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Year 2023, Volume: 4 Issue: 1, 12 - 24, 24.07.2023

Emre Koşar Gürer Kutluğ Gökhan Ak Tülin Şahin

Abstract

References

  • [1] Zhao, N.-Y. Lian, J.-Y., Wang, P.-F., & Xu, Z.-B. (2022). Recent progress in minimizing the warpage and shrinkage deformations by the optimization of process parameters in plastic injection molding: a review. The International Journal of Advanced Manufacturing Technology, 120, 85−101. [CrossRef]
  • [2] Gürün H, Özdemir A, Acar T. (2009). Computer aided design of the cooling system for plastic injection molds. Pamukkale Üniversitesi, Mühendislik Bilimleri Dergisi, 15(2), 263−268.
  • [3] Shoemaker, J. (2006). Moldflow Design Guide (1th ed). Carl Hanser Verlag. [CrossRef]
  • [4] Beaumont, J. P. (2019). Runner and gating design handbook. Carl Hanser Verlag. [CrossRef]
  • [5] Uluer, O. (2008). Enjeksiyonla kalıplamada işleme parametrelerinin katılaşmış katman oluşumuna etkisi. Gazi Üniversitesi Mühendislik Mimarlık Fakültesi Dergisi, 23(1), 249−255.
  • [6] Rambhau, I. A., Ashwinkumar, J. S., & Rajendra, P., Kulkarni Nikhil Narayan and B.D. Patil, (2016). Design and Analysis of Cover Handle Bar Top (Injection moulding process). International Journal of Current Engineering and Technology, Suppl 4, 291−295.
  • [7] Beaumont, J. P. (2004). Runner and gating design handbook: tools for successful injection molding. Hanser.
  • [8] Chu, H., Liu, Z., Zhang, C., Liu, Z., Zhao, Y., & Yang, C. (2022). Decision‑making for structural parameters of injection mold gating system based on agent model and intelligent algorithm. The International Journal of Advanced Manufacturing Technology, 119, 7599−7614. [CrossRef]
  • [9] Nuruzzaman, D. M., Kusaseh, N., Basri, S., Oumer, A. N., & Hamedon, Z. (2016). Modeling and flow analysis of pure nylon polymer for injection molding process. Materials Science and Engineering 114, Article 012043. [CrossRef]
  • [10] Sedighi, R., Maiabadi, S. M., & Sedighi, M. (2017). Optimisation of gate location based on weld line in plastic injection moulding using computer-aided engineering, artificial neural network, and genetic algorithm. International Journal of Automotive and Mechanical Engineering, 14(3), 4419−4444. [CrossRef]
  • [11] Wong, C. T., Sulaiman, S., Ismail, N., & Hamouda, A. M. S. (2004). Design and simulation of plastic injection moulding process. Pertanika Journal of Science & Technology Supplement 12(2), 85−99.
  • [12] Mircheski, I., Lukaszewicz, A., & Szczebiot, R. (2019). Injection process design for manufacturing of bicycle plastic bottle holder using CAx tools. Procedia Manufacturing, 32, 68−73. [CrossRef]
  • [13] Ravikiran, B., Pradhan, D. K., Jeet, S., Bagal, D. K., Barua, A., & Nayak, S, (2021). Parametric optimization of plastic injection moulding for FMCG polymer moulding (PMMA) using hybrid Taguchi-WASPAS-Ant Lion optimization algorithm. Materials Today, 56(5), 2411−2420. [CrossRef]
  • [14] Zhai, M., Lam, Y. C., Au, C. K., & Liu D. S. (2005). Automated selection of gate location for plastic injection molding processing. Polymer-Plastics Technology and Engineering, 44, 229−242. [CrossRef]
  • [15] Pandelidis, Q., & Zou, I. (1990). Optimization of injection molding design. Part I: Gate location optimization. Polymer Engineering and Science, 30(75), 873−882. [CrossRef]
  • [16] Pandelidis, Q., & Zou, I. (1990). Optimization of injection molding design. Part II: Molding conditions optimization. Polymer Engineering and Science, 30(75), 883−892. [CrossRef]
  • [17] Zhao, Z., Liao, L., Tang, F., & Liu, B. (2010). Moldflow software in a complex plastic shell injection mold design. Applied Mechanics and Materials, 29-32, 646−650. [CrossRef]
  • [18] Menga, L., Wangb, Z., Liuc, D., & Haod, W. (2011). Optimal design of plastic injection mould gating system. Advanced Materials Research, 189-193, 2371−2375. [CrossRef]
  • [19] Yan, D., & Han, J. (2012). Improving design of cricoid plastic gating system based on moldflow. Advanced Materials Research, 472-475, 2264−2269. [CrossRef]
  • [20] Altan, M. (2010). Reducing shrinkage in injection moldings via the Taguchi, ANOVA and neural”network methods. Materials and Design 31, 599−604. [CrossRef]
  • [21] Zhai, M., Lam, Y., Au, C. (2009). Gate location optimization scheme for plastic injection molding. e-Polymers, 9(1), Article 1515. [CrossRef]
  • [22] Sedighi, R., Saleh Meiabadi, M., & Sedighi, M. (2017). Optimisation of gate location based on weld line in plastic injection moulding using computer-aided engineering, artificial neural network, and genetic algorithm. International Journal of Automotive and Mechanical Engineering, 14(3), 4419−443. [CrossRef]
  • [23] Kapila, A., Singh, K., Arora, G., & Agarwal, N. (2015). Effect of varying gate size on the air traps in injection molding. International Journal of Current Engineering and Technology, Vol. 5(1), 161−166.
  • [24] Thongkaew, K., & Naemsai, T. (2020). Mechanical properties and cost-minimized design of 6-liter PET bottle using finite element method. Walailak Journol of Science and Technology, 17(6), 579−587. [CrossRef]
  • [25] Moayyedian, M. (2017). Intelligent optimization of mold design and process parameters in injection molding. Springer.

