Sulaiman Hasan

The Effects of Parameter Settings on Shrinkage and Warpage in Injection Molding through Cadmould 3D-F Simulation and Taguchi Method

This study is focused on the effects of process parameters in plastic injection molding towards shrinkage and warpage problem of High Density Polyethylene (HDPE) specimen. The aim was to identify the main effects of different process parameters on warpage and shrinkage defects via numerical simulation software and experimental validation. Series of simulations were carried out using Cadmould 3D-F in order to utilize the combination of process parameters based on three level of L9 Taguchi orthogonal design. The Signal to Noise (S/N) ratio and the Analysis of Variance (ANOVA) were used to optimize the levels and to point out the impact of the process parameters on warpage and shrinkage. From the results, it showed that the most affected parameter on the warpage and shrinkage is packing time, with the P value of 48.93%, followed by melting temperature with 40.58%. The filling time and packing pressure were not a significant factor because they only contribute 7.30% and 3.19% of P value, respectively.

The Effects of Injection Moulding Processing Parameters and Mould Gate Size towards Weld Line Strength

Plastic moulded parts should have good mechanical properties and free from defects. Tensile behaviour of plastics plays an important role in defining the quality of injection-moulded products. In this study, numerical simulation (Cadmould) was employed to investigate the influence of gate sizes as well as the injection moulding parameters towards the occurrences of weld lines at Acrylonitrile Butadiene Styrene (ABS) specimens. This research begins from the simulation, fabrication of mould, practical injection process and tensile test. The double gates mould was used to present the weld line defects. The result shows that the smaller gate size produces less weld line in plastic parts, which was verified through simulation process. The optimal parameter setting that produced good tensile strength specimens was also validated experimentally in this research

Effect of Thermodynamic Properties on Porosity of Ceramic Membrane Prepared by Phase Inversion

In this present work, the effects of phase inversion ceramic membranes prepared by phase inversion were investigated. Kaolin with 25µm was used as the composition of membrane preparation. The amounts of kaolin investigated were 60g, 70g and 80g respectively while the temperature was conducted assist room temperature and 3°C. Non-solvent additive with 6g distilled water present formation of pore during phase inversion.The effects of phase inversion temperature and kaolin composition on morphology and porosity were investigated in detail. Result of porosity showed that by decreasingphase inversion temperature improve the membrane porosity up to 64%. In addition, the FESEM images explained that membrane morphology obviously change with the effect of temperature during phase inversion process.

Optimising Injection Moulding Parameter Setting in Processing Polypropylene-Clay Composites through Taguchi Method

The main purpose of this research is to optimise the injections moulding parameters in processing of thermoplastics samples made from Polypropylene (PP)-Clay with the fraction of 95% PP and 5% Clay, through Design of Experiment -Taguchi Method. The selection of defects or responses that need to be controlled for these thin layer products were warpage and shrinkage. The parameters that were taken into consideration were packing pressure; melt temperature, screw speed and filling time. In this research, the L934 orthogonal from Taguchi Method was chosen as the experiment setup. According to the results, 170°C of melt temperature, 80% of packing pressure, 70% of screw speed and 3 seconds of filling time gave minimum shrinkage of 3.45%. As for the warpage results, the best parameters combinations are 170°C of melt temperature, 70% of packing pressure, 70% of screw speed and 2 seconds of filling time. The Analysis of Variance for warpage shows that screw speed was the most significant factor with 41.83% contribution. As for shrinkage, the most influential factor was packing pressure with 98.48% contribution. Two factors have been pooled which are screw speed and filling time. Based on these findings, it is concluded that by controlling the optimum parameter setting, the best quality of desired product can be easily achieved and maintain through the in process production.

Finite scheduling of collaborative design and manufacturing activity: a Petri net approach

Purpose – This paper aims to present an approach of utilizing Petri net (PN) to model and schedule collaborative design and manufacturing activities at a cyber manufacturing centre (CMC).Design/methodology/approach – A conceptual PN model consisting of all activities at the CMC is drafted. This model is then simplified to generate a conflict free PN for scheduling analysis purposes. Based on this simplified PN, generalized scheduling algorithms were developed. The algorithms were used in spreadsheets to process and analyze the operation database before finally transforming it into a dynamic finite scheduling sequence in the form of Gantt chart.Findings – The PN is found to be very useful in modelling and analysing the scheduling sequence for a CMC with collaborative activities resembling flow shop with shared resources.Originality/value – The models and methods described in this paper are practical means of utilizing PN in managing the scheduling and manufacturing activities.

