Materiale Plastice
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Materiale Plastice (Mater. Plast.), Year 2010, Volume 47, Issue 4,

Neculai Ivascu, Catalin Fetecau, Felicia Stan, Ion Postolache Optimization of the Injection Molding Process Simulation Using Taguchi Method

This work aims to present the optimization of the design of a plastic part manufactured at Accurate Machine and Tool Ltd. Canada, by using Moldflow <1> combined with the optimization method developed by Dr. Genichi Taguchi. The method uses statistical principles and involves reducing the variation in a process through robust design of experiments. The experimental design proposed by Taguchi uses orthogonal arrays to organize the parameters affecting the process and the levels at which they should be varied; it allows for the collection of the necessary data to determine which factors most affect product quality with a minimum amount of experimentation, thus saving time and resources. Moldflow allows part designers and mold makers to predict the manufacturability and quality of their design during preliminary product development stages. It helps to select the best injection gates configuration, as well as the values of mold temperature (Tw), melt temperature (Tm) and an optimized body shape for a part in order to minimize variability in a key performance measure. This presentation discusses the application of these tools on a real life production of the parts. Using this method, with a modest number of simulations runs, the resultant savings are significant. The part has the weight reduced from 0.03lb for the initial part to 0.022lb. On this one design alone it is saved 27% of the material for each part. Keywords: polymers, injection molding, design, optimization, Taguchi Method

Issue: 2010 Volume 47, Issue 4
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