Abstract: This paper focuses on using six sigma methodologies to reach the desired shrinkage of a manufactured high-density polyurethane (HDPE) part produced by the injection molding machine. It presents a case study where the correct shrinkage is required to reduce or eliminate defects and to improve the process capability index Cp and Cpk for an injection molding process. To improve this process and keep the product within specifications, the six sigma methodology, design, measure, analyze, improve, and control (DMAIC) approach, was implemented in this study. The six sigma approach was paired with the Taguchi methodology to identify the optimized processing parameters that keep the shrinkage rate within the specifications by our customer. An L9 orthogonal array was applied in the Taguchi experimental design, with four controllable factors and one non-controllable/noise factor. The four controllable factors identified consist of the cooling time, melt temperature, holding time, and metering stroke. The noise factor is the difference between material brand 1 and material brand 2. After the confirmation run was completed, measurements verify that the new parameter settings are optimal. With the new settings, the process capability index has improved dramatically. The purpose of this study is to show that the six sigma and Taguchi methodology can be efficiently used to determine important factors that will improve the process capability index of the injection molding process.
Abstract: The increasing demand of thermoplastic elastomers is related to the wide range of applications, such as automotive, footwear, wire and cable industries, adhesives and medical devices, cell phones, sporting goods, toys and others. These materials are susceptible to microbial attack. Moisture and organic matter present in some areas (such as shower area and sink), provide favorable conditions for microbial proliferation, which contributes to the spread of diseases and reduces the product life cycle. Compounds based on SEBS copolymers, poly(styrene-b-(ethylene-co-butylene)-b-styrene, are a class of thermoplastic elastomers (TPE), fully recyclable and largely used in domestic appliances like bath mats and tooth brushes (soft touch). Zinc oxide and zinc ions loaded in personal and home care products have become common in the last years due to its biocidal effect. In that sense, the aim of this study was to evaluate the effect of zinc as antimicrobial agent in compounds based on SEBS/polypropylene/oil/ calcite for use as refrigerator seals (gaskets), bath mats and sink squeegee. Two zinc oxides from different suppliers (ZnO-Pe and ZnO-WR) and one masterbatch of zinc ions (M-Zn-ion) were used in proportions of 0%, 1%, 3% and 5%. The compounds were prepared using a co-rotating double screw extruder (L/D ratio of 40/1 and 16 mm screw diameter). The extrusion parameters were kept constant for all materials. Tests specimens were prepared using the injection molding machine. A compound with no antimicrobial additive (standard) was also tested. Compounds were characterized by physical (density), mechanical (hardness and tensile properties) and rheological properties (melt flow rate - MFR). The Japan Industrial Standard (JIS) Z 2801:2010 was applied to evaluate antibacterial properties against Staphylococcus aureus (S. aureus) and Escherichia coli (E. coli). The Brazilian Association of Technical Standards (ABNT) NBR 15275:2014 were used to evaluate antifungal properties against Aspergillus niger (A. niger), Aureobasidium pullulans (A. pullulans), Candida albicans (C. albicans), and Penicillium chrysogenum (P. chrysogenum). The microbiological assay showed a reduction over 42% in E. coli and over 49% in S. aureus population. The tests with fungi showed inconclusive results because the sample without zinc also demonstrated an inhibition of fungal development when tested against A. pullulans, C. albicans and P. chrysogenum. In addition, the zinc loaded samples showed worse results than the standard sample when tested against A. niger. The zinc addition did not show significant variation in mechanical properties. However, the density values increased with the rise in ZnO additives concentration, and had a little decrease in M-Zn-ion samples. Also, there were differences in the MFR results in all compounds compared to the standard.
Abstract: Internal circulation two-platen clamping system for
injection molding machine (IMM) has many potential advantages on
energy-saving. In order to estimate its properties, experiments were
carried out in this paper. Displacement and pressure of the components
were measured. In comparison, the model of hydraulic clamping
system was established by using AMESim. The related parameters as
well as the energy consumption could be calculated. According to the
analysis, the hydraulic system was optimized in order to reduce the
energy consumption.
