Beruflich Dokumente
Kultur Dokumente
DOI 10.1007/s00170-009-2149-x
ORIGINAL ARTICLE
Received: 4 January 2009 / Accepted: 26 May 2009 / Published online: 10 June 2009
# Springer-Verlag London Limited 2009
1 Introduction
Plastic injection is one of the most considerable molding
processes thanks to some significant reasons. The first
important reason is that the use of plastic parts in daily life
has tremendously increased in the last decades. For
instance, most of the communication, electronic, kitchen,
and daily consumer products are made of plastic materials.
M. Kurt (*) : Y. Kaynak : O. S. Kamber : B. Mutlu : B. Bakir :
U. Koklu
Technical Education Faculty, Marmara University,
34722, Kadikoy,
Istanbul, Turkey
e-mail: mkurt@marmara.edu.tr
572
573
2 Experimental details
In order to do experimental study in molding process, there
are several steps which have to be followed. The first step
is to draw specimens with exact dimension which are
shown in Fig. 1. The design mold was modeled considering
all over dimensions and simulated by using the Pro-Eng
software (Fig. 2). Finally, the modeled mold was fabricated
taking into account the modeled dimensions. As shown in
Fig. 3, four cavity inserts were used in this research. A
dimmer cover is used for some kinds of home appliances.
For assembly of such parts, the dimensional and positional
tolerance is tight. The tolerance of the part during the
plastic injection molding process has therefore been
considered.
This experiment was conducted on a Haitian type
HTW58 injection molding machine with 244 MPa injection
pressure, 25 mm screw diameter, and 2.43 ton ejector
tonnage. The initial molding parameters for the experimental study were determined by consulting the literature and
considering industrial application. The material used in the
Tensile strength
Elongation
Flexural strength
Impact strength
Rockwell hardness
Condition
Method (ASTM 750)
Unit
General purpose
23C
D 638
kg/cm2
500
23C
D 638
%
30
23C
D 790
kg/cm2
600
6.1 mm
D 256
kg cm/cm
21
D 785
R-scale
104
574
575
576
y-direction shrinkage
x-direction shrinkage
Roundness
577
cavity conditions; hence, the molded parts can be influenced from this new cavity condition. Although, all
measurement costs are high, this study clarifies the effects
of initial condition and process conditions of plastic
injection molding.
One of the remarkable factors of molding conditions is
melt temperature. In order to obtain homogeny of molded
parts and reduction of defects, melt temperature is the key
parameter. Therefore, in this study, the effect of melt
temperature on total shrinkage in x and y directions of
parts and error of roundness have been investigated.
Contrary to the packing pressure effects, the collected data
from the present experimental study show that when the
melt temperature was increased from 185C to 210C, the
total shrinkage in x and y directions of the part decreased
from 0.23 to 0.18 mm; however, after that point, the
shrinkage was increased at 0.20 mm (Fig. 12). The reason
for these results is the 950-bar packing pressure. This high
pressure was the cause of higher melting temperature and
increased cooling time for plastic part. Because of this,
determination of optimal melt temperature is necessary to
obtain acceptable part quality. Similar variation behavior
was observed from the error of roundness of molded parts.
The error of roundness is a kind of warpage defects. Hence,
578
4 Conclusions
In this study, the molding process has been accurately
delineated and analyzed by using effective experimental
measurement techniques, highlighting the relationships
between molding parameters and the defects of the final
parts. Continuous sensitive measurement and data collection from a cavity mold have been successfully performed
by using piezoelectric pressure transducers and a pressure
temperature-combined transducer. The influence of initial
molding parameters on cavity pressure and mold temperature was clarified correctly. Also, the selected molding
parameters considerably affect the shrinkage of the product
in the y- and x-directions and its roundness. In addition,
although the cooling time influences the error of roundness
strongly, its effect on cavity pressure is not effective. It is
also highlighted that packing pressure is one of the
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