Warpage Analysis on Ultra-Thin Shell by Using Taguchi Method and Analysis of Variance (ANOVA) for Three-Plate Mold

Shayfull, Z.; Fathullah, M.; Sharif, S.; Nasir, S. M.; Shuaib, N. A.
September 2011
International Review of Mechanical Engineering;Sep2011, Vol. 5 Issue 6, p1116
Academic Journal
One of the major problems in the plastic injection process of thin wall parts is warpage. In addition, the increase demand on smaller parts with reducing thickness has posed a great challenge to product design engineers, mold designers as well as manufacturing engineers. Studies on the significant factors that influenced warpage on general plastic parts had been conducted by many researches, however studies on warpage of ultra-thin parts are still lacking. This paper reports on the investigation of warpage on ultra-thin shell part of dimension 50mm x 40mm x 5mm and thickness 0.3mm using a three plate mold with a pin point gating system. Experiments were simulated using Autodesk Moldflow Insight (AMI) and warpage of the ultra-thin shell part was evaluated with and without considering the differences effect on mold temperature (core and cavity plates). Thermoplastic Polycarbonate/Acrylonitrile Butadiene Styrene (PC/ABS) was used as the plastic material and Taguchi method was adopted to establish the optimum parameters of the injection molding process. Finally the results were analyzed statistically using ANOVA to obtain the most significant factors affecting the warpage. Results showed that the mold temperature of cavity and core plates are the most significant factor affecting the warpage in ultra-thin shell part while the temperature difference on the core and cavity plates was not significant.


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