Optimization of injection molding parameters for WC-TaC-6Co

The main purpose of this paper is to optimize the injection moulding parameters of WC-Co with TaC as Grain Growth Inhibitor (GGI), through Design of Experiment – Taguchi Method. The selected responses that need to be controlled are shrinkage and warpage. The parameters that were taken into considerations were GGI percentage, injection temperature, injection pressure and injection speed. In this study, L9 (34) orthogonal array from Taguchi Method was chosen as experimental setup and the responses were analyzed using Minitab version 16. Best parameters combinations chosen are, GGI (0.8 wt. % and 1.2 wt. %), injection temperature (145°C), injection pressure (45% and 55%) and injection speed (40%) for minimal shrinkage and warpage. Based on these findings, it is concluded that by controlling the optimum parameter setting, best quality of desired product can be easily achieved and maintained throughout the process

Preparation of injection moulding processing for high density polyethylene via moldflow advisor 2015 simulation

Injection moulding simulation is one of the optimization methods which may reduce the cost due to the occurrence of defects. In order to utilise this method during the preparation of injection moulding for high density polyethylene, a processing verification through simulation and the validation through practical injection moulding needs to be conducted. In this research, Moldflow Advisor 2015 software was utilised to simulate the process while Nissei NP-7F machine was used for practical injection moulding experimentation. The criteria evaluation that was considered were filling time, time to reach ejection temperature, volumetric shrinkage, warpage, and sink marks. Through the simulation, the filling time was 3.232 seconds, the time to reach ejection temperature was 36.2 seconds, and the volumetric shrinkage was 17.69%. The warpage of 0.006 mm was also predicted in this simulation. While during practical injection moulding, the filling time was 3 seconds, the volumetric shrinkage was 16.6% and 0.07 mm warpage. Both simulation and practical results have no sink marks. Therefore, it can be concluded that the simulation process had provided a good prediction for practical injection moulding preparation. The findings of this research shall be beneficial by providing the manufacturing processing reference in related with injection moulding and high density polyethylene products

Modelling of integral hinges via CadMould 3d-F injection moulding simulation

This project was conducted to define the suitable model of runner size and gate location of the integral hinges samples, via CadMould 3D-F simulation. This simulation was used to analyse the effects of mould design towards the quality and injection moulding processing output of thermoplastics integral hinges test samples. Runner size and gate location were chosen for design parameter. The result shows that the mould design 2 with larger runner size (Test 1) has lowest temperature when filled, which is 240.1°C and lowest completely time filled (0.147 seconds). It also have lowest value of volume shrinkage (0.564%) and second lowest warpage (0.025 mm).As for the conclusion, the findings this project could be a reference for the mould makers for products consisting of integral hinge or tension band region. Moreover, good mould produces better samples, therefore the effect of mould design towards samples’ quality could be controlled and confined