Effect of bottle handle design on injection molding production parameters and usage performance

Year 2023, Volume: 4 Issue: 1, 12 - 24, 24.07.2023

Emre Koşar Gürer Kutluğ Gökhan Ak Tülin Şahin

Abstract

The trial and error method traditionally used in injection molding machines can lead to losses in terms of time and cost for the determination of process parameters. This method cannot guarantee an optimum result. Therefore, computer-aided engineering software for plastic flow analysis has become an important tool for optimizing injection molding processes. This software helps to optimize the process parameters used in the production of plastic parts through the simulation of plastic flow. Simulation consists of a series of steps, starting from the design of the plastic part, through the design of the injection mold, material selection, determination of process parameters and finally validation of the production process. In this way, all parameters are optimized before production, making the injection molding process efficient and cost-effective.

The use of plastic flow analysis software improves the performance of injection molding machines and reduces the number of defective products. This means that the production process produces less waste and production time is reduced. Furthermore, this software can be used to quickly analyze the effects of changes in product design and mold design on the injection molding process. As a result, computer-aided engineering software that performs plastic flow analysis enables the optimization of injection molding processes in a faster, more accurate and cost-effective way instead of the trial-and-error method in injection molding machines.

In this study, the moldability characteristics of different gate concepts, injection filling points and gate diameters affecting the production parameters of water bottle handles produced by plastic injection molding method were investigated. Based on the production values obtained, appropriate choices were made for the handling performance of water bottles. The handle is made of High Density Polyethylene (HDPE) material to facilitate the transportation of water bottles. By determining the optimum values of parameters such as melting temperature, molding temperature, injection time, holding pressure, holding time, cooling time of the material, the results of Filling time, Filling Pressure Analysis, Temperature Analysis, Frozen Layer Analysis and Joint Line Analysis were obtained by using the Moldflow program on 3D models of bottle handles. As a result of these analyses, the best gate concept and gate diameter for the best gate filling zone were determined and evaluated in terms of usage performance and manufacturability.

As a result of the analysis for the same process parameters, the optimum production parameters were reduced to the final two by considering the optimum parameters in breaking force and molding. Although the first design has the highest breaking force, it is not suitable for mass production due to the weight increase of 12.1%. It was concluded that the second design should be approved as it provided a 44.4% increase in breaking force while the handle weight increased by 2.1%.

