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<p>Injection molding is one of the most popular manufacturing techniques for polymer materials due to its high production rate and low process cost. However, injection-molded polymer products are prone to many faults, including geometrical, shape, and optical defects. Shrinkage and weld line defects are the primary defects affecting the mechanical and product dimension accuracy properties. This study investigates the multi-objective optimization (MOO) of process parameters to improve shrinkage and weld line strength in injection-molded plastic flat parts using the response surface methodology (RSM). The parameters studied include packing pressure, cooling time, packing time, and melt temperature. Regression models were developed to estimate the shrinkage and weld line strength of specimens and determine an optimal setup parameter of the process to achieve the optimal shrinkage and weld line strength of the molded part. MOO revealed that a combination of 60.62 MPa packing pressure, 13.66 (s) cooling time, 8.34 (s) packing time, and 220°C melt temperature achieved notable improvements. Specifically, shrinkage in the <i>x</i>- and <i>y</i>-directions was reduced by 15.10% and 8.77%, respectively, while weld line strength increased by 2.17%. These results demonstrate the efficacy of the RSM-based optimization model in enhancing critical performance metrics for injection-molded parts.</p>

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Multi-objective optimization and evaluation of shrinkage and weld line strength in flat plastic parts using response surface methodology in injection molding

  • 期刊论文

  • 发表日期：

    2025年4月23日

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  • Adel Ali Azawqari,
  • Shayfull Zamree Abd Rahim,
  • Mohd Fathullah,
  • Mohd Nasir Mat Saad,
  • Nurul Hidayah Huzaim

摘要

Injection molding is one of the most popular manufacturing techniques for polymer materials due to its high production rate and low process cost. However, injection-molded polymer products are prone to many faults, including geometrical, shape, and optical defects. Shrinkage and weld line defects are the primary defects affecting the mechanical and product dimension accuracy properties. This study investigates the multi-objective optimization (MOO) of process parameters to improve shrinkage and weld line strength in injection-molded plastic flat parts using the response surface methodology (RSM). The parameters studied include packing pressure, cooling time, packing time, and melt temperature. Regression models were developed to estimate the shrinkage and weld line strength of specimens and determine an optimal setup parameter of the process to achieve the optimal shrinkage and weld line strength of the molded part. MOO revealed that a combination of 60.62 MPa packing pressure, 13.66 (s) cooling time, 8.34 (s) packing time, and 220°C melt temperature achieved notable improvements. Specifically, shrinkage in the x- and y-directions was reduced by 15.10% and 8.77%, respectively, while weld line strength increased by 2.17%. These results demonstrate the efficacy of the RSM-based optimization model in enhancing critical performance metrics for injection-molded parts.