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optimization and Simulation of Plastic Injection Process using genetic algorithm and Moldflow

Chinese Journal of Mechanical Engineering 2017年第2期30卷 398-406页

作者： Sigit Yoewono Martowibowo Agung Kaswadi Faculty of Mechanical and Aerospace Engineering Institut Teknologi BandungBandung 40132Indonesia Politeknik Manufaktur Astra Jakarta 14330Indonesia

The use of plastic-based products is continuously increasing. The increasing demands for thinner products, lower production costs, yet higher product quality has triggered an increase in the number of research projects on plastic molding processes. An important branch of such research is focused on mold cooling system. Conventional cooling systems are most widely used because they are easy to make by using conventional machining processes. However, the non-uniform cooling processes are considered as one of their weaknesses. Apart from the conven- tional systems, there are also conformal cooling systems that are designed for faster and more uniform plastic mold cooling. In this study, the conformal cooling system is applied for the production of bowl-shaped product made of PP AZ564. optimization is conducted to initiate machine setup parameters, namely, the melting temperature, injection pressure, holding pressure and holding time. The genetic algorithm method and Moldflow were used to optimize the injection process parameters at a minimum cycle time. It is found that, an optimum injection molding processes could be obtained by setting the parameters to the following values： TM=180℃; Pinj = 20MPa; Phold= 16MPa and thold=8s, with a cycle time of 14.11 s. Experiments using the conformal cooling system yielded an average cycle time of 14.19 s. The studied conformal cooling system yielded a volumetric shrinkage of 5.61% and the wall shear stress was found at 0.17 MPa. The difference between the cycle time obtained through simulations and experiments using the conformal cooling system was insignificant （below 1%）. Thus, combining process parameters optimization and simulations by using genetic algorithm method with Moldflow can be considered as valid.

关键词： Conformal cooling parameters optimization genetic algorithm Moldflow Cycle time

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