm optimisation gso
    3RD ELECTRONIC AND GREEN MATERIALS INTERNATIONAL CONFERENCE 2017 (EGM 2017), 2017
    Co-Authors: M. H. M. Hazwan, Z. Shayfull, S. M. Nasir, Safian Sharif, N Zainal
    Abstract:

    In Injection Moulding Process, quality and productivity are notably important and must be controlled for each product type produced. Quality is measured as the extent of warpage of moulded parts while productivity is measured as a duration of Moulding cycle time. To control the quality, many researchers have introduced various of optimisation approaches which have been proven enhanced the quality of the moulded part produced. In order to improve the productivity of Injection Moulding Process, some of researches have proposed the application of conformal cooling channels which have been proven reduced the duration of Moulding cycle time. Therefore, this paper presents an application of alternative optimisation approach which is Response Surface Methodology (RSM) with Glowworm Swarm Optimisation (GSO) on the moulded part with straight-drilled and conformal cooling channels mould. This study examined the warpage condition of the moulded parts before and after optimisation work applied for both cooling channels. A front panel housing have been selected as a specimen and the performance of proposed optimisation approach have been analysed on the conventional straight-drilled cooling channels compared to the Milled Groove Square Shape (MGSS) conformal cooling channels by simulation analysis using Autodesk Moldflow Insight (AMI) 2013. Based on the results, melt temperature is the most significant factor contribute to the warpage condition and warpage have optimised by 39.1% after optimisation for straight-drilled cooling channels and cooling time is the most significant factor contribute to the warpage condition and warpage have optimised by 38.7% after optimisation for MGSS conformal cooling channels. In addition, the finding shows that the application of optimisation work on the conformal cooling channels offers the better quality and productivity of the moulded part produced.In Injection Moulding Process, quality and productivity are notably important and must be controlled for each product type produced. Quality is measured as the extent of warpage of moulded parts while productivity is measured as a duration of Moulding cycle time. To control the quality, many researchers have introduced various of optimisation approaches which have been proven enhanced the quality of the moulded part produced. In order to improve the productivity of Injection Moulding Process, some of researches have proposed the application of conformal cooling channels which have been proven reduced the duration of Moulding cycle time. Therefore, this paper presents an application of alternative optimisation approach which is Response Surface Methodology (RSM) with Glowworm Swarm Optimisation (GSO) on the moulded part with straight-drilled and conformal cooling channels mould. This study examined the warpage condition of the moulded parts before and after optimisation work applied for both cooling channe...

  • warpage optimisation on the moulded part using response surface methodology rsm and genetic algorithm ga optimisation approaches
    AIP Conference Proceedings, 2017
    Co-Authors: M. H. M. Hazwan, Z. Shayfull, S. M. Nasir, Safian Sharif, M M Rashidi
    Abstract:

    Todays, many optimisation approaches have been explored by many researchers to find the appropriate Processing parameters setting for the Injection Moulding Process. From the previous researches, it was reported that the optimisation work has improved the moulded part quality. In this study, the application of optimisation work to improve warpage of the front panel housing have been explored. By selecting cooling time, coolant temperature, packing pressure and melt temperature as the variable parameters, design of experiment (DOE) have been constructed by using the rotatable central composite design (CCD) approach. Response Surface Methodology (RSM) was performed to obtain the mathematical model. This mathematical model then will be used in Genetic Algorithm (GA) optimisation method as a fitness function to determine the appropriate Processing parameters setting which will optimise the warpage condition. Based on the results, Coolant temperature give the most significant contribution to the warpage condit...

Z. Shayfull - One of the best experts on this subject based on the ideXlab platform.

  • cycle time improvement for plastic Injection Moulding Process by sub groove modification in conformal cooling channel
    3RD ELECTRONIC AND GREEN MATERIALS INTERNATIONAL CONFERENCE 2017 (EGM 2017), 2017
    Co-Authors: Khairu Kamarudin, A A Raus, Mohd Faizal Mohideen Batcha, Z. Shayfull, M. S. Wahab, Aqeel Ahmed
    Abstract:

