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Multi-objective process parameter optimization for minimizing weldline and cycle time using heater-assisted rapid heat cycle molding

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Abstract

Rapid heat cycle molding (RHCM) that actively controls the mold temperature is an innovative plastic injection molding (PIM) technology. The melt plastic smoothly flows into cavity due to the high mold temperature, and weldline reduction can be achieved. The overall mold heating in the conventional RHCM leads to long cooling time, which makes the cycle time long. To shorten the cycle time as well as weldline reduction, the RHCM using a heater called the heater-assisted RHCM is developed. It is easy to install the heater in the mold, and the local region around which the weldline is observed is heated up. Consequently, the weldline will be reduced. Since the mold is locally heated up, short cycle time will be expected. Since the process parameters in the heater-assisted RHCM are unknown in advance, design optimization is used to determine the process parameters. The numerical simulation is computationally so expensive that sequential approximate optimization that response surface is repeatedly constructed and optimized is adopted to determine the optimal process parameters. It is found from the numerical result that the weldline and the cycle time are well reduced. Based on the numerical result, the experiment using the PIM machine (MS100, Sodick) is conducted. It is confirmed through the numerical and experimental result that the heater-assisted RHCM is effective to the weldline reduction and the short cycle time.

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Funding

This research is partially supported by Grants-in-Aided for Scientific Research from Japan Society for the Promotion of Science (JSPS).

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Authors and Affiliations

  1. Kanazawa University, Kakuma-Machi, Kanazawa, 920-1192, Japan

    Satoshi Kitayama

  2. Graduate School of Natural Science & Technology, Kanazawa University, Kakuma-Machi, Kanazawa, 920-1192, Japan

    Shogo Tsurita

  3. Industrial Research Institute of Ishikawa, 2-1, Kuratsuki, Kanazawa, 920-8203, Japan

    Masahiro Takano

  4. Sodick Co., Ltd, Ka-1-1, Miya-Machi, Kaga-Shi, Ishikawa, 922-0595, Japan

    Yusuke Yamazaki, Yoshikazu Kubo & Shuji Aiba

Authors
  1. Satoshi Kitayama
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  2. Shogo Tsurita
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  3. Masahiro Takano
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  4. Yusuke Yamazaki
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  5. Yoshikazu Kubo
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  6. Shuji Aiba
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Contributions

Satoshi Kitayama organized the whole research, performed the design optimization, and wrote the manuscript. Shogo Tsurita conducted the numerical simulation using Moldex3D. Masahiro Takano developed the cooling channel. Yusuke Yamazaki, Yoshikazu Kubo, and Shuji Aiba conducted the experiment using the PIM machine.

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Correspondence to Satoshi Kitayama.

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Kitayama, S., Tsurita, S., Takano, M. et al. Multi-objective process parameter optimization for minimizing weldline and cycle time using heater-assisted rapid heat cycle molding. Int J Adv Manuf Technol 128, 5635–5646 (2023). https://doi.org/10.1007/s00170-023-12245-9

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  • DOI: https://doi.org/10.1007/s00170-023-12245-9

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