Abstract: Polylactic acid (PLA) is the most commercially
available bio-based and biodegradable plastic at present. PLA has
been used in plastic related industries including single-used
containers, disposable and environmentally friendly packaging owing
to its renewability, compostability, biodegradability, and safety.
Although PLA demonstrates reasonably good optical, physical,
mechanical and barrier properties comparable to the existing
petroleum-based plastics, its brittleness and mold shrinkage as well as
its price are the points to be concerned for the production of rigid and
semi-rigid packaging. Blending PLA with other bio-based polymers
including thermoplastic starch (TPS) is an alternative not only to
achieve a complete bio-based plastic, but also to reduce the
brittleness, shrinkage during molding and production cost of the
PLA-based products. TPS is a material produced mainly from starch
which is cheap, renewable, biodegradable, compostable, and nontoxic.
It is commonly prepared by a plasticization of starch under
applying heat and shear force. Although glycerol has been reported as
one of the most plasticizers used for preparing TPS, its migration
caused the surface stickiness of the TPS products. In some cases,
mixed plasticizers or natural fibers have been applied to impede the
retrogradation of starch or reduce the migration of glycerol. The
introduction of fibers into TPS-based materials could reinforce the
polymer matrix as well. Therefore, the objective of the present
research is to study the effect of starch type (i.e. native starch and
phosphate starch), plasticizer type (i.e. glycerol and xylitol with a
weight ratio of glycerol to xylitol of 100:0, 75:25, 50:50, 25:75 and
0:100) and fiber content (i.e. in the range of 1-25 %wt) on properties
of PLA/TPS blend and composite. PLA/TPS blends and composites
were prepared using a twin-screw extruder and then converted into
dumbbell-shaped specimens using an injection molding machine. The
PLA/TPS blends prepared by using phosphate starch showed higher
tensile strength and stiffness than the blends prepared by using native
one. In contrast, the blends from native starch exhibited higher
extensibility and heat distortion temperature (HDT) than those from
the modified starch. Increasing xylitol content resulted in enhanced
tensile strength, stiffness and water resistance, but decreased
extensibility and HDT of the PLA/TPS blend. Tensile properties and
hydrophobicity of the blend could be improved by incorporating
silane treated-jute fibers.
Abstract: Inconel718 has been widely used as a super alloy in aerospace application due to the high strength at elevated temperatures, satisfactory oxidation resistance and heat corrosion resistance. In this study, the Inconel718 has been fabricated using high technology of Metal Injection Molding (MIM) process due to the cost effective technique for producing small, complex and precision parts in high volume compared with conventional method through machining. Through MIM, the binder system is one of the most important criteria in order to successfully fabricate the Inconel718. Even though, the binder system is a temporary, but failure in the selection and removal of the binder system will affect on the final properties of the sintered parts. Therefore, the binder system based on palm oil derivative which is palm stearin has been formulated and developed to replace the conventional binder system. The rheological studies of the mixture between the powder and binders system have been determined properly in order to be successful during injection into injection molding machine. After molding, the binder holds the particles in place. The binder system has to be removed completely through debinding step. During debinding step, solvent debinding and thermal pyrolysis has been used to remove completely of the binder system. The debound part is then sintered to give the required physical and mechanical properties. The results show that the properties of the final sintered parts fulfill the Standard Metal Powder Industries Federation (MPIF) 35 for MIM parts.
Abstract: The effective machine-job assignment of injection
molding machines is very important for industry because it is not
only directly affects the quality of the product but also the
performance and lifetime of the machine as well. The phase of
machine selection was mostly done by professionals or experienced
planners, so the possibility of matching a job with an inappropriate
machine might occur when it was conducted by an inexperienced
person. It could lead to an uneconomical plan and defects. This
research aimed to develop a machine selection system for plastic
injection machines as a tool to help in decision making of the user.
This proposed system could be used both in normal times and in
times of emergency. Fuzzy logic principle is applied to deal with
uncertainty and mechanical factors in the selection of both quantity
and quality criteria. The six criteria were obtained from a plastic
manufacturer's case study to construct a system based on fuzzy logic
theory using MATLAB. The results showed that the system was able
to reduce the defects of Short Shot and Sink Mark to 24.0% and
8.0% and the total defects was reduced around 8.7% per month.