OPTIMIZATION OF PLASTIC

INJECTION MOULDING PROCESS

PARAMETERS USING TAGUCHI
AND FACE CENTERED CUBIC
(FCC) TECHNIQUES
By
K.Poornima (SM21677)
Supervisor : Dr. Mohammed Ansari M. Nainar
Department of Mechanical Engineering,
College of Engineering, Universiti Tenaga
Nasional
1

AGENDA

Optimization Of Process Parameters Of Plastic

Injection Moulding Using Taguchi And FCC
Techniques

Introduction
Problem Statements
Objectives
Literature Review
Materials and Methods
Preliminary Results
Work Schedule
Expected Outcome
References
Publications
2

INTRODUCTION
Molten metal

Filling phase

Solidification
period

Cooling
phase

Part Ejection

Optimization Of Process Parameters Of Plastic

Injection Moulding Using Taguchi And FCC
Techniques

Figure 1 -Plastic Injection Moulding

Cycle

Chart 1-Plastic Injection Moulding

Process Flow
3

PROBLEM
STATEMENTS

Optimization Of Process Parameters Of Plastic

Injection Moulding Using Taguchi And FCC
Techniques

Improper selection of injection moulding process

parameters (melt temperature and mould
surface
temperature)
leads
to
manufacturing/moulding defects such as
shrinkage, warpage, etc.
Moulding defects cause higher part rejection
as the assembly of parts require dimensional
precision and tolerance.
Part rejection leads to material wastage, low
productivity level, higher production cost as
well as time constraint.
4

In terms of
temperature
as
temperature
material

Melt
temperature

PIM, melt
is referred
processing
of
the

PP
is a crystalline
material
-doesnt have a sharp
melting point
-due to different level of
crystallinity
PP with different Melt
Flow Index (MFI)
Low viscosity - easier
flow and vice-versa

Optimization Of Process Parameters Of Plastic

Injection Moulding Using Taguchi And FCC
Techniques

Melt temperature is the

actual temperature of
the polymer as it exits
the nozzle and enters
the mould.
Melt temperature has a
higher impact on final
properties
of
parts
produced
-final molecular weight
of the polymer in the
moulded part.

Figure 2-Melt temperature and cylinder

settings

Optimization Of Process Parameters Of Plastic

Injection Moulding Using Taguchi And FCC
Techniques

Mould surface
temperature

In
semi-crystalline
materials
the
mould
temperature
is
an
important
factor
in
determining the degree
of crystallinity in the
polymer.
Different
temperatures
can affect polymer flow,
causing
asymmetrical
flow, should be kept
uniformed throughout the
process
Heat is extracted out of
mould
through
the
circulation of coolant.
Higher
mould
temperature- longer cycle
time
Lower
mould
temperatureShorter cycle time

Sources: Michael Sepefrom Michael P.

Sepe LLC [1]

Figure 3 Effect of mold temperature

on modulus vs. Temperature
behaviour of a PPA

Optimization Of Process Parameters Of Plastic

Injection Moulding Using Taguchi And FCC
Techniques

THE RELATIONSHIP BETWEEN MOULD SURFACE TEMPERATURE

AND MELT TEMPERATURE

Figure 4 Symmetrical flow front

A
study
was
done
on
thermokinetical asymmetry [2]. If
melt flows inside a mould
channel, the flow front is formed
in a fountain flow. The flow is
symmetrical to axis of symmetry.
It happens only if the conditions of
flow are the same near both
mould walls . ( equal temperature,
surface roughness etc.)

