Manufacturing Process and Productivity Improvement of Plastics Injection Molding Parts

Too, Mei Chin (2011) Manufacturing Process and Productivity Improvement of Plastics Injection Molding Parts. Final Year Project (Other), Tunku Abdul Rahman University College.

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Abstract

This thesis includes a major study on the processing parameters in plastics injection molding which will affect the properties of finished products. The defects in the products can be minimized by changing the processing parameters and then increase the productivity. The processing parameters which affect the properties of finished products are pressure, temperature and cycle time. In order to find the optimum processing parameters with the least cost and time saving, Moldflow software was being used to analyze the parts. Moldflow software can help to simplify and optimize plastic injection molding processes and geometry affecting manufacturability. The result which had obtained by using Moldflow analysis had been proven that various parameters setting affect the qualities of finished products. For example, impropriate injection pressure may cause flash or short shot in the end of the product. Mold temperature is a major factor in surface quality. Cycle time is important for fast fill which include a hold time just long enough for the gates to freeze and a cooling time long enough so that the part ejectors do not penetrate the part. In fact, all the parameters setting are interrelated, so in order to improve the productivity, we need to use by trial and error of each setting to get the optimum processing parameters to fabricate products with the best qualities. Moldflow also help to guides designers through analysis setup and result interpretations. Besides that, changes to wall thickness, gate location, material used and features such as gates, runners and cavity layouts through simulation can also be analyzed.