Warpage

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Tuncay Erzurumlu - One of the best experts on this subject based on the ideXlab platform.

  • application of taguchi optimization technique in determining plastic injection molding process parameters for a thin shell part
    Materials & Design, 2007
    Co-Authors: Hasan Oktem, Tuncay Erzurumlu, Ibrahim Uzman
    Abstract:

    Abstract This paper deals with the application of Taguchi optimization technique to reduce Warpage problem related to the shrinkage variation depended on process parameters during production of thin-shell plastic components for orthose part. For this purpose, a number of MoldFlow analyses are carried out by utilizing the combination of process parameters based on three-level of L 27 and L 9 Taguchi orthogonal design. The signal-to-noise ( S / N ) and the analysis of variance (ANOVA) are used to find the optimum levels and to indicate the impact of the process parameters on Warpage and shrinkage. The results show that Warpage and shrinkage are improved by about 2.17% and 0.7%. A verification test is also performed to prove the effectiveness of Taguchi technique after the optimum levels of process parameters are determined. It can be clearly inferred from this conclusion that Taguchi optimization is sufficient to solve the Warpage problem with shrinkage for thin-shell plastic components of orthose part.

  • comparison of the Warpage optimization in the plastic injection molding using anova neural network model and genetic algorithm
    Journal of Materials Processing Technology, 2006
    Co-Authors: Babur Ozcelik, Tuncay Erzurumlu
    Abstract:

    Abstract Plastic injection processes comprise plastication, injection, packing, cooling, ejection and process/part quality control applications. These steps are followed for the parts, which are designed to be produced by plastic injection method. Having initial knowledge about the process that will be undertaken is necessary because of present-day competitive conditions that forces us to produce faster and cheaper with a higher quality, such as minimum Warpage, sink marks, etc. Computer-aided analysis and engineering softwares are used in order to meet this necessity. For plastic injection process, one of the commercial computer-aided engineering softwares is the MoldFlow Plastic Insight. In this study, best gate location, filling and flow, Warpage applications have done for minimum Warpage of plastic part with this tool. Process parameters such as mold temperature, melt temperature, packing pressure, packing time, cooling time, runner type and gate location are considered as model variables. The effects of process parameters for thin shell plastic part were exploited using both design of experiment (DOE), Taguchi orthogonal array and finite element software MoldFlow (FE). The most important process parameters influencing Warpage are determined using finite element analysis results based on analysis of variance (ANOVA) method. Artificial neural network (ANN) is interfaced with an effective GA to find the minimum Warpage value.

  • Efficient Warpage optimization of thin shell plastic parts using response surface methodology and genetic algorithm
    The International Journal of Advanced Manufacturing Technology, 2006
    Co-Authors: Hasan Kurtaran, Tuncay Erzurumlu
    Abstract:

    During the production of thin shell plastic parts by injection molding, Warpage depending on the process conditions is often encountered. In this study, efficient minimization of Warpage on thin shell plastic parts by integrating finite element (FE) analysis, statistical design of experiment method, response surface methodology (RSM), and genetic algorithm (GA) is investigated. A bus ceiling lamp base is considered as a thin shell plastic part example. To achieve the minimum Warpage, optimum process condition parameters are determined. Mold temperature, melt temperature, packing pressure, packing time, and cooling time are considered as process condition parameters. FE analyses are conducted for a combination of process parameters organized using statistical three-level full factorial experimental design. The most important process parameters influencing Warpage are determined using FE analysis results based on analysis of variance (ANOVA) method. A predictive response surface model for Warpage data is created using RSM. The response surface (RS) model is interfaced with an effective GA to find the optimum process parameter values.

  • determination of effecting dimensional parameters on Warpage of thin shell plastic parts using integrated response surface method and genetic algorithm
    International Communications in Heat and Mass Transfer, 2005
    Co-Authors: Babur Ozcelik, Tuncay Erzurumlu
    Abstract:

    Decreasing Warpage is a very significant topic to improve the quality of injection-molded parts. Dimensional stability is an important factor for the minimum Warpage of thin shell plastic part. In this study, efficient minimization of Warpage on thin shell plastic parts by integrating finite element analysis, statistical design of experiment method, response surface methodology and genetic algorithm is investigated. A thin shell plastic part model is considered as an example. To achieve the minimum Warpage, optimum process condition dimensional parameters are determined. X dimension, Y dimension, and Z dimension are considered as model variables. Another parameters of effecting minimum Warpage are taken into consideration as constant, such as mold temperature, melt temperature, injection time, injection pressure, etc. Finite element analyses are conducted for combination of process parameters organized using statistical three-level full factorial experimental design. A predictive model for Warpage is created using response surface methodology exploiting finite element analysis results. Response surface model is interfaced with an effective genetic algorithm to find the optimum process parameter values.

