Strength of the Weld Line and Warpage Defects on the Molded Parts in Injection Molding Process


(*) Corresponding author


Authors' affiliations


DOI's assignment:
the author of the article can submit here a request for assignment of a DOI number to this resource!
Cost of the service: euros 10,00 (for a DOI)

Abstract


Strength at weld the line location and warpage problem in injection molding plastic component were not new problems in injection molding industries. Many researchers had emerged with several improvement techniques to reduce these problems that been applied to a verity of customer products that injected with various types of polymers. This paper reviewed the improvement techniques previously studied to maximize strength at weld line location and minimize warpage or deflections of the molded parts. From the review, it can be seen that by using mechanical and thermal assistance during injection molding process, and the optimization of machine parameters for stated problems can be improved. However, there was lack on the multi objectives optimization which should be apply to ensure the weld line and warpage were improved together to get the best quality products.
Copyright © Praise Worthy Prize - All rights reserved.

Keywords


Injection Molding; Weld line Strength; Warpage; Optimization

Full Text:

PDF


References


J. G. Kovács and B. Sikló, “Experimental validation of simulated weld line formation in injection moulded parts,” Polymer Testing, vol. 29, no. 7, pp. 910–914, Oct. 2010.

T. A. O. C. Chang and E. Faison, “Optimization of Weld Line Quality in Injection Molding Using an Experimental Design Approach,” vol. 3, no. 2, pp. 61–66, 1999.

A. M. Tom, A. Kikuchi, and J. P. Coulter, “Experimental Determination of Optimized Vibration-assisted Injection Molding Processing Parameters for Atactic Polystyrene,” Special Molding Techniques, pp. 245–252, 1980.

A. Kikuchi, J. P. Coulter, D. Angstadt, and A. Pinarbasi, “Localized Material and Processing Aspects Related to Enhanced Recycled Material Utilization Through Vibration-Assisted Injection Molding,” Journal of Manufacturing Science and Engineering, vol. 127, no. 2, p. 402, 2005.

G. Zhao, G. Wang, Y. Guan, and H. Li, “Research and application of a new rapid heat cycle molding with electric heating and coolant cooling to improve the surface quality of large LCD TV panels,” Polymers for Advanced Technologies, vol. 22, no. 5, pp. 476–487, May 2011.

G. Wang, G. Zhao, and Y. Guan, “Thermal response of an electric heating rapid heat cycle molding mold and its effect on surface appearance and tensile strength of the molded part,” Journal of Applied Polymer Science, p. n/a–n/a, Jul. 2012.

L. Xie and G. Ziegmann, “Mechanical properties of the weld line defect in micro injection molding for various nano filled polypropylene composites,” Journal of Alloys and Compounds, vol. 509, no. 2, pp. 226–233, Jan. 2011.

C. Lu, S. Guo, L. Wen, and J. Wang, “Weld line morphology and strength of polystyrene/polyamide-6/poly(styrene-co-maleic anhydride) blends,” European Polymer Journal, vol. 40, no. 11, pp. 2565–2572, Nov. 2004.

B. Ozcelik, “Optimization of injection parameters for mechanical properties of specimens with weld line of polypropylene using Taguchi method,” International Communications in Heat and Mass Transfer, pp. 7–12, May 2011.

C.-Y. Wu, C.-C. Ku, and H.-Y. Pai, “Injection molding optimization with weld line design constraint using distributed multi-population genetic algorithm,” The International Journal of Advanced Manufacturing Technology, vol. 52, no. 1–4, pp. 131–141, May 2010.

B. Ozcelik and T. Erzurumlu, “Comparison of the warpage optimization in the plastic injection molding using ANOVA, neural network model and genetic algorithm,” Journal of Materials Processing Technology, vol. 171, no. 3, pp. 437–445, Feb. 2006.

Y.-M. Deng, Y. Zhang, and Y. C. Lam, “A hybrid of mode-pursuing sampling method and genetic algorithm for minimization of injection molding warpage,” Materials & Design, vol. 31, no. 4, pp. 2118–2123, Apr. 2010.

W. J. Chen and J. R. Lin, “Design of Optimization Parameters with Hybrid Genetic Algorithm Method in Multi-Cavity Injection Molding Process,” Advanced Materials Research, vol. 463–464, pp. 587–591, Feb. 2012.