Keywords

Injection molding Moldability analysis Injection fill point analysis Plastic flow analysis Gate System

References

  • [1] Zhao, N.-Y. Lian, J.-Y., Wang, P.-F., & Xu, Z.-B. (2022). Recent progress in minimizing the warpage and shrinkage deformations by the optimization of process parameters in plastic injection molding: a review. The International Journal of Advanced Manufacturing Technology, 120, 85−101. [CrossRef]
  • [2] Gürün H, Özdemir A, Acar T. (2009). Computer aided design of the cooling system for plastic injection molds. Pamukkale Üniversitesi, Mühendislik Bilimleri Dergisi, 15(2), 263−268.
  • [3] Shoemaker, J. (2006). Moldflow Design Guide (1th ed). Carl Hanser Verlag. [CrossRef]
  • [4] Beaumont, J. P. (2019). Runner and gating design handbook. Carl Hanser Verlag. [CrossRef]
  • [5] Uluer, O. (2008). Enjeksiyonla kalıplamada işleme parametrelerinin katılaşmış katman oluşumuna etkisi. Gazi Üniversitesi Mühendislik Mimarlık Fakültesi Dergisi, 23(1), 249−255.
  • [6] Rambhau, I. A., Ashwinkumar, J. S., & Rajendra, P., Kulkarni Nikhil Narayan and B.D. Patil, (2016). Design and Analysis of Cover Handle Bar Top (Injection moulding process). International Journal of Current Engineering and Technology, Suppl 4, 291−295.
  • [7] Beaumont, J. P. (2004). Runner and gating design handbook: tools for successful injection molding. Hanser.
  • [8] Chu, H., Liu, Z., Zhang, C., Liu, Z., Zhao, Y., & Yang, C. (2022). Decision‑making for structural parameters of injection mold gating system based on agent model and intelligent algorithm. The International Journal of Advanced Manufacturing Technology, 119, 7599−7614. [CrossRef]
  • [9] Nuruzzaman, D. M., Kusaseh, N., Basri, S., Oumer, A. N., & Hamedon, Z. (2016). Modeling and flow analysis of pure nylon polymer for injection molding process. Materials Science and Engineering 114, Article 012043. [CrossRef]
  • [10] Sedighi, R., Maiabadi, S. M., & Sedighi, M. (2017). Optimisation of gate location based on weld line in plastic injection moulding using computer-aided engineering, artificial neural network, and genetic algorithm. International Journal of Automotive and Mechanical Engineering, 14(3), 4419−4444. [CrossRef]
  • [11] Wong, C. T., Sulaiman, S., Ismail, N., & Hamouda, A. M. S. (2004). Design and simulation of plastic injection moulding process. Pertanika Journal of Science & Technology Supplement 12(2), 85−99.
  • [12] Mircheski, I., Lukaszewicz, A., & Szczebiot, R. (2019). Injection process design for manufacturing of bicycle plastic bottle holder using CAx tools. Procedia Manufacturing, 32, 68−73. [CrossRef]
  • [13] Ravikiran, B., Pradhan, D. K., Jeet, S., Bagal, D. K., Barua, A., & Nayak, S, (2021). Parametric optimization of plastic injection moulding for FMCG polymer moulding (PMMA) using hybrid Taguchi-WASPAS-Ant Lion optimization algorithm. Materials Today, 56(5), 2411−2420. [CrossRef]
  • [14] Zhai, M., Lam, Y. C., Au, C. K., & Liu D. S. (2005). Automated selection of gate location for plastic injection molding processing. Polymer-Plastics Technology and Engineering, 44, 229−242. [CrossRef]
  • [15] Pandelidis, Q., & Zou, I. (1990). Optimization of injection molding design. Part I: Gate location optimization. Polymer Engineering and Science, 30(75), 873−882. [CrossRef]
  • [16] Pandelidis, Q., & Zou, I. (1990). Optimization of injection molding design. Part II: Molding conditions optimization. Polymer Engineering and Science, 30(75), 883−892. [CrossRef]
  • [17] Zhao, Z., Liao, L., Tang, F., & Liu, B. (2010). Moldflow software in a complex plastic shell injection mold design. Applied Mechanics and Materials, 29-32, 646−650. [CrossRef]
  • [18] Menga, L., Wangb, Z., Liuc, D., & Haod, W. (2011). Optimal design of plastic injection mould gating system. Advanced Materials Research, 189-193, 2371−2375. [CrossRef]
  • [19] Yan, D., & Han, J. (2012). Improving design of cricoid plastic gating system based on moldflow. Advanced Materials Research, 472-475, 2264−2269. [CrossRef]
  • [20] Altan, M. (2010). Reducing shrinkage in injection moldings via the Taguchi, ANOVA and neural”network methods. Materials and Design 31, 599−604. [CrossRef]
  • [21] Zhai, M., Lam, Y., Au, C. (2009). Gate location optimization scheme for plastic injection molding. e-Polymers, 9(1), Article 1515. [CrossRef]
  • [22] Sedighi, R., Saleh Meiabadi, M., & Sedighi, M. (2017). Optimisation of gate location based on weld line in plastic injection moulding using computer-aided engineering, artificial neural network, and genetic algorithm. International Journal of Automotive and Mechanical Engineering, 14(3), 4419−443. [CrossRef]
  • [23] Kapila, A., Singh, K., Arora, G., & Agarwal, N. (2015). Effect of varying gate size on the air traps in injection molding. International Journal of Current Engineering and Technology, Vol. 5(1), 161−166.
  • [24] Thongkaew, K., & Naemsai, T. (2020). Mechanical properties and cost-minimized design of 6-liter PET bottle using finite element method. Walailak Journol of Science and Technology, 17(6), 579−587. [CrossRef]
  • [25] Moayyedian, M. (2017). Intelligent optimization of mold design and process parameters in injection molding. Springer.
There are 25 citations in total.

