In this study, the effect of injection parameters on sink marks and photometric properties in the production of reflector used in automobiles was investigated. Mold filling analysis was performed with Moldflow software and sinkmarks and warpage were determined before production. Afterwards, the reflector was produced. The effects of injection parameters such as melt temperature, mold temperature, injection speed, injection pressure, holding time and cooling time on sink marks and photometry were investigated by Taguchi and Anova analysis. In the mold filling simulation, a sink mark of 0.05 mm was formed, while an average of 0.053 mm of sink mark was formed in the experimental results. It was found that the most effective parameter on the sink mark was melt temperature, while cooling time was found for photometry. In the experiment, the lowest sink marks value was 0.053 mm in avarage, and the highest photometry value (923.33 mcd/lux) was measured in the same test. The lowest photometry value was measured as 700.33 mcd/lux and the sink marks value in this experiment was 0.082 mm. The sink marks on the reflector surface change the illumination angles by disrupting the surface planarity, and the reflector’s reflective properties are also affected by this.
KazmerDO. Injection mold design engineering. Carl Hanser Verlag GmbH Co KG, 2022.
2.
SubaşıMKarataşÇ. Investigation of molding and sintering parameters of feedstock prepared from Ti-6Al-4V alloy powder. J Fac Eng Archit Gazi Univ. 2016; 31(2): 473–483.
3.
SatoFEKNakataT. Energy consumption analysis for vehicle production through a material flow approach. Energies2020; 13(9): 2396. https://doi.org/10.3390/en13092396
AngeliniJMG. Estudo de Tensão e Deformação em Policarbonato Moldadas por Injeção [Stress and strain study in injection molded polycarbonate]. PhD Thesis, UNICAMP, 1999, p. 122.
KjellanderCKNielsenTBGhanbari-SiahkaliA, et al.ESC resistance of commercial grade polycarbonates during exposure to butter and related chemicals. Polym Degrad Stabil2008; 93(8): 1486–1495. https://doi.org/10.1016/j.polymdegradstab.2008.05.011
11.
TurnbullAMaxwellASPillaiS. Residual stress in polymers: evaluation of measurement techniques. J Mater Sci1999; 34: 451–459. https://doi.org/10.1023/a:1004574024319
SinghGVermaA. A brief review on injection moulding manufacturing process. Mater Today Proc2017; 4: 1423–1433.
14.
ShenCWangLCaoW, et al.Investigation of the effect of molding variables on sink marks of plastic injection molded parts using Taguchi DOE technique. Polym-Plast Technol Eng2007; 46(3): 219–225. https://doi.org/10.1080/03602550601152887
ErzurumluTBaburÖ. Minimization of warpage and sink index in injection-molded thermoplastic parts using Taguchi optimization method. Mater Des2006; 27(10): 853–861. https://doi.org/10.1016/j.matdes.2005.03.017
17.
GuoWHuaLMaoH. Minimization of sink mark depth in injection-molded thermoplastic through design of experiments and genetic algorithm. Int J Adv Manuf Technol2014; 72: 365–375. https://doi.org/10.1007/s00170-013-5603-8
18.
SreedharanJJeevananthamAK. Optimization of injection molding process to minimize weld-line and sink-mark defects using Taguchi based grey relational analysis. Mater Today Proc2018; 5(5): 12615–12622. https://doi.org/10.1016/j.matpr.2018.02.244
19.
ParkJCYuMJParkKY. Design of feed system and process conditions for automobile lamp garnish lens with injection molding analysis. J Korean Soc Manuf Process Eng2019; 18(11): 1–8. https://doi.org/10.14775/ksmpe.2019.18.11.001
20.
RavikiranBPradhanDKJeetS, et al.Parametric optimization of plastic injection moulding for FMCG polymer moulding (PMMA) using hybrid Taguchi-WASPAS-Ant lion optimization algorithm. Mater Today Proc2022; 56(5): 2411–2420. https://doi.org/10.1016/j.matpr.2021.08.204
21.
NasEÖzarslanF. Polietilan+ Eva Karışımı Malzemenin Farklı parametrelerde plastik enjeksiyon Makinesi İle Üretiminin deneysel ve İstatiksel olarak İncelenmesi [Experimental and statistical investigation of the production of polyethylene + EVA blend material with different parameters using a plastic injection molding machine]. Marmara Fen Bilimleri Dergisi2018; 30(4): 365–372. https://doi.org/10.7240/marufbd.440255
ChoSHKimHKSohnJS, et al.Effect of foaming processes on the reduction of warpage in glass fiber reinforced plastic composites. J Mech Sci Technol2019; 33: 4227–4232. https://doi.org/10.1007/s12206-019-0735-x
25.
LiJQLiDQGuoZY, et al.Single gate optimization for plastic injection mold. J Zhejiang Univ - Sci A2007; 8: 1077–1083. https://doi.org/10.1631/jzus.2007.a1077
26.
ZhaoNYLianJYWangPF, et al.Recent progress in minimizing the warpage and shrinkage deformations by the optimization of process parameters in plastic injection molding: a review. Int J Adv Manuf Technol2022; 120(1-2): 85–101. https://doi.org/10.1007/s00170-022-08859-0
27.
PościkASzkudlarekJOwczarekG. Photometric properties of retroreflective materials in dependence on their structure and angle of illumination. Fibres Text East Eur2019; 3(135): 58–64. https://doi.org/10.5604/01.3001.0013.0743
28.
LeHTLeLTChenMJ, et al.ECE/SAE dual functional superpin plus curved reflex reflector by use of new structured corner cubes. Appl Sci2020; 10(2): 454. https://doi.org/10.3390/app10020454
29.
NilsenRobert B.Retroreflective microprismatic material with top face curvature and method of making same (US5780140A). US Patent. 1998.
30.
KimHLeeB. Optimal design of retroreflection corner cube sheets by geometric optics analysis. Opt Eng2007; 46: 094002. https://doi.org/10.1117/1.2779030
31.
BrinksmeierEGläbeRFluckeC. Manufacturing of molds for replication of micro corner cube retroreflectors. Prod Eng2008; 2: 33–38. https://doi.org/10.1007/s11740-008-0082-8
32.
HusseinSHamiltonBTutunea-FatanOR, et al.Novel retroreflective micro-optical structure for automotive lighting applications. SAE Int J Passeng Cars Mech Syst2016; 9: 497–506. https://doi.org/10.4271/2016-01-1407
33.
SegreSEZanzaV. Mueller calculus of polarization change in the corner cube retroreflector. J Opt Soc Am A2003; 20: 1804–1811. https://doi.org/10.1364/josaa.20.001804
