Nozzle Pressure and Clamping Force