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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
ORIGINAL ARTICLE

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.

Keywords

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

Nomenclature

CAE

computer-aided engineering

IM

injection molding

DOE

design of experiment

S/N

signal-to-noise ratio

Yn

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

H1

the height of the torsion specimen

H2

the height of the tensile specimen

H3

the height of the dynamic tensile specimen

E2

the thickness of the tensile specimen

E3

the thickness of the dynamic tensile specimen

Er

the runner system’s thickness

Ip

the injection point

Tma

the material temperature

Tmo

the mold temperature

Pinj

the injection pressure

th

the holding time

MPa

mega Pascal

°C

Celsius temperature scale

bar

bar pressure scale

sec

second time scale

Notes

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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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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