Optimization Plastic Mold Injection Parameters for Sprinkler Valve Production Process Using Problem Solving and Experimental Design
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Abstract
The goal of this research was to optimize the injection molding process using problem-solving technique and experimental design to determine appropriate parameters for sprinkler valve production. The analysis identified that the main cause of defects was due to inappropriate parameter settings in the injection molding process. To address this, a method was developed that began with screening factors influencing incomplete injection and burn marks on the surface of the workpiece by expert teams. Four key factors were identified: injection pressure, injection speed, end-of-fill temperature, and start-of-fill temperature. Experiment design involved a factorial 24 experimental design with each factor divided into 2 levels, repeating experiments 3 times, for a total of 48 experiments. Statistical analysis was conducted to determine the optimal levels for all four factors, resulting in the following optimal factor levels: injection pressure of 65 MPa, injection speed of 10 mm/s, end-of-fill temperature of 175 °C, and start-of-fill temperature of 180 °C. Additionally, the defect rate was reduced from the original 11.6% decreased to 8.7%.
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