Optimization of Rheology Parameters for Feedstock by Powder Injection Molding (PIM) Via Taguchi Analysis

The most critical process in the powder injection molding method is determining the powder/binder rate and its properties. The most important feature that distinguishes the powder injection molding method from other powder metallurgy production methods is its advantage in producing high raw density and complex shaped parts. However, providing these advantages includes a multi-parameter process that directly affects the injection molding parameters and the final part's mechanical properties. In addition, the difficulty of experimental studies causes energy, time, and cost losses in determining the powder/binder rate and rheological properties of the feedstock so that the advantages of the method turn into a manageable disadvantage. This study performed rheology studies for three different feedstocks (PW/CW/SA, PW/PE/SA, and PEG8000/PP/SA). In this context, this paper determined the rheological properties of different feedstocks to take advantage of the Taguchi analysis. Flow behavior index, viscosity and optimum loading rates were determined separately for all feedstocks. The results exhibited the injection molding can be done with the determined best (58% steatite+PEG8000/PP/SA) F3 feedstock by volume. Based on it was found that viscosity and melt flow index were not a problem for injection molding in three different feedstocks used in the result, advantages and disadvantages were observed

Optimization of Rheology Parameters for Feedstock by Powder Injection Molding (PIM) Via Taguchi Analysis

The most critical process in the powder injection molding method is determining the powder/binder rate and its properties. The most important feature that distinguishes the powder injection molding method from other powder metallurgy production methods is its advantage in producing high raw density and complex shaped parts. However, providing these advantages includes a multi-parameter process that directly affects the injection molding parameters and the final part's mechanical properties. In addition, the difficulty of experimental studies causes energy, time, and cost losses in determining the powder/binder rate and rheological properties of the feedstock so that the advantages of the method turn into a manageable disadvantage. This study performed rheology studies for three different feedstocks (PW/CW/SA, PW/PE/SA, and PEG8000/PP/SA). In this context, this paper determined the rheological properties of different feedstocks to take advantage of the Taguchi analysis. Flow behavior index, viscosity and optimum loading rates were determined separately for all feedstocks. The results exhibited the injection molding can be done with the determined best (58% steatite+PEG8000/PP/SA) F3 feedstock by volume. Based on it was found that viscosity and melt flow index were not a problem for injection molding in three different feedstocks used in the result, advantages and disadvantages were observed

Investigation and Optimization of Cutting Performance of High Chrome White Cast Iron by Wire Erosion

Wire electric discharge machining (WEDM) is an emerging approach to producing more accurate and precise complex products in the unconventional machining process. The WEDM process is affected by several process factors. Therefore, the appropriate combination of process factors is required to achieve economical and quality machining. Machining is very difficult due to the presence of chromium carbide in the structure of high-Cr white cast irons (HCCIs) with 12–17% Cr content in machining processes. Therefore, the machinability of HCCIs has always been a disadvantage. In this study, specially molded HCCIs samples were subjected to softening, casting (not heat treated) and hardened heat treatment processes, respectively. We aimed to experimentally investigated the changes in HCCIs samples characteristics, pulse on time, pulse of time, wire speed, and cutting performance in the WEDM process in this study. The L18 orthogonal array was used using the Taguchi method, and an experimental study was prepared. Afterward, an optimization study was carried out using mathematical models for WEDM with the help of performance outputs via ANOVA analysis. The experimental performances examined in this study are material removal rate and surface roughness. The experimental study determined that the material removal rate and surface roughness increased when the pulse on time increased. Later, machined samples morphological and structures properties were analyzed X-ray spectroscopy (EDS), scanning electron microscopy, microhardness and surface roughness. Furthermore, electrical conductivity of them was measured. © 2023, King Fahd University of Petroleum & Minerals