Optimization of Process Parameters for ABS, Nylon, Polypropylene Material in Injection Molding Using Taguchi Method

Abstract

The process of plastic injection molding (IMP) itself is a multifarious of time, temperature and pressure variables with a profusion of manufacturing defects that can occur without upright fusion of processing parameters and design components. Ascertaining the reform foremost process parameter settings commentative dominates productivity, quality, and costs of production in the plastic injection molding industry. Most plastic injection molding industries are using trial-and-error method/approximation method, based on experience of operator, to determine initial settings of machine and process parameters. In the present research work, methodology for estimating optimal set of process parameters to reduce cycle time of the process is reported. Melting temperature, injection pressure, cooling time, and holding temperature are chosen as process parameters. Taguchi L 27 Orthogonal Array is chosen is chosen as design of experimentation. Three different materials (ABS, nylon, and polypropylene) are selected for experimentation. Regression models are developed based on the S/N values of experimental results of cycle time. Analysis of variance is performed to check the adequacy of the results using Minitab 16. It can be revealed from the analysis that melting temperature for ABS material, and injection pressure for nylon and polypropylene material are significantly affecting the process parameters for IMP in specified condition. The result culminates the endorsed values of the parameters for IM for the framed component design. Defect anticipation coupled with least cycle time results in revamp of the process.