Babur Ozcelik - One of the best experts on this subject based on the ideXlab platform.

  • comparison of the Warpage optimization in the plastic injection molding using anova neural network model and genetic algorithm
    Journal of Materials Processing Technology, 2006
    Co-Authors: Babur Ozcelik, Tuncay Erzurumlu
    Abstract:

    Abstract Plastic injection processes comprise plastication, injection, packing, cooling, ejection and process/part quality control applications. These steps are followed for the parts, which are designed to be produced by plastic injection method. Having initial knowledge about the process that will be undertaken is necessary because of present-day competitive conditions that forces us to produce faster and cheaper with a higher quality, such as minimum Warpage, sink marks, etc. Computer-aided analysis and engineering softwares are used in order to meet this necessity. For plastic injection process, one of the commercial computer-aided engineering softwares is the MoldFlow Plastic Insight. In this study, best gate location, filling and flow, Warpage applications have done for minimum Warpage of plastic part with this tool. Process parameters such as mold temperature, melt temperature, packing pressure, packing time, cooling time, runner type and gate location are considered as model variables. The effects of process parameters for thin shell plastic part were exploited using both design of experiment (DOE), Taguchi orthogonal array and finite element software MoldFlow (FE). The most important process parameters influencing Warpage are determined using finite element analysis results based on analysis of variance (ANOVA) method. Artificial neural network (ANN) is interfaced with an effective GA to find the minimum Warpage value.

  • determination of effecting dimensional parameters on Warpage of thin shell plastic parts using integrated response surface method and genetic algorithm
    International Communications in Heat and Mass Transfer, 2005
    Co-Authors: Babur Ozcelik, Tuncay Erzurumlu
    Abstract:

    Decreasing Warpage is a very significant topic to improve the quality of injection-molded parts. Dimensional stability is an important factor for the minimum Warpage of thin shell plastic part. In this study, efficient minimization of Warpage on thin shell plastic parts by integrating finite element analysis, statistical design of experiment method, response surface methodology and genetic algorithm is investigated. A thin shell plastic part model is considered as an example. To achieve the minimum Warpage, optimum process condition dimensional parameters are determined. X dimension, Y dimension, and Z dimension are considered as model variables. Another parameters of effecting minimum Warpage are taken into consideration as constant, such as mold temperature, melt temperature, injection time, injection pressure, etc. Finite element analyses are conducted for combination of process parameters organized using statistical three-level full factorial experimental design. A predictive model for Warpage is created using response surface methodology exploiting finite element analysis results. Response surface model is interfaced with an effective genetic algorithm to find the optimum process parameter values.

M D Azaman - One of the best experts on this subject based on the ideXlab platform.

  • shrinkages and Warpage in the processability of wood filled polypropylene composite thin walled parts formed by injection molding
    Materials & Design, 2013
    Co-Authors: S M Sapuan, Shamsuddin Sulaiman, M D Azaman, E S Zainudin, A Khalina
    Abstract:

    Reducing volumetric shrinkages and Warpage during the injection molding process is a challenging problem in the production of molded thin-walled parts. In this study, the injection molding of shallow, thin-walled parts (thickness 0.7 mm), composed of lignocellulosic polymer composites (polypropylene (PP) + 50 wt% wood), was simulated. The volumetric shrinkages and Warpage in the thin-walled parts were evaluated under different process conditions, with varying post-filling parameters, such as mold temperature, cooling time, packing pressure and packing time. The analysis showed that the cooling time and packing time had less of an effect on the shrinkage and Warpage; nevertheless the optimal levels for both parameters are required in the molding process for the thin-walled part to achieve the best results. The volumetric shrinkage was lower near the gate than at the end-of-fill location along the flow path. The results also showed that the volumetric shrinkage correlates with the Warpage measured on the molded part. The optimum parameters ranges is 40–45 °C for the mold temperature; 20–30 s for cooling time; 0.85 from injection pressure (Pinject) for packing pressure; and 15–20 s for the packing time to achieve the best results with the least amount of volumetric shrinkage and Warpage.

Shamsuddin Sulaiman - One of the best experts on this subject based on the ideXlab platform.

