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Optimization of the injection molding process for the PC/ABS parts by integrating Taguchi approach and CAE simulation

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Abstract

This study was an application of the Taguchi method to optimize injection molding (IM) process parameters of the polycarbonate/acrylonitrile-butadiene styrene (PC/ABS) blends. A 4-factor, 3-level injection experiment was conducted using Taguchi L9 orthogonal array through the statistical design method. The parameters considered were material temperature, injection pressure, holding time, and mold temperature. The signal-to-noise (S/N) ratio was performed to obtain higher shear stress by defining the optimum injection parameters. The Taguchi method showed that injection pressure was the most influential parameter on the shear stress for the PC/ABS blends. The optimal injection parameter levels tested via Taguchi were verified via CAE simulation. SW plastics software was used to predict if the injected part contained injection defects through computation of key parameters such as the easy filling, the flow front central temperature, and the residual stress. The numerical simulation showed no injection defects observed on the injected PC/ABS parts. Therefore, the optimal combination parameters provided injected PC/ABS parts with a better shear stress and no injection defects. Such conditions would enhance the metallization process.

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Abbreviations

CAE:

computer-aided engineering

IM:

injection molding

DOE:

design of experiment

S/N:

signal-to-noise ratio

Y n :

the responses data of the shear stress

n :

the number of replicates

OA:

the orthogonal array

τ :

the shear stress

T :

tangential force in Newton

S :

section of the specimen in mm2

SW:

SolidWorks

C :

torsion torque in Nm

R :

radius of the specimen in mm

γ :

the shear strain (%)

θ :

the torsion angle calculated in rad/mm

α :

torsion angle measured in rad

x :

length of the active area in mm

H 1 :

the height of the torsion specimen

H 2 :

the height of the tensile specimen

H 3 :

the height of the dynamic tensile specimen

E 2 :

the thickness of the tensile specimen

E 3 :

the thickness of the dynamic tensile specimen

E r :

the runner system’s thickness

I p :

the injection point

T ma :

the material temperature

T mo :

the mold temperature

P inj :

the injection pressure

t h :

the holding time

MPa:

mega Pascal

°C:

Celsius temperature scale

bar:

bar pressure scale

sec:

second time scale

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Acknowledgments

The authors are grateful for the help of the SKG staff during the materialization of this study.

We also would like to thank Dr. Ayadi Hajji for his help in proofreading, correcting, and improving the English of the manuscript.

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Authors and Affiliations

  1. National Engineering School of Sfax, Laboratory of Electromechanical Systems (LASEM), University of Sfax, BP 1173, 3038, Sfax, Tunisia

    Fatma Hentati, Ismail Hadriche, Neila Masmoudi & Chedly Bradai

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  1. Fatma Hentati
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  2. Ismail Hadriche
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Correspondence to Fatma Hentati.

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Hentati, F., Hadriche, I., Masmoudi, N. et al. Optimization of the injection molding process for the PC/ABS parts by integrating Taguchi approach and CAE simulation. Int J Adv Manuf Technol 104, 4353–4363 (2019). https://doi.org/10.1007/s00170-019-04283-z

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