Optimization of injection molding parameters for thermoplastic composter bottom

• Main Authors: Tujmer, Mislav, Pilipović, Ana, Godec, Damir
• Format: Conference Proceeding
• Language: English
• Subjects: Air flow; Composting; Cooling systems; Defects; Design of experiments; Design optimization; Injection molding; Injection molding machines; Melt temperature; Molding parameters; Optimization techniques; Organic matter; Parameter identification; Parameter sensitivity; Process parameters; Product design; Product quality; Shrinkage; Temperature; Warpage
• ISSN: 0094-243X; 1551-7616
• DOI: 10.1063/5.0206924

Decomposition of organic matter is sensitive to air flow, humidity and temperature, thus appropriate conditions are needed for effective composting which are achieved through a correct composter design. The paper focuses on a simulation analysis for the injection molding process of the bottom part of a composter. Contemporary injection molding machines require fine tuning to ensure successful mold filling and the attainment of satisfactory product quality. Addressing plastic product design from a manufacturing perspective helps ease challenges related to injection molding process and mold design. Process optimization commonly involves variables such as injection pressure, injection time, packing pressure, packing pressure holding time, melt temperature, mold cavity temperature and features of the cooling system. To ensure consistent product quality, it’s crucial to optimize process parameters for specific cases due to substantial variability among injection molding input parameters. The use of Moldex3D software aids in identifying locations of critical values of defects, such as shrinkage and warpage. Warpage and shrinkage defects are minimized by Design of Experiments (DOE) optimization method. The results show that simulation, combined with optimization techniques, significantly improves product quality and process efficiency. Reducing warpage is achievable by extending the packing pressure time and using a lower coolant temperature. However, while extending the packing pressure time and reducing the melt temperature have a marginal effect on reducing shrinkage, higher cooling temperatures, as predicted, results in diminished shrinkage.