Exprimental and simulation Study on the Effect of Process Parameters on the Warpage of thin-shell Injection Molded Parts

This paper aim to determine the injection molding conditions to minimize the warpage of an injection molded Part with the thin-shell feature. A set-square, 14 cm with the thickness of 2 mm is considered as a thin-shell plastic part. Used thermoplastic, Poly Carbonate Bayer 2407 GE was dried for 4 hours in 120 ºC before Injection Processing. To achieve the minimum warpage, optimum process condition parameters are determined, melt temperature, packing pressure, packing time, cooling time and injection speed are considered as process parameters. Applying the taguchi method as an effective method to deduce the optimum set of effective factors in injection molding to produce parts with minimum warpage. The injection process were also simulated using the moldflow software . The results showed that melt temperature had the greatest influence on the warpage, followed by packing Time, packing pressure and cooling time. However, warpage was only slightly influenced by the injection speed. the proposed optimization can effectively decrease the warpage of injection molded part.

Keywords:

Injection Molding , Warpage , Taguchi , Experimental and Simulation Study