Optimization Of Wall Bracket Process Parameters Using the Taguchi Method for Sink Mark Defect

Abstract

Injection Molding is a widely used process for producing plastic products. In the design of injection-molded products, determining the ideal process parameters is a crucial task, as it affects product quality, production rate, production cost, and energy consumption. Achieving optimal process conditions and mold design is the key challenge to enhancing product quality. Sink marks are one of several significant defects in injection-molded parts. This paper combines numerical simulation with the Taguchi design-of-experiment (DOE) technique to assess the impact of process conditions and cavity geometry on sink marks in injection-molded parts and to optimize process conditions and cavity design. The simulation process parameters considered in this study, in addition to melting temperature and injection pressure, are detailed. During the research, polypropylene was injected into a wall bracket product under various processing conditions. Moldflow software simulated the injection process to examine the effect of process parameters on sink mark deflection in the wall bracket. The Taguchi orthogonal arrays and signal-to-noise ratio were utilized to identify the optimal parameter settings and to highlight the influence of the process parameters on sink marks. The most significant parameter identified was the melt temperature for the design.