Documentos de Académico
Documentos de Profesional
Documentos de Cultura
Jesse Columbus
Larry Lake
Steve Lish
Section(Tuesday, 1p.m.)
Lab Group #6
_________________________,_________________________,_____________________
___
Abstract:
The following report will convey information five different factors of plastic injections
molding and how they affect the final part weight. The five independent variables include
barrel temperature, nozzle temperature, dwell time, injection pressure, and flow rate. This
independent variable will or may have an effect on the final part weight which is the
dependent variable. By using a half factorial in this experiment and 3 replications for each
factor studied can help conclude which factors have the most affect. The resulting data
from this experiment was used in conjunction with Design Experiment to look at what
factors and interactions cause the biggest.
Table of Contents
Abstracts..
.2
Table of
Contents.3
Introduction.........
.4
Theory...
4
Experimental
Procedure....5-6
Discussion
.7-8
Table A
(ANOVA)....10
Graph A (Barrel
temp)......11
Graph B (Nozzle
temp)..11
Graph C (Dwell
time)....12
Graph D (Injection
pressure).....12
Graph E (Flow
rate)...13
Conclusion..
.13
Appendices
.....14
Work
Cited..15
Introduction:
This lab takes a look at a half factorial experiment on plastic injection molding and how
independent variables affect the dependent variables. These independent variables include
Barrel Temperature, Nozzle Temperature, Dwell Time, Injection Pressure, and Flow Rate.
This independent variable will be tested to see what affects they have on the final part
weight (dependent variable). The range of the half factorial and 3 replication will help give
a broad range of data to further understand what affects have the most impact on the final
outcome.
Theory:
The first plastic injection molding machine was introduced in 1872 by John Wesley Hyatt
and his brother Isaiah. When World War II hit in the 1940's the industry boomed and mass
production plastic injection came about. Today's industry supplies a wide variety of
injection plastics ranging from bottle caps to automotive dash boards and hair combs.
Plastic injection can be very cost efficient to run with high production rates, high tolerance
repeatability, low scrap and little finishing needed. Most injected polymers are either
thermoplastics, thermosets or some elastomers. They range in a wide variety of alloys and
blends from epoxy, phenolic, nylon, polyethylene, and polystyrene.
The plastic injection machine consists of a heating and injecting unit to make the plastic
injection. A heated barrel with a screw type feeder or ram feeds the material into the
machine to be heated before injection. By means of pressure and the ram the material is
fed into the heater to melt the plastic pellets. With more pressure and force of the ram the
plastic flows into the nozzle as a liquid and into the mold where it fills the mold and cools
until it is hardened. The mold is place near the nozzle of the plastic injection machine and
clamped into place with a large force to keep the mold firmly in place during injection.
This helps to reduce flash from the mold. After cooling the part can be ejected from the
mold and the sprue can be moved as well.
Many factors play into the final outcome of the injected plastic part. Temperature of the
barrel and nozzle play a vital role in how viscous the plastic is when it is being injected.
Pressure and flow rate aid in the injection rate and flow, too high and jetting can occur
from turbulence in the flow. Flow marks can also occur is the speed is to slow for
injecting. Mold design is critical to make sure that the mold fills with material and that it
can be ejected from the mold. Draft angles and fillets or chamfers can help reduce voids in
molds and help with ejection from the mold.
Experimental Procedure:
Variables: By varying the independent variables stated down below will conclude the
interactions between them and show if there is significant cause of that variable. Also
interactions of combinations of variables will be taken into account as well.
Equipment Used:
1. Safety Goggles
2. Plastic Injection Machine
3. Air Compressor
4. Injections Die Molds
5. Polyethylene
6. Gloves
7. Cutting Snips
8. Weight Scale
Procedure:
Preliminary:
1) Turn on the plastic injection machine and let it warm up to proper operating
temperature.
2) Put clean Die Mold into alignment bolts.
3) make sure the table clamp holds the mold securely. Clamp should click into place
insuring proper mold clamping. (between 7 and 10 Tons) if necessary use allen
wrench to adjust clamp pressure.