Figure 5 Asymmetrical flow front [2]

In a case of temperature
difference, flow front is not
symmetrical. It shifts towards one
of the walls which is of a higher
temperature.
This is caused by lower viscosity
of melt which is in contact with
higher temperature mould wall
and therefore is heated up.
7

OBJECTIVES

Optimization Of Process Parameters Of Plastic

Injection Moulding Using Taguchi And FCC
Techniques

To investigate the influence of process

parameters (melt temperature and mould
surface temperature) on moulding defects such
as shrinkage, warpage, etc.
To optimize the process parameters (melt
temperature and mould surface temperature) for
plastic injection moulding using Taguchi and
Face Cubic Centered (FCC) techniques.
To determine the warpage before and after the
moulding process parameters (melt temperature
and mould surface temperature) optimization.
8

LITERATURE REVIEW

Optimization Of Process Parameters Of Plastic

Injection Moulding Using Taguchi And FCC
Techniques

The need to optimize

-To increase productivity by improving the cycle time [3,4]
Benefits of Computer Aided Simulations
-Simulations help to identify the possible shrinkages, orientation
effects,
[5,6]

warpage & sink marks without re-producing the mould

Cooling phase
-Many researches were done on cooling channels [7-10]. Feature
based approach
(FBA), Configuration space method, visibility
based approach and
solid freeform fabrication (SFF) supporting on
Recent
of optimization
conformalmethods
cooling channels
(CCC).
-Taguchi method, Artificial neural network
(ANN), Fuzzy logic, Genetic algorithm (GA),
Finite element method, Response surface
methodology, Blackboard- based expert
system a case-based reasoning (CBR), Linear
Figure 6 Types of cooling
regression model, Grey relational analysis and
channels
Cavity pressure
signals and principals
9
component analysis [11].

Optimization Of Process Parameters Of Plastic

Injection Moulding Using Taguchi And FCC
Techniques

MATERIALS AND METHODS

PROJECT METHODOLOGY

Design and
Conduct
Experiments

Problem Identification

Problem Analysis
Determine
Input Variables
and the
Number of
Quality Criteria

Concept Evaluation

Statistical
analysis

Variable
influence
analysis TAGUCHI

The optimum
level of
parameters
are
determined

Variable
response
analysis]-Face
centered cubic
(FCC)

Simulation Work
Result Analysis/
Discussion
Experimental Work
10

Optimization Of Process Parameters Of Plastic

Injection Moulding Using Taguchi And FCC
Techniques

MATERIALS AND METHODS

AMI SIMULATION METHODOLOGY
Development of CAD model

Meshing
Assigning boundary
conditions (mesh density,
injection location,
material, inlet/outlet of
cooling circuit)
Filling and Cooling
Analysis

Fill + Pack Analysis

Warpage Analysis

11

Optimization Of Process Parameters Of Plastic

Injection Moulding Using Taguchi And FCC
Techniques

MATERIALS AND METHODS

OPTIMIZATION METHODOLOGY

Taguchi
technique
is
used as a screening
method to rank the
importance of the input
variables
on
overall
quality. The relationship
of variables over the
quality criterion is shown
in terms of percentages.

1. Analysis of
variable (Taguchi
technique)

2. Analysis of
variable
responses
(Quadratic modelFace Centered
Cubic (FCC)
technique)

Face
centered
cubic
design is to examine the
non-linear
interactions
between input variables
and a set of criteria that
define part quality. The
result is shown in terms
of
a
response
plot
indicating how sensitive
each quality criterion is
to the selected input
variable.
12

Optimization Of Process Parameters Of Plastic

Injection Moulding Using Taguchi And FCC
Techniques

MATERIALS AND METHODS

GENERAL SPECIFICATIONS AND DESIGN GEOMETRIES OF THE

PARTS
Table 1 - General settings of process
parameters

Melt
Mold

Coolant

Material

PP

Material

Tool Steel P-20

Medium

Water (pure)

Temperature

20 C

Flow rate

10.00 (lit/min)

Reynolds Number

20000<RE<30000

Table 2 - Characteristics of the imported

rectangular plate

Parts (3mm wall

Characteristics

thickness)
Rectangular plate

Overall dimension (mm)

Figure 7-CAD Model of a

rectangular plate

120 x 50 x 3

Total part weight (g)

13.703

Shot volume (cm^3)

18.0000
13

Optimization Of Process Parameters Of Plastic

Injection Moulding Using Taguchi And FCC
Techniques

PRELIMINARY RESULTS

Estimated
cycle time:
Table 3 - Fill and cool Analyses of 3mm rectangular
24.9 s
plate
Fill analysis
Cool analysis

