DAV INSTITUTE OF ENGINEERING AND

TECHNOLOGY
Minor Project

Supervisor
Mr. Gaurav Dhuria
Associate prof. & Head
Mechanical Engg. Department

Group Members:Akhilesh Bhardwaj (505/13)

Alok Bharti (507/13)
Arvind Kumar (514/14)
Mukesh Kumar (531/13)

Objective
Investigation and optimization of
Process parameters in injection
moulding using polypropylene (pp) as
work material

Introduction
Injection moulding is the most common method of
producing parts made of plastic. The process includes the
injection or forcing of heated molten plastic into a mold
which is in the form of the part to be made. Upon cooling
and solidification, the part is ejected and the process
continues.
The injection molding process is capable of producing an
infinite variety of part designs containing an equally
infinite variety of details such as threads, springs, and
hinges, and all in a single molding operation

Introduction-Imm

Introduction- injection moulding cycle

LITERATURE REVIEW

1.Application of Taguchi Method in the

Optimization of Injection Moulding Parameters for
Manufacturing Products from Plastic Blend
PP and LDPE (75:25) as work material
improved the quality characteristic (shrinkage)
Melting temperature is the most significant parameter while
injection speed is the insignificant parameter.

2.Optimization of Injection Moulding Process Parameters

in the Moulding of Low Density Polyethylene (LDPE)

LDPE as work material

To Reduce shrinkage
The result showed that melting temperature of 190 oC, injection
pressure of 55 MPa, refilling pressure of 85 MPa and cooling time of 11
sec. gave minimum shrinkage for LDPE.

3. Effect of Injection Moulding

Process Parameter on Tensile
Strength Using Taguchi Method
PP as work material
Optimizes tensile strength

4.Parameter Optimization of Injection

Molding of Polypropylene by using
Taguchi Methodology
PP as work material
Reduced the weight of product

5.Minimization of sink mark defects in

injection molding process Taguchi approach

ABS as work material

Pro/E is used for disc preparation and further the used
mold flow for simulation

METHODOLOGY

Design of Experiments

It is a systematic method to determine the relationship between factors affecting a

process and the output of that process.

DOE methodology include: controllable and uncontrollable input factors, responses,

hypothesis testing, blocking, replication and interaction.

Design of experiment is conducted with Taguchi method which are based on well
defined guidelines.

TAGUCHI METHOD

Taguchi method is also called Robust Design method.

This method is use to reduce waste during manufacturing and operations.

This method uses a special set of arrays called orthogonal arrays.

These standard arrays stipulates the way of conducting the minimal number of
experiments which could give the full information of all the factors that affect the
performance parameter.

The orthogonal arrays has the special properties that reduces the number of
experiments to be conducted.

The minimum number of experiments that are required to conduct the Taguchi
method can be
calculated based on the degrees of freedom approach.

Taguchi techniques also approach the noise factors.

Taguchi techniques aim to reduce the effect or impact of the noise on

the product quality.

S/N Ratio

S/N ratio is the most significant and useful parameter in taking into account of
target and variation in comparing two sets of samples, when compared
comparing the mean alone.

The term "signal" represents the desirable value and the"noise" represents the
undesirable value.

The signal to noise ratio provides a measure of the impact of noise factors on
performance. The larger the S/N, the more robust the product is against noise.

Taguchi method of DoE, uses S/N ratio in ANOVA calculations.

Calculation of the S/N ratio depends

on the experimental objective
Bigger-the-Better

Smaller-the-Better

Nominal-is-Best

Analysis of Variance (ANOVA)

ANOVA is the statistical treatment most commonly applied to the results

ofthe experiment to determine the percent contribution of each factor.

ANOVA table helps to determine which of the factors need control and
which do not.

Once the optimum condition is determined, it is usually a good practice

to run a confirmation experiment.

It helps to estimate performance at the optimum condition.

References

1.S. Kamaruddin, Zahid A. Khan and S. H. Foong, Application of Taguchi Method in

the Optimization of Injection Moulding Parameters for Manufacturing Products from
Plastic Blend , IACSIT International Journal of Engineering and Technology, Vol.2,
No.6, December 2010

2.Sajjan Kumar Lal, Dr. Hari Vasudevan, Optimization of Injection Moulding Process
Parameters in the Moulding of Low Density Polyethylene (LDPE) , International
Journal of Engineering Research and Development e-ISSN: 2278-067X, p-ISSN: 2278800X, www.ijerd.com Volume 7, Issue 5 (June 2013), PP.35-39

3.Gurjeet Singh, M. K. Pradhan, Ajay Verma, Effect of Injection Moulding Process

Parameter on Tensile Strength Using Taguchi Method , World Academy of Science,
Engineering and Technology International Journal of Mechanical, Aerospace,
Industrial, Mechatronic and Manufacturing Engineering Vol:9, No:10, 2015

4.Alireza Akbarzadeh and Mohammad Sadeghi, Parameter Study in Plastic Injection

Molding Process using Statistical Methods and IWO Algorithm , International Journal
of Modeling and Optimization, Vol. 1, No. 2, June 2011

5.D. Mathivanan, M. Nouby and R. Vidhya, Minimization of sink mark defects in

injection molding process Taguchi approach , International Journal of Engineering,
Science and Technology Vol. 2, No. 2, 2010, pp. 13-22