4) Check to following:
a) Barrel Temperature
b) Nozzle Temperature
c) Tooling Temperature
d) Clamp Pressure
e) Injection Pressure
f) Flow Rate
5) Injection pressure control is controlled by a T screw at air line.
6) Flow rate is controlled in the back by turning the adjustment knob.
7) Double check all settings before continuing.
Injection Procedure:
Discussion:
Questions:
1. From the ANOVA table that was produced from the collected data of the
experiment it was observed that the flow rate and the injection pressure were the most
impacting factors on the outcome. This conclusion can be made by comparing the F value
of those two factors to the corresponding F critical values. For the injection pressure, it
had an F value of 121.93 and an F critical of less than 0.0001, which makes it very
significant. The F value for the flow rate was 129.74 with an F critical value of less than
0.0001, which also makes this parameter the most significant. The other parameters for
this experiment also had an impact on the final result but none of them were as significant
as the flow rate and the injection pressure. The next most significant factor was the dwell
time, having an F value of 8.53 and an F critical value of 0.0056. the least critical factor in
this process turned out to be the nozzle temperature. It had an F value of 2.10 and an F
critical value of 0.1544.
Another thing that will prove that the two most impacting factors were the injection
pressure and the flow rate is the sum of squares that was calculated in the ANOVA table.
The sum of squares describes the variance of the factors of the process. The sum of
squares for the injection pressure is .68 which indicates that it has a great effect on the
outcome of the product. The sum of squares for the flow rate is .72 which is greater than
the sum of squares value for the injection pressure. Therefore making this the factor that
impacts the part the most. The sum of squares value for the least impacting factor is for the
nozzle temp which had a value of 0.012.
Injection pressure and the flow rate had the most impact because they determined how
much material was being put into the mold for the given time that the injection process
was to last. Once the material was melted, the pressure that it was forced into the mold.
The flow rate, which we judged by the number of turns of the knob on the injection
molding machine (1/2 or 2 turns), was the second most impacting factor. That is because
the more turns on the flow rate of the machine, the more material would be allowed to be
injected into the mold. This factor also is impacted by the time of the injection and the
pressure at which the injection occurs.
The observed error in this data could be described by the Residual sum of squares.
This describes the value of the extra/ unneeded material/ variance in the data from the
predicted values. The residual sum of squares for the data that we calculated was 0.23,
which is not very high, which indicates that our values were fairly close to the predicted/
expected values for this experiment. Another thing that would indicate that we have an
error in our data is the R2 value that the program calculated for a fitted line for our data. It
had a value of 0.8635 which is indicates that our data has a fairly linear relationship, but
also indicates that our data has error in it as well.
Polyethylene is a synthetic fiber used in making various products like beverage and
containers. It is a good barrier against gas, moisture, alcohol, and solvents. The chemical
composition for polyethylene is (C10H8O4) and is a thermoplastic. Has a crystalline density
of 1.455 g/cm3, a tensile strength of 55-75 MPa, a Youngs Modulus (E) of 2800-3100
MPa, and a melting temperature of 260oC. It is strong and impact resistant. It has a semi-
crystalline structure and is transparent or opaque depending on the structure and particle
size. Polyethylene is commonly referred to as polyester for packaging materials. Before
the material can be processed it must be dried to bring down its moisture content as far as
possible. Polyethylene can be formed through plastic molding injection or blow molding.
After a product has reached its end of life cycle the polyethylene can be recycled back into
the system and used again once it has been process and chipped back up to be used again
in molding.
fiber and plastic molds. PP is commonly used for Tupperware due to its higher melting
point, whic
h allows it to heat foods without melting. It is also highly resistive to fatigue and
stress, allowing it to be used in high wear application. Its main weakness is degradation
due to UV radiation.
The Model F-value of 53.14 implies the model is significant. There is only
a 0.01% chance that a "Model F-Value" this large could occur due to noise.
