Sage Journals: Discover world-class research

Abstract

This study analyzes contour distortions, wear mass losses and tensile properties of polypropylene (PP) composite components applied to the interior coffer of automobiles. The specimens are prepared under different injection molding conditions by changing melting temperatures, injection speeds, and injection pressures via three computer-controlled progressive strokes. The contour distortions, wear and tensile properties are selected as quality targets. The arrangement of sixteen experiments is based on an orthogonal array table. Both the Taguchi method and the design of experiments (DOE) method are applied to determine an optimal parameter setting. In addition, a side-by-side comparison of two different approaches is provided. In this study, regression models that link the controlled parameters and the targeted outputs are developed, and the mathematic models can be utilized to predict the contour distortions, wear and tensile properties at various injection molding conditions.

Keywords

contour distortions wear mass losses tensile strength injection molding Taguchi DOE optimization.

Get full access to this article

View all access options for this article.

References

Chien, R.D. , Chen, S.C. , Lee, P.H. and Huang, J.S. (2004). Study on the Molding Characteristics and Mechanical Properties of Injection-Molded Foaming Polypropylene Parts, Journal of Reinforced Plastics and Composites, 23(4): 429-444.

Ismail, H. and Suryadiansyah. ( 2004). A Comparative Study of the Effect of Degradation on the Properties of PP/NR and PP/RR Blends, Polymer-Plastics Technology and Engineering, 43(2): 319-340.

Sain, M. , Suhara, P. , Law, S. and Bouilloux, A. (2005). Interface Modification and Mechanical Properties of Natural Fiber-Polyolefin Composite Products, Journal of Reinforced Plastics and Composites, 24(2): 121-130.

Yao, W. , Jia, Y. , An, L. and Li, B. (2005). Elongational Properties of Biaxially Oriented Polypropylene with Different Processing Properties, Polymer-Plastics Technology and Engineering, 44(3): 447-462.

Modesti, M. , Lorenzetti, A. , Bon, D. and Besco, S. (2005). Effect of processing conditions on morphology and mechanical properties of compatibilized polypropylene nanocomposites, Polymer, 46(23): 10237-10245.

Yang, Y.K. , Shie, J.R. , Yang, R.T. and Chang, H.A. (2006). Optimization of Injection Molding Process for Contour Distortions of Polypropylene Composite Components via Design of Experiments Method, Journal of Reinforced Plastics and Composites, 25(15): 1585-1599.

Tarng, Y.S. and Yang, W.H. (1998). Application of Taguchi Method to the Optimization of the Submerged Arc Welding Process, Materials and Manufacturing Processes, 13(3): 455-467.

Connor, A.M. (1999). Parameter Sizing for Fluid Power Circuits Using Taguchi Method, Engineering Design, 10(4): 377-390.

Liu, S.J. and Chang, C.Y. (2003). The Influence of Processing Parameters on Thin-Wall Gas Assisted Injection Molding of Thermoplastic Materials , Journal of Reinforced Plastics and Composites , 22(8): 711-731.

10.

Lin, C.L. (2004). Use of the Taguchi Method and Grey Relational Analysis to Optimize Turning Operations with Multiple Performance Characteristics, Materials and Manufacturing Processes , 19(2): 209-220.

11.

Yang, Y.K. and Tzeng, C.J. (2006). Die Casting Parameter Sizing for AZ91D in Notebook Computer Base Shell, Materials and Manufacturing Processes , 21(5): 484-489.

12.

Chao, P.Y. and Hwang, Y.D. (1997). An Improved Taguchi's Method in Design of Experiments for Milling CFRP Composite, International Journal of Production Research, 35(1): 51-66.

13.

Puertas, I. and Luis, C.J. (2004). A study of Optimization of Machining Parameters for Electrical Discharge Machining of Boron Carbide, Materials and Manufacturing Processes, 19(6): 1041-1070.

14.

Lin, T. and Chananda, B. (2004). Quality Improvement of an Injection-Molded Product Using Design of Experiments: a Case Study, Quality Engineering , 16(1): 99-104.

15.

Yang, Y.K. (2006). Optimization of a Photo Resists Coating Process for Photolithography in Wafer Manufacturing via Design of Experiments Method , Microelectronics International, 23(3): 26-32.

16.

Myers, R.H. and Montgomery, D.C. (2002). Response Surface Methodology , 2nd edn, John Wiley and Sons Inc., New York.

17.

Yang, Y.K. (2006). Optimization of Injection Molding Process for Mechanical and Tribological Properties of Short Glass Fiber and Polytetrafluoroethylene Reinforced Polycarbonate Composites with Grey Relational Analysis: A Case Study, Polymer-Plastics Technology and Engineering, 45(7): 769-777.

18.

Douglas, C.M. (1997). Design and Analysis of Experiments, 4th edn, John Wiley & Sons, Inc., pp. 101-245.

19.

Minitab Inc. (2000). Quality Plaza, 1829 Pine Hall Road, State College, PA 16801-3008, USA.

A Study of Taguchi and Design of Experiments Method in Injection Molding Process for Polypropylene Components

Abstract

Keywords

Get full access to this article

References