Cooling
channel Fill
Design
diamete time
r (mm)
(s)

D1

D2

D3

D4

Injection Pressur
pressure e drop
(MPa)
(MPa)

Time to Circuit Coola

Temp.
reach
press
nt
part (
ejection
ure temp
C)
temp. (s) (KPa) (C)

Time to
reach
Cycle
ejection time
temp.
(s)
(s)

Cooling
time
(s)

6.00

1.703

4.500

4.500

30.530

64.490 25.220 48.480

16.950

19.530

2.860

8.00

1.737

3.852

3.852

51.550

17.640 25.200 53.870

17.800

21.810

5.100

10.00

1.762

4.105

4.105

52.330

9.386 25.200 55.900

18.120

22.830

6.100

6.00

1.702

4.484

4.484

31.450

31.260 25.110 51.780

17.380

20.490

3.820

8.00

1.740

3.848

3.848

51.660

8.236 25.110 53.940

17.840

21.160

4.450

10.00

1.741

3.848

3.848

51.380

3.105 25.110 53.240

17.770

21.380

4.670

6.00

1.700

4.510

4.510

31.290

108.60
25.220 53.330
0

17.610

20.490

3.820

8.00

1.740

3.855

3.855

51.530

31.190 25.220 52.320

17.580

21.030

4.330

10.00

1.739

3.850

3.850

51.750

11.900 25.220 53.090

17.710

21.750

5.050

6.00

1.701

4.506

4.506

30.420

214.20
25.440 48.870
0

16.920

8.00

1.738

3.880

3.880

50.250

59.750 25.240 50.450

10.00

1.689

7.368

7.368

22.420

23.560 25.220 48.560

18.92
0
19.75
17.260
0
20.17
17.020
14
0

2.250
3.040
3.520

PRELIMINARY RESULTS
DESIGN OF EXPERIMENT-TAGUCHI

Optimization Of Process Parameters Of Plastic

Injection Moulding Using Taguchi And FCC
Techniques

Table 4 - DOE

Part
thickne
ss
(mm)

Process
Parameters
(Input
variables)
Le
ve
ls

1
2

Quality criterion (Output variables)

Mould
surfac
e
temp.
(C)

Melt
temp.
(C)

Cooling
time
(s)

Cycle
time
(s)

Volumetric
shrinkage
(%)

Warpage
in +Z
direction
(m)

Sink
mark
index
(%)

25

220

65 5 - 240
Table
Taguchi
A

Runs

Melt temp.
(C)

Mould surface
temp. (C)

220

25

220

65

260

25

260

65

Taguchi Design
Taguchi Orthogonal Array
Design
L4(2**2)

15

PRELIMINARY RESULTS
DESIGN OF EXPERIMENT-TAGUCHI

Optimization Of Process Parameters Of Plastic

Injection Moulding Using Taguchi And FCC
Techniques

Table 6 Taguchi data analysis

Runs

Melt
temp.
(C)

Mould
surface
temp.
(C)

Cooling
time
(s)

Cycle
time
(s)

Volumet
ric
shrinkag
e
(%)

Warpage
in +Z
direction
(m)

Sink
Mark
Index
(%)

220

25

26.9448

43.6615

8.0390

220

65

0.0051

17.1833

8.3143

260

25

33.0345

49.4007

8.8826

260

65

0.0065

16.6019

9.1041

0.03667
3
0.04471
6
0.04026
3
0.05075
3

16

1.2504
1.2517
1.7078
1.7723

Optimization Of Process Parameters Of Plastic

Injection Moulding Using Taguchi And FCC
Techniques

PRELIMINARY RESULTS

Table 7- Taguchi Analysis

results

Melt
temp.
(C)
Mould
surface
temp.
(C)

Cooling
time
(s)

Cycle
time
(s)

Volumetri
c
shrinkage
(%)

Warpage
in +Z
direction
(mm)

Sink Mark
Index
(%)

