Robust Multi-Response Optimization of Productivity and Product Quality in Injection Molding using Taguchi Grey Technique

Abstract

Abstract There is a popular use and demand of plastic products worldwide. Therefore, their quality and production rate ought to be high. Injection molding has gained populace in the manufacture of plastics because it is economical, repeatable and can manufacture complex shaped products. However, straight cooling channels characterize most injection mold tools which leads to slow and non-uniform cooling consequently resulting in low production rate and defective products. This study deals with optimization of circular cross-section conformal cooling channel design. Design of experiments is based on Taguchi method with the variable design factors being diameter, depth and pitch. Solidworks is used for 3D design, numerical simulation is conducted using Solidworks Plastics and grey relational analysis is used for multi-response optimization. Grey relational grade results showed that the optimal design was characterized by a minimum diameter (D), depth and pitch of 8 mm, 1.5 D and 2 D respectively. Analysis of variance (ANOVA) findings depicted the diameter as the only and most significant factor that contributed to all the responses concurrently. The performance of all CCC designs were superior to that of SCC. Overall, Grey relational analysis sufficed multi-response optimization in injection molding process through CCC design. The methodology adopted can be used to optimize the designs of injection mold tool components for efficiency in the production process.