F. Yin, H. Mao, and L. Hua, “A hybrid of back propagation neural network and genetic algorithm for optimization of injection molding process parameters,” Materials & Design, vol. 32, no. 6, pp. 3457–3464, Jun. 2011.

G. Wang, G. Zhao, H. Li, and Y. Guan, “Multi-objective optimization design of the heating/cooling channels of the steam-heating rapid thermal response mold using particle swarm optimization,” International Journal of Thermal Sciences, vol. 50, no. 5, pp. 790–802, May 2011.

a. Kikuchi, J. P. Coulter, and R. R. Gomatam, “Assessing the effect of processing variables on the mechanical response of polysytrene molded using vibration-assisted injection molding process,” Journal of Applied Polymer Science, vol. 99, no. 5, pp. 2603–2613, Mar. 2006.

Y. Li and K. Shen, “Improving the Mechanical Properties of Polypropylene via Melt Vibration,” Journal of Applied Polymer Science, vol. 109, pp. 90–96, 2008.

S.-C. Nian and M.-S. Huang, “Enhancement of weld line mechanical strength using a novel ejector-pins compression system,” Journal of Applied Polymer Science, p. n/a–n/a, Jul. 2012.

C. Lu, X. Yu, and S. Guo, “Ultrasonic improvement of weld line strength of injection-molded polystyrene and polystyrene/polyethylene blend parts,” Polymer Engineering & Science, vol. 45, no. 12, pp. 1666–1672, Dec. 2005.

C. Lu, X. Yu, and S. Guo, “The Mechanism of Ultrasonic Improvement of Weld Line Strength of Injection Molded Polystyrene and Polystyrene / Polyethylene Blend Parts,” Journal of Polymer Science, vol. 44, pp. 1520–1530, 2006.

X.-P. Li, G.-Q. Zhao, Y.-J. Guan, and M.-X. Ma, “Optimal design of heating channels for rapid heating cycle injection mold based on response surface and genetic algorithm,” Materials & Design, vol. 30, no. 10, pp. 4317–4323, Dec. 2009.

G. Wang, G. Zhao, and X. Wang, “Effects of cavity surface temperature on mechanical properties of specimens with and without a weld line in rapid heat cycle molding,” JOURNAL OF MATERIALS&DESIGN, vol. 46, pp. 457–472, 2013.

O. G. Ersoy and N. Nugay, “A new approach to increase weld line strength of incompatible polymer blend composites: selective filler addition,” Polymer, vol. 45, no. 4, pp. 1243–1252, Feb. 2004.

R. Selden, “Effect of Processing on Weld Line Strength in Five Thermoplastics,” vol. 37, no. 1, 1997.

S.-J. Liu, J.-Y. Wu, J.-H. Chang, and S.-W. Hung, “An experimental matrix design to optimize the weldline strength in injection molded parts,” Polymer Engineering & Science, vol. 40, no. 5, pp. 1256–1262, May 2000.

H. Li, Z. Guo, and D. Li, “Reducing the effects of weldlines on appearance of plastic products by Taguchi experimental method,” The International Journal of Advanced Manufacturing Technology, vol. 32, no. 9–10, pp. 927–931, Apr. 2006.

C.-H. Wu and W.-J. Liang, “Effects of geometry and injection-molding parameters on weld-line strength,” Polymer Engineering & Science, vol. 45, no. 7, pp. 1021–1030, Jul. 2005.

Y.-M. Deng, D. Zheng, B.-S. Sun, and H.-D. Zhong, “Injection Molding Optimization for Minimizing the Defects of Weld Lines,” Polymer-Plastics Technology and Engineering, vol. 47, no. 9, pp. 943–952, Aug. 2008.

B. Ozcelik, E. Kuram, and M. M. Topal, “Investigation the effects of obstacle geometries and injection molding parameters on weld line strength using experimental and finite element methods in plastic injection molding,” International Communications in Heat and Mass Transfer, vol. 39, no. 2, pp. 275–281, Feb. 2012.

B. Sun and Z. Wu, “Optimization of injection molding process parameters based on Response Surface Methodology and genetic algorithm,” 2010 2nd International Conference on Computer Engineering and Technology, pp. V5–397–V5–400, 2010.