Values of "Prob > F" less than 0.0500 indicate model terms are significant.
In this case C, D, E are significant model terms.
Values greater than 0.1000 indicate the model terms are not significant.
If there are many insignificant model terms (not counting those required to support
hierarchy),
model reduction may improve your model.
The "Lack of Fit F-value" of 17.99 implies the Lack of Fit is significant. There is only a
0.01% chance that a "Lack of Fit F-value" this large could occur due to noise.
Significant lack of fit is bad -- we want the model to fit.
X = A: Barrel Temp
Actual Factors
B: Nozzle Temp = Average 1.8225
The graph at the left shows the
C: Dwell Time = Average
D: Injection Pressure = Average
E: Flow Rate = Average effect the Barrel temp has on the
Part weight
1.665
375 400
the
can final weight
see that of the the
the hotter partbarrel
when
A: Barrel Temp all
wasother factorsthe
the lighter arepart
left became
at their
basic levels.
although For this setup you
minimal.
DESIGN-EXPERT Plot One Factor Plot can see that the hotter the
Part weight 1.98
Actual Factors
became although minimal.
1.8225
A: Barrel Temp = Average
C: Dwell Time = Average
D: Injection Pressure = Average
E: Flow Rate = Average
Part weight
1.665
1.5075
1.35
400 425
B: Nozzle Temp
1.35
2500 3000
D: Injection Pressure
DESIGN-EXPERT Plot One Factor Plot The graph at the left shows the effect
Part weight 1.98 the Injection Pressure has on the final
X = C: Dwell Time weight of the part when the all the
Actual Factors
other factors are left at their basic
1.8225
A: Barrel Temp = Average levels. For this setup you can see that
B: Nozzle Temp = Average
D: Injection Pressure = Average as injection pressure increased the
E: Flow Rate = Average
part became heavier. This is one of
Part weight
1.665
1.35
5 10
C: Dwell Time
DESIGN-EXPERT Plot One Factor Plot The graph at the left shows the
Part weight 1.98 effect the Flow Rate has on the
X = E: Flow Rate
final weight of the part when the
all the other factors are left at
Actual Factors
A: Barrel Temp = Average 1.8225 their basic levels. For this setup
B: Nozzle Temp = Average
C: Dwell Time = Average
you can see that as the flow rate
D: Injection Pressure = Average
Part weight
increased from one half to two
1.665
turns the part weight drastically
increased. This factor is the
other factor that has a significant
1.5075
effect on the final weight of the
part.
1.35
1/2 2
E: Flow Rate
Conclusion
In conclusion this lab was useful in exploring and understanding how different control
factors have different effects on a desired characteristic for a part. Through the use of
design expert it was shown how some control variables have a strong effect on a specified
characteristic, while others have little to no effect. Through design expert it was found that
the variables affecting the final weight of the plastic mold injected part the most, were
pressure and flow weight. Each of these factors had a larger impact than the nozzle
temperature, barrel temperature and dwell time combined. Even though this experiment
was a half factorial, a lot of useful data was collected about the different factors and how
they interact with each other. Factors A (Barrel Temp.), B (Nozzle Temp.), C (Dwell
Time) had almost no affect on the parts final weight. Factors D (Injection Pressure), E
(Flow Rate) had a major effect on the final part weight. This was shown by the sum of
squares factor in the ANOVA table. The ANOVA tables were very helpful in showing the
interactions and affects of the different factors on the part weight.
Appendix
Work Cited
"Injection molding - Wikipedia, the free encyclopedia." Main Page - Wikipedia, the free
encyclopedia. N.p., n.d. Web. 20 Apr. 2010.
<http://en.wikipedia.org/wiki/Injection_molding>.
"Plastic Injection Molding Company ." CNC Machine Shop | Custom Waterjet, Plasma,
Laser Cutting | eMachineShop.com . N.p., n.d. Web. 20 Apr. 2010.
<http://www.emachineshop.com/machine-shop/Plastic-Injection-Molding/page80.html>.