Abstract: This paper presents an evaluation of a plastic defect in injection molding before it occurs in the process; it is known as the short shot defect. The evaluation of different parameters which affect the possibility of short shot defect is the aim of this paper. The analysis of short shot possibility is conducted via SolidWorks Plastics and Taguchi method to determine the most significant parameters. Finite Element Method (FEM) is employed to analyze two circular flat polypropylene plates of 1 mm thickness. Filling time, part cooling time, pressure holding time, melt temperature and gate type are chosen as process and geometric parameters, respectively. A methodology is presented herein to predict the possibility of the short-shot occurrence. The analysis determined melt temperature is the most influential parameter affecting the possibility of short shot defect with a contribution of 74.25%, and filling time with a contribution of 22%, followed by gate type with a contribution of 3.69%. It was also determined the optimum level of each parameter leading to a reduction in the possibility of short shot are gate type at level 1, filling time at level 3 and melt temperature at level 3. Finally, the most significant parameters affecting the possibility of short shot were determined to be melt temperature, filling time, and gate type.
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.