C.-S. Chen, T.-J. Chen, R.-D. Chien, and S.-C. Chen, “Investigation on the weldline strength of thin-wall injection molded ABS parts,” International Communications in Heat and Mass Transfer, vol. 34, no. 4, pp. 448–455, Apr. 2007.

D. H. Chun, “Cavity filling analyses of injection molding simulation: bubble and weld line formation,” Journal of Materials Processing Technology, vol. 90, no. 89–90, pp. 177–181, 1999.

M. H. Othman, S. Shamsudin, S. Hasan, and M. N. A. Rahman, “The Effects of Injection Moulding Processing Parameters and Mould Gate Size towards Weld Line Strength,” Advanced Materials Research, vol. 488–489, pp. 801–805, Mar. 2012.

Y. Gao and X. Wang, “An effective warpage optimization method in injection molding based on the Kriging model,” The International Journal of Advanced Manufacturing Technology, vol. 37, no. 9–10, pp. 953–960, Jun. 2007.

F. Yin, H. Mao, L. Hua, W. Guo, and M. Shu, “Back Propagation neural network modeling for warpage prediction and optimization of plastic products during injection molding,” Materials & Design, vol. 32, no. 4, pp. 1844–1850, Apr. 2011.

H. Kurtaran and T. Erzurumlu, “Efficient warpage optimization of thin shell plastic parts using response surface methodology and genetic algorithm,” The International Journal of Advanced Manufacturing Technology, vol. 27, no. 5–6, pp. 468–472, Apr. 2005.

T. Erzurumlu and B. Ozcelik, “Minimization of warpage and sink index in injection-molded thermoplastic parts using Taguchi optimization method,” Materials & Design, vol. 27, no. 10, pp. 853–861, Jan. 2006.

M. Fathullah, Z. Shayfull, N. A. Shuaib, and S. M. Nasir, “Optimal Process Conditions of Warpage with Thin-Shallow Features Molded with Pin-Point Gating System II . Design III . Materials and Methods,” International Review of Mechanical Engineering, vol. Volume 5, no. Issue 7, November 2011, pp. 1295–1301, 2011.

S. H. Tang, Y. J. Tan, S. M. Sapuan, S. Sulaiman, N. Ismail, and R. Samin, “The use of Taguchi method in the design of plastic injection mould for reducing warpage,” Journal of Materials Processing Technology, vol. 182, no. 1–3, pp. 418–426, Feb. 2007.

Z. Shayfull, M. Fathullah, S. Sharif, S. M. Nasir, and N. A. Shuaib, “Warpage Analysis on Ultra-Thin Shell by Using Taguchi Method and Analysis of Variance ( ANOVA ) for Three-Plate Mold,” vol. 5, no. September, pp. 1116–1124, 2011.

B. Ozcelik and I. Sonat, “Warpage and structural analysis of thin shell plastic in the plastic injection molding,” Materials & Design, vol. 30, no. 2, pp. 367–375, Feb. 2009.

Y.-K. Yang, J.-R. Shie, H.-T. Liao, J.-L. Wen, and R.-T. Yang, “A Study of Taguchi and Design of Experiments Method in Injection Molding Process for Polypropylene Components,” Journal of Reinforced Plastics and Composites, vol. 27, no. 8, pp. 819–834, Jan. 2008.

H. Oktem, T. Erzurumlu, and I. Uzman, “Application of Taguchi optimization technique in determining plastic injection molding process parameters for a thin-shell part,” Materials & Design, vol. 28, no. 4, pp. 1271–1278, Jan. 2007.

M.-C. Huang and C.-C. Tai, “The effective factors in the warpage problem of an injection-molded part with a thin shell feature,” Journal of Materials Processing Technology, vol. 110, no. 1, pp. 1–9, Mar. 2001.

R. T. Marler and J. S. Arora, “Survey of multi-objective optimization methods for engineering,” Structural and Multidisciplinary Optimization, vol. 26, no. 6, pp. 369–395, Apr. 2004.

B. Farshi, S. Gheshmi, and E. Miandoabchi, “Optimization of injection molding process parameters using sequential simplex algorithm,” Materials & Design, vol. 32, no. 1, pp. 414–423, Jan. 2011.


Refbacks

  • There are currently no refbacks.


Please send any question about this web site to info@praiseworthyprize.com
Copyright © 2005-2024 Praise Worthy Prize