Article: Multi-objective optimisation of plastic injection moulding process using mould flow analysis and response surface methodology Journal: International Journal of Materials and Product Technology (IJMPT) 2022 Vol.64 No.2 pp.140 - 155 Abstract: Concurrently maintaining a stable part weight and high production rate has remained a challenge in injection moulding. As a statistical tool, response surface methodology (RSM) was exploited to examine effects of process parameters on part weight and production rate. The objective was to optimise process parameters in order to obtain weight stability at high rates of production. The study took advantage of validated numerical simulations using MoldFlow to generate input data required in statistical analysis. Analysis of variance revealed that packing time has a consequential impact on both responses, where an increase in packing time resulted in high part stability, but a low production rate. Real-scale test using optimal parameters producing the best trade-off between part weight and production rate was performed to validate efficiency of the optimisation procedure. The part weight and production rate predicted by RSM were in good accordance with experimental observations, with relative errors of less than 2.5%. Inderscience Publishers - linking academia, business and industry through research

Title: Multi-objective optimisation of plastic injection moulding process using mould flow analysis and response surface methodology

Authors: Mohammad Saleh Meiabadi; Mamoud Moradi; Afshin Kazerooni; Vincent Demers

Addresses: Department of Mechanical Engineering, École de Technologie Supérieure, 1100 Notre Dame West, Montreal, QC, H3C-1K3, Canada ' School of Mechanical, Aerospace and Automotive Engineering, Faculty of Engineering, Environment and Computing, Coventry University, Gulson Road, Coventry, CV1-2JH, UK ' Department of Mechanical Engineering, Faculty of Engineering, SRTT University, Tehran, Iran ' Department of Mechanical Engineering, École de Technologie Supérieure, 1100 Notre Dame West, Montreal, QC, H3C-1K3, Canada

Abstract: Concurrently maintaining a stable part weight and high production rate has remained a challenge in injection moulding. As a statistical tool, response surface methodology (RSM) was exploited to examine effects of process parameters on part weight and production rate. The objective was to optimise process parameters in order to obtain weight stability at high rates of production. The study took advantage of validated numerical simulations using MoldFlow to generate input data required in statistical analysis. Analysis of variance revealed that packing time has a consequential impact on both responses, where an increase in packing time resulted in high part stability, but a low production rate. Real-scale test using optimal parameters producing the best trade-off between part weight and production rate was performed to validate efficiency of the optimisation procedure. The part weight and production rate predicted by RSM were in good accordance with experimental observations, with relative errors of less than 2.5%.

Keywords: plastic injection moulding; numerical simulation; MoldFlow; analysis of variance; ANOVA; part weight; production rate.

DOI: 10.1504/IJMPT.2022.120657

International Journal of Materials and Product Technology, 2022 Vol.64 No.2, pp.140 - 155

Accepted: 03 Aug 2021
Published online: 31 Jan 2022 *

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Title: Multi-objective optimisation of plastic injection moulding process using mould flow analysis and response surface methodology

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