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

  • Fatma HentatiEmail author
  • Ismail Hadriche
  • Neila Masmoudi
  • Chedly Bradai


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.


Injection molding Taguchi technique CAE simulation PC/ABS parts Shear stress Injection defects 



computer-aided engineering


injection molding


design of experiment


signal-to-noise ratio


the responses data of the shear stress


the number of replicates


the orthogonal array


the shear stress


tangential force in Newton


section of the specimen in mm2




torsion torque in Nm


radius of the specimen in mm


the shear strain (%)


the torsion angle calculated in rad/mm


torsion angle measured in rad


length of the active area in mm


the height of the torsion specimen


the height of the tensile specimen


the height of the dynamic tensile specimen


the thickness of the tensile specimen


the thickness of the dynamic tensile specimen


the runner system’s thickness


the injection point


the material temperature


the mold temperature


the injection pressure


the holding time


mega Pascal


Celsius temperature scale


bar pressure scale


second time scale



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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Copyright information

© Springer-Verlag London Ltd., part of Springer Nature 2019

Authors and Affiliations

  • Fatma Hentati
    • 1
    Email author
  • Ismail Hadriche
    • 1
  • Neila Masmoudi
    • 1
  • Chedly Bradai
    • 1
  1. 1.National Engineering School of Sfax, Laboratory of Electromechanical Systems (LASEM)University of SfaxSfaxTunisia

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