  • shrinkages and Warpage in the processability of wood filled polypropylene composite thin walled parts formed by injection molding
    Materials & Design, 2013
    Co-Authors: S M Sapuan, Shamsuddin Sulaiman, M D Azaman, E S Zainudin, A Khalina
    Abstract:

    Reducing volumetric shrinkages and Warpage during the injection molding process is a challenging problem in the production of molded thin-walled parts. In this study, the injection molding of shallow, thin-walled parts (thickness 0.7 mm), composed of lignocellulosic polymer composites (polypropylene (PP) + 50 wt% wood), was simulated. The volumetric shrinkages and Warpage in the thin-walled parts were evaluated under different process conditions, with varying post-filling parameters, such as mold temperature, cooling time, packing pressure and packing time. The analysis showed that the cooling time and packing time had less of an effect on the shrinkage and Warpage; nevertheless the optimal levels for both parameters are required in the molding process for the thin-walled part to achieve the best results. The volumetric shrinkage was lower near the gate than at the end-of-fill location along the flow path. The results also showed that the volumetric shrinkage correlates with the Warpage measured on the molded part. The optimum parameters ranges is 40–45 °C for the mold temperature; 20–30 s for cooling time; 0.85 from injection pressure (Pinject) for packing pressure; and 15–20 s for the packing time to achieve the best results with the least amount of volumetric shrinkage and Warpage.

  • the use of taguchi method in the design of plastic injection mould for reducing Warpage
    Journal of Materials Processing Technology, 2007
    Co-Authors: Sai Hong Tang, Y J Tan, S M Sapuan, Shamsuddin Sulaiman, Napsiah Ismail, Razali Samin
    Abstract:

    Abstract Plastic injection moulding is one of the most important polymer processing operations in the plastic industry today. However, lack of skill in mould making and injection moulding machine control will lead to defective plastic product. Warpage is one type of defect that usually appears in products with thickness less than 1 mm. This project is going to fabricate a mould that produced a thin plate with dimension 120 mm × 50 mm × 1 mm. The thin plate will be used for Warpage testing. In mould fabrication, the mould base that purchase will be machined and assembled. After that, the mould is fixed on the injection moulding machine. The machine setting should be made to produce the product. Then, the product will be used for testing on the effective factors in Warpage problem by applying the experimental design of Taguchi method. From the results, it shows that the most effective factor on the Warpage is melt temperature. The filling time only slightly influenced on the Warpage. The optimum parameters that can minimize the Warpage defect are melt temperature (240 °C), filling time (0.5 s), packing pressure (90%) and packing time (0.6 s).

S M Sapuan - One of the best experts on this subject based on the ideXlab platform.

  • shrinkages and Warpage in the processability of wood filled polypropylene composite thin walled parts formed by injection molding
    Materials & Design, 2013
    Co-Authors: S M Sapuan, Shamsuddin Sulaiman, M D Azaman, E S Zainudin, A Khalina
    Abstract:

    Reducing volumetric shrinkages and Warpage during the injection molding process is a challenging problem in the production of molded thin-walled parts. In this study, the injection molding of shallow, thin-walled parts (thickness 0.7 mm), composed of lignocellulosic polymer composites (polypropylene (PP) + 50 wt% wood), was simulated. The volumetric shrinkages and Warpage in the thin-walled parts were evaluated under different process conditions, with varying post-filling parameters, such as mold temperature, cooling time, packing pressure and packing time. The analysis showed that the cooling time and packing time had less of an effect on the shrinkage and Warpage; nevertheless the optimal levels for both parameters are required in the molding process for the thin-walled part to achieve the best results. The volumetric shrinkage was lower near the gate than at the end-of-fill location along the flow path. The results also showed that the volumetric shrinkage correlates with the Warpage measured on the molded part. The optimum parameters ranges is 40–45 °C for the mold temperature; 20–30 s for cooling time; 0.85 from injection pressure (Pinject) for packing pressure; and 15–20 s for the packing time to achieve the best results with the least amount of volumetric shrinkage and Warpage.

  • the use of taguchi method in the design of plastic injection mould for reducing Warpage
    Journal of Materials Processing Technology, 2007
    Co-Authors: Sai Hong Tang, Y J Tan, S M Sapuan, Shamsuddin Sulaiman, Napsiah Ismail, Razali Samin
    Abstract:

    Abstract Plastic injection moulding is one of the most important polymer processing operations in the plastic industry today. However, lack of skill in mould making and injection moulding machine control will lead to defective plastic product. Warpage is one type of defect that usually appears in products with thickness less than 1 mm. This project is going to fabricate a mould that produced a thin plate with dimension 120 mm × 50 mm × 1 mm. The thin plate will be used for Warpage testing. In mould fabrication, the mould base that purchase will be machined and assembled. After that, the mould is fixed on the injection moulding machine. The machine setting should be made to produce the product. Then, the product will be used for testing on the effective factors in Warpage problem by applying the experimental design of Taguchi method. From the results, it shows that the most effective factor on the Warpage is melt temperature. The filling time only slightly influenced on the Warpage. The optimum parameters that can minimize the Warpage defect are melt temperature (240 °C), filling time (0.5 s), packing pressure (90%) and packing time (0.6 s).