Optimization of Resin Molding Process by Functional Evaluation Method Focusing on Melting Energy Related to Resin Filling Characteristics
In recent years, along with the increasing demand for plastic products and the deepening of academics, mass production, weight reduction, and higher precision are progressing. In the field of design development and production technology, there is an increasing need for analysis technology related to resin flow and behavior in order to solve problems related to quality assurance such as molding defects and product strength. Especially in the resin molding process, it is an important issue to create a quality function that applies the analysis of complex multidimensional information because of the high degree of freedom in product shape and mold structure. In order to solve the quality issues regarding the strength and dimensional stability of resin materials, it is effective to apply the “Functionality Evaluation Method” in robust design which is an analytical evaluation method. In this study, we focus on the function of managing the resin filling density in the mold (the input/output relationship of the melting energy related to the resin filling characteristics) for the optimization of resin strength and dimensional stability. We propose a functional evaluation method with the ideal function of stabilizing the resin filling density based on the original definition of material mechanics. As a result of verification of the proposed method, it was clarified that it is extremely important to make the resin filling density in the mold uniform to stabilize the strength of the resin injection molded product.
Taguchi G. and Yano H., “Quality Engineering Application Course “Technology Development of Machinery, Materials and Processing”, Japanese Standards Association, pp.57- 89, 2001.
Taguchi G., “Quality Engineering Response Course (5) Quality Engineering Cases”, General Edition for Japan, Japan Standards Association, pp.25-100, 1992.
Iwano M., “Development of plastics for automobile parts”, Nippon Kogyo Publishing, pp.57-80, 2011.
Taguchi G., “Experimental Design and Quality Engineering”, Journal of Quality Engineering, Vol.2, No.1, pp.2-8, 1993.
Taguchi G., “Quality Engineering Course (1) “Quality Engineering at Development and Design Stage”, Japan Standards Association, pp.34-68, 1988.
Sugiyama A., “Reexamination of shape retention in injection molding”, Proceedings of 10th Quality Engineering Research Conference, pp.18-21, 2002.
Masuda Y., “Optimization of processing conditions in press punching”, Journal of Quality Engineering, Vol.12, No.1, pp.97-104, 2004.
Hatakeyama T., Ishimaru S. and Yasuda M., “Utilization of quality engineering in semiconductor manufacturing process (1)-Method of company-wide development”, Journal of Quality Engineering, Vol.12, No.6, pp.66-72, 2004.
Tsuneda S. and Shimizu H., “Study on production process design method of injection molding-From parameter design of plasticizer to analysis by MT system”, Journal of Quality Engineering, Vol.19, No.1, pp.44-51, 2011.
Tsuneda S., “Optimization of material drop shape in injection molding machine”, Journal of Quality Engineering, Vol.15, No.5, pp.174-180, 2007.
Tsuneda S., “Optimization of injection molding machine conditions for bar flow molds”, Journal of Quality Engineering, Vol.16, No.4, pp.53-57, 2008.
Takahashi K., “Optimization of plasticizing equipment for injection molding machines”, Journal of Quality Engineering, Vol.13, No.2, pp.53-59, 2005.
Suzuki, M., “Quality engineering not difficult”, Nikkan Kogyo Shimbun, pp.34-48, 2016.
Yano, H., “Introduction to Quality Engineering Calculation Method”, Japan Standards Association, pp.74-137. 2002.
Koshimizu S and Suzuki M., “Practical Quality Engineering”, Nikkan Kogyo Shimbun, pp.3-56, 2007.
Hirose K. and Ueda T., “Introduction to Taguchi Method Analysis”, Doyukan, pp.1-24, 2015.
Yano, H., “Introduction to Quality Engineering Calculation Method”, Japan Standards Association, pp.74-137, 2002.
Sugiyama A, Hori N. and Yano H., “Transferability and bending of injection molded products Of Injection Molding Machine and Molding Conditions by Surge Test”, Journal of quality engineering, Vol.9, No.1, pp.22-30, 2001.
Koshimizu S and Suzuki M., “Practiceandqualityengineer- ing acquired by virtual experiments”, Nikkan Kogyo Shim- bun, pp.45-68. 2007.
Taguchi G., “Experimental design and quality engineering”, Journal of quality engineering, Vol.2, No.1, pp.2-8, 1993.
Tsuruta H., “Energetic S/N ratio”, Nikka Giren, pp.17-72, 2016.
Sakurai M. et al., “Evaluation of uniform filling property of injection molded products by MT system”, Lecture summary at Nihon University College of Industrial Science, pp.9-12, 2007.
Morita H. and Matsuda J., “Advanced research on ceramics injection molding technology-Optimization of injection conditions for ribbed molded products by quality engineering”, Kagoshima Industrial Technology Center Research Report, No.7, pp.29-35, 1993.
Toma E., “Analytical research on resin injection molding process applying “Quality Engineering”, The 4th Inter- national Conference on Manufacturing Process Technology 2017 (ICMPT-4 2017), August 24-27, 2017.
Copyright (c) 2020 EIJI TOMA, Hiroshi TANAKA
This work is licensed under a Creative Commons Attribution 4.0 International License.
Authors who publish with this journal agree to the following terms:
- Authors retain copyright and grant the journal right of first publication with the work simultaneously licensed under a Creative Commons Attribution License that allows others to share the work with an acknowledgement of the work's authorship and initial publication in this journal.
- Authors are able to enter into separate, additional contractual arrangements for the non-exclusive distribution of the journal's published version of the work (e.g., post it to an institutional repository or publish it in a book), with an acknowledgement of its initial publication in this journal.
- Authors are permitted and encouraged to post their work online (e.g., in institutional repositories or on their website) prior to and during the submission process, as it can lead to productive exchanges, as well as earlier and greater citation of published work (See The Effect of Open Access).