    Mould designers have been struggling for the improvement of the cooling system performance, despite the fact that the cooling system complexity is physically limited by the fabrication capability of the conventional tooling methods. However, the growth of Solid Free Form Technology (SFF) allow the mould designer to develop more than just a regular conformal cooling channel. Numerous researchers demonstrate that conformal cooling channel was tremendously given significant result in the improvement of productivity and quality in the plastic Injection Moulding Process. This paper presents the research work that applies the passive enhancement method in square shape cooling channel to enhance the efficiency of cooling performance by adding the sub groove to the cooling channel itself. Previous design that uses square shape cooling channel was improved by adding various numbers of sub groove to meet the best sub groove design that able reduced the cooling time. The effect of sub groove design on cooling time was investigated by Autodesk Modlflow Insight software. The simulation results showed that the various sub groove designs give different values to ejection time. The Design 7 showed the lowest value of ejection time with 24.3% increment. The addition of sub groove significantly increased a coolant velocity and a rate of heat transfer from molten plastic to coolant.Mould designers have been struggling for the improvement of the cooling system performance, despite the fact that the cooling system complexity is physically limited by the fabrication capability of the conventional tooling methods. However, the growth of Solid Free Form Technology (SFF) allow the mould designer to develop more than just a regular conformal cooling channel. Numerous researchers demonstrate that conformal cooling channel was tremendously given significant result in the improvement of productivity and quality in the plastic Injection Moulding Process. This paper presents the research work that applies the passive enhancement method in square shape cooling channel to enhance the efficiency of cooling performance by adding the sub groove to the cooling channel itself. Previous design that uses square shape cooling channel was improved by adding various numbers of sub groove to meet the best sub groove design that able reduced the cooling time. The effect of sub groove design on cooling time w...

  • applying response surface methodology rsm in optimizing warpage of a thin Injection moulded part
    AIP Conference Proceedings, 2017
    Co-Authors: A Yasiin, M. Fathullah, Z. Shayfull, S. M. Nasir, M. H. M. Hazwan, S Shazzuan
    Abstract:

    Injection Moulding Process usually used in industry manufacturing for producing variety plastic parts. The most serious issues in manufacturing is to minimize the cost of producing product without influencing their final product quality. To produce a high quality of product, it’s important to control the parameters of Injection Moulding machine. So that, this paper presents a systematic methodology to analyse on the quality (warpage) on a top part of optical mouse using Response Surface Methodology (RSM). Acrylonitrile Butadiene Styrene (ABS) were selected as a material that used in simulation. The variable parameters were selected based on previous researches that influence the warpage and shrinkage on the moulded part which are packing pressure, packing time, melt temperature, mould temperature and cooling time. The result show that the warpage on the top part of optical mouse was improved 28.4% after the optimization Process. Mould temperature was selected as the most significant factors affects the wa...

  • warpage optimisation on the moulded part with straight drilled and mgss conformal cooling channels using response surface methodology rsm
    AIP Conference Proceedings, 2017
    Co-Authors: M. H. M. Hazwan, Z. Shayfull, S. M. Nasir, Safian Sharif, M M Rashidi
    Abstract:

    Today, there are various optimisation methods that have been explored by many researchers to find the appropriate Processing parameters setting in Injection Moulding Process. Based on previous researches, the application of optimisation work enhanced the moulded part quality. Apart from the quality, the productivity also plays an important role in the Injection Moulding Process. Thus, some researchers have introduced the application of conformal cooling channels which have been proven improved both quality and productivity of the moulded part. Nonetheless, most of the previous researches in optimisation work are only focusing on the conventional straight- drilled cooling channels and the application of optimisation work on conformal cooling channels are still lacking. Therefore in this study, the application of optimisation work to improve warpage of the front panel housing part with straight-drilled and Milled Groove Square Shape (MGSS) conformal cooling channels has been presented. By performing Response Surface Methodology (RSM) optimisation approach, warpage of the moulded part has been optimised for both cooling channels. Based on the results warpage has optimised by 47.l% for straight-drilled cooling channels. While, for MGSS conformal cooling channels warpage has optimised by 46.5%. In addition, the finding also shows that the application of optimisation work on the conformal cooling channels offers the best outcome.Today, there are various optimisation methods that have been explored by many researchers to find the appropriate Processing parameters setting in Injection Moulding Process. Based on previous researches, the application of optimisation work enhanced the moulded part quality. Apart from the quality, the productivity also plays an important role in the Injection Moulding Process. Thus, some researchers have introduced the application of conformal cooling channels which have been proven improved both quality and productivity of the moulded part. Nonetheless, most of the previous researches in optimisation work are only focusing on the conventional straight- drilled cooling channels and the application of optimisation work on conformal cooling channels are still lacking. Therefore in this study, the application of optimisation work to improve warpage of the front panel housing part with straight-drilled and Milled Groove Square Shape (MGSS) conformal cooling channels has been presented. By performing Respons...