Surface roughness and tool wear on cryogenic treated CBN insert on titanium and Inconel 718 alloy steel

Machining of materials by super hard tools like cubic boron nitride (cbn) and poly cubic boron nitride (pcbn) is to reduce tool wear to obtain dimensional accuracy, smooth surface and more number of parts per cutting edge. wear of tools is inevitable due to rubbing action between work material and tool edge. however, the tool wear can be minimized by using super hard tools by enhancing the strength of the cutting inserts. one such process is cryogenic process. this process is used in all materials and cutting inserts which requires wear resistance. the cryogenic process is executed under subzero temperature -186° celsius for longer period of time in a closed chamber which contains liquid nitrogen. in this research, cbn inserts with cryogenically treated was used to turn difficult to cut metals like titanium, inconel 718 etc. the turning parameters used is different cutting speeds, feed rates and depth of cut. in this research, titanium and inconel 718 material were used. the results obtained are surface roughness, flank wear and crater wear. the surface roughness obtained on titanium was lower at high cutting speed compared with inconel 718. the flank wear was low while turning titanium than inconel 718. crater wear is less on inconel 718 than titanium alloy. all the two materials produced saw tooth chips.

Design Selection of In-UVAT Using MATLAB Fuzzy Logic Toolbox

The design of tool holder was a crucial step to make sure the tool holder is enough to handle all forces on turning process. Because of the direct experimental approach is expensive, a few design of innovative ultrasonic vibration assisted tuning (In-UVAT) has proposed. This design has analyzed using finite element simulation to predict feasibility of tool holder displacement and effective stress. SS201 and AISI 1045 materials were used with sharp and ramp corners flexure hinges on design. To decide which one the design is selected was used MATLAB Fuzzy Logic Toolbox. The result shows that AISI 1045 material and which has ramp corner flexure hinge was the best choice to be produced. It has the Eff. Stress Static equal 3, Displacement Static equal 17.5, Eff. Stress Dynamic equal 3, Displacement Dynamic equal 17.5 and Durability Value is 86.4.

Comparison of high temperature oxidation of nanocrystalline FeCr alloy consolidated by spark plasma sintering and hot pressing

The oxidation kinetics and microstructure characteristics of oxide scales thermally grown on the surface of developed FeCr alloy were investigated at 900 °C. The influence of difference sintering technique, i.e. spark plasma sintering and hot pressing, to improve nanostructured alloy performance was studied. The La-implantation was also considered in this study. It was found that the SPS sintered sample showed better performance than the HP sintered sample. Moreover, it also found that a combining of La-implantation and nanostructured alloy was most beneficial. While nanostructured alloy reduced the oxidation rate, the La-implantation increased the Cr2O3 scale conductivity.

The Effect of Parameter Setting towards the Processing of Hinges Test Samples through Cadmould 3D-F Injection Moulding Simulation

The objective of this study is to analyze the main parameter setting in injection moulding that influenced the processing of selected thermoplastics components. The test sample used for this project was a hinge made from Polypropylene (PP). This sample was being utilised to analyse the parameters affecting the quality of plastic products, which were warpage and shrinkage. Computer-Aided Engineering (CAE) was applied through CadMould 3D-F simulation software. The processing parameters such as filling time, melt temperature, wall temperature and cooling time were selected to determine the quality of the product. By adopting Taguchi Method, the orthogonal array, Signal-to-Noise (S/N) ratio and Analysis of Variance (ANOVA) were used to find the optimum levels as well as to indicate the impact of the process parameters on warpage and shrinkage. The verification test was also performed to prove the effectiveness of Taguchi technique after the optimum levels of process parameters. The ANOVA results show that cooling time and wall temperature are found to be the most significant factors for shrinkage and warpage, with the contribution of 66.96% and 56.82% respectively. The verification test with the optimal settings shows that warpage were improved by about 0.4% and shrinkage with 4.2% improvement. These findings are useful for production engineer to determine optimal parameter during performing injection moulding on hinges products.

A Study of Injection Moulding Optimum Parameters to Control Shrinkage and Warpage of Polypropylene-Nanoclay Hinges Samples

Injection moulding is one of the most efficient processes in mass production that can easily attain up to complex geometry product within a very short cycle time. To choose a suitable setting of parameter was very crucial, in controlling the quality of product with regard to their function. The main propose of this research is to optimize the injection moulding parameter for controlling the shrinkage and warpage of thermoplastics sample through practical injection moulding. The additional study for this project is to investigate the effect of nanoclay contents towards the parameter setting. In this experiment, the selected parameters were packing pressure; melt temperature, screw speed and filling time. The material that was selected for this project was a mixture of polypropylene and nanoclay with the addition of polypropylene-grafted-maleic anhydride as the compatibilizer. Three formulations were chosen, which was 0 wt%, 3 wt% and 5 wt% of Nanoclay. Each formulation was added with 15 wt% of compatibilizer. The experiment design for this project shall adopt the L943 Orthogonal Array of Taguchi Method. By using the Signal to Noise Ratio responses, the optimum parameter for each formulation has been obtained. The findings of this experiment shall be useful for future manufacturing process in order to control shrinkage and warpage specifically for products made from polypropylene-nanoclay.