Details

Primary Language English
Subjects Mechanical Engineering, Manufacturing and Industrial Engineering
Journal Section Research Articles
Authors

Emre Koşar 0000-0003-4293-0575

Gürer Kutluğ 0000-0002-0903-7657

Gökhan Ak 0000-0002-8174-361X

Tülin Şahin 0000-0001-7676-2093

Publication Date July 24, 2023
Published in Issue Year 2023 Volume: 4 Issue: 1

Cite

APA Koşar, E., Kutluğ, G., Ak, G., Şahin, T. (2023). Effect of bottle handle design on injection molding production parameters and usage performance. Journal of Advances in Manufacturing Engineering, 4(1), 12-24.
AMA Koşar E, Kutluğ G, Ak G, Şahin T. Effect of bottle handle design on injection molding production parameters and usage performance. J Adv Manuf Eng. July 2023;4(1):12-24.
Chicago Koşar, Emre, Gürer Kutluğ, Gökhan Ak, and Tülin Şahin. “Effect of Bottle Handle Design on Injection Molding Production Parameters and Usage Performance”. Journal of Advances in Manufacturing Engineering 4, no. 1 (July 2023): 12-24.
EndNote Koşar E, Kutluğ G, Ak G, Şahin T (July 1, 2023) Effect of bottle handle design on injection molding production parameters and usage performance. Journal of Advances in Manufacturing Engineering 4 1 12–24.
IEEE E. Koşar, G. Kutluğ, G. Ak, and T. Şahin, “Effect of bottle handle design on injection molding production parameters and usage performance”, J Adv Manuf Eng, vol. 4, no. 1, pp. 12–24, 2023.
ISNAD Koşar, Emre et al. “Effect of Bottle Handle Design on Injection Molding Production Parameters and Usage Performance”. Journal of Advances in Manufacturing Engineering 4/1 (July 2023), 12-24.
JAMA Koşar E, Kutluğ G, Ak G, Şahin T. Effect of bottle handle design on injection molding production parameters and usage performance. J Adv Manuf Eng. 2023;4:12–24.
MLA Koşar, Emre et al. “Effect of Bottle Handle Design on Injection Molding Production Parameters and Usage Performance”. Journal of Advances in Manufacturing Engineering, vol. 4, no. 1, 2023, pp. 12-24.
Vancouver Koşar E, Kutluğ G, Ak G, Şahin T. Effect of bottle handle design on injection molding production parameters and usage performance. J Adv Manuf Eng. 2023;4(1):12-24.
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