  • warpage optimisation on the moulded part with conformal cooling channels using response surface methodology rsm and genetic algorithm ga optimisation approaches
    3rd Electronic and Green Materials International Conference 2017 EGM 2017, 2017
    Co-Authors: M. H. M. Hazwan, Z. Shayfull, S. M. Nasir, Safian Sharif, M M Rashidi
    Abstract:

    In the Injection Moulding Process, quality and productivity are important and must be controlled for each product that have been produced in Moulding industries. To control the quality of the moulded part, many researchers have introduced various of optimisation methods to get an appropriate combination of Processing parameters setting. On the other hand, to improve the productivity of Injection Moulding Process, some researchers have introduced the application of conformal cooling channels in mould fabrication which have been proven will shorten the Moulding cycle time. Thus in this paper, the application of Response Surface Methodology (RSM) with Genetic Algorithm (GA) optimisation methods on the moulded part with a conformal cooling channels moulds will be presented. A front panel housing made from ABS has been selected as a specimen and the performance of the proposed optimisation method have been applied on the Milled Groove Square Shape (MGSS) conformal cooling channels. Based on the simulation resu...

  • warpage optimisation on the moulded part with straight drilled and conformal cooling channels using response surface methodology rsm and glowworm swarm optimisation gso
    3RD ELECTRONIC AND GREEN MATERIALS INTERNATIONAL CONFERENCE 2017 (EGM 2017), 2017
    Co-Authors: M. H. M. Hazwan, Z. Shayfull, S. M. Nasir, Safian Sharif, N Zainal
    Abstract:

    In Injection Moulding Process, quality and productivity are notably important and must be controlled for each product type produced. Quality is measured as the extent of warpage of moulded parts while productivity is measured as a duration of Moulding cycle time. To control the quality, many researchers have introduced various of optimisation approaches which have been proven enhanced the quality of the moulded part produced. In order to improve the productivity of Injection Moulding Process, some of researches have proposed the application of conformal cooling channels which have been proven reduced the duration of Moulding cycle time. Therefore, this paper presents an application of alternative optimisation approach which is Response Surface Methodology (RSM) with Glowworm Swarm Optimisation (GSO) on the moulded part with straight-drilled and conformal cooling channels mould. This study examined the warpage condition of the moulded parts before and after optimisation work applied for both cooling channels. A front panel housing have been selected as a specimen and the performance of proposed optimisation approach have been analysed on the conventional straight-drilled cooling channels compared to the Milled Groove Square Shape (MGSS) conformal cooling channels by simulation analysis using Autodesk Moldflow Insight (AMI) 2013. Based on the results, melt temperature is the most significant factor contribute to the warpage condition and warpage have optimised by 39.1% after optimisation for straight-drilled cooling channels and cooling time is the most significant factor contribute to the warpage condition and warpage have optimised by 38.7% after optimisation for MGSS conformal cooling channels. In addition, the finding shows that the application of optimisation work on the conformal cooling channels offers the better quality and productivity of the moulded part produced.In Injection Moulding Process, quality and productivity are notably important and must be controlled for each product type produced. Quality is measured as the extent of warpage of moulded parts while productivity is measured as a duration of Moulding cycle time. To control the quality, many researchers have introduced various of optimisation approaches which have been proven enhanced the quality of the moulded part produced. In order to improve the productivity of Injection Moulding Process, some of researches have proposed the application of conformal cooling channels which have been proven reduced the duration of Moulding cycle time. Therefore, this paper presents an application of alternative optimisation approach which is Response Surface Methodology (RSM) with Glowworm Swarm Optimisation (GSO) on the moulded part with straight-drilled and conformal cooling channels mould. This study examined the warpage condition of the moulded parts before and after optimisation work applied for both cooling channe...