1- the most influential

2- the less influential

17

GANTT CHART
PROJECT
ACTIVITIES
Stage A
Selection Project
Title
Problem
Identification and
Analysis
Concept
Evaluation
Stage B
Concept
Generation
Build and conduct
DOE's
Tabulation of
simulation results
Stage C
Optimization
Statistical Analysis
Stage D
Experimental work
(IM)
Troubleshooting
Data and Result
tabulation
Stage E
Report Preparation
Thesis Submission

JUL

Table 8- Gantt Chart

2012
SEP
OCT

AUG

Optimization Of Process Parameters Of Plastic

Injection Moulding Using Taguchi And FCC
Techniques

NOV

2013
MAR
APR

DEC

JAN

FEB

MAY

JUN

18

EXPECTED OUTCOME

Optimization Of Process Parameters Of Plastic

Injection Moulding Using Taguchi And FCC
Techniques

By optimizing the various process parameters that

determine the quality criteria of the parts produced, it is
expected to minimize the cycle time as well as to
eliminate the manufacturing/moulding defects.

Minimizing cycle time leads to saving the manufacturing

costs as well as increasing the productivity level.

As for the first phase, based on the design of experiments,

the simulations will be done and the results will be further
analysed. In the second phase, experimental work will be
carried out in order to validate the simulation results.

19

REFERENCES

Optimization Of Process Parameters Of Plastic

Injection Moulding Using Taguchi And FCC
Techniques

[1] C.L Li, C.G. Li, A.C.K Mok. Analysis of thermal residual stress in plastic
injection by J.
Mater. Process.
[2] C.L. Li, C.G. Li, A.C.K. Mok, Automatic layout design of plastic injection
mould cooling
system. Computer Aided Design 37, (2005) pp. 645-662.
[3] A.B.M. Saifullah, S.H.Masood, Igor Sbarski, New cooling channel design for
injection
moulding. Proceedings of the World Congress on Engineering
(2009), Vol I.
[4] D.E Dimla, M. Camilotto, F.Miani, Design and optimization of conformal
cooling channels in injection moulding tools.
[5] Xu,X.Sachs,E.Allen,Samuel.Cima, Michael. (1998). Designing Conformal
Cooling Channels for Tooling.Proceedings of the Solid Freeform Fabrication
Symposium, University Of Texas, Austin. 1 (1), pp131-146.
[6] Duleba,Branislac,Ing. (2011). Conformal Cooling for Plastics Injection
Moulding.Department of Technologies and Materials, Technical University of
Kosice, Letna. 1 (1), pp1-5.
[7] Choi,J.H.Choi.S.H.Park,D.Park.C.H.Rhee.B.O . (2012). Design Optimization
for an
Injection Mould
for Minimizing Temperature Deviation. International
Journal of
Automotive Technology. 13 (2),
pp273-277.
[8] Hassan, Hamdy. (2008). Effect of Cooling System on the polymer
temperature and solidification during Injection Molding.Applied Thermal
Engineering. 29 (1), 1786-1791
[9] Bharti, P.K. Khan, M.I. (2010). Recent methods for optimization of plastic
injection
molding process- A retrospective and literature
review.
20
International Journal of
Engineering Science and Technology. 2 (9), p4540-

PUBLICATIONS

Optimization Of Process Parameters Of Plastic

Injection Moulding Using Taguchi And FCC
Techniques

K.Poornima, M.N.M. Ansari Injection Moulding Process & Cooling

Channel Optimization using Moldflow Plastic Insight Proceedings of
International conference on Advancement in Polymeric Materials
(APM 2013) on 1-3 March,2013, Lucknow, India, organized by
Central Institute of Plastics and Engineering Technology (CIPET),
page 333.
K.Poornima, M.N.M. Ansari, Design analysis of multi-cavity plastic
injection moulding Proceedings of National Graduate Conference
2012 (NatGrad2012) on 8-10 Nov 2012, organized by College of
Graduate Studies (COGS), Universiti Tenaga Nasional, Selangor,
Malaysia.

21

Optimization Of Process Parameters Of Plastic

Injection Moulding Using Taguchi And FCC
Techniques

D1

D3

D2

D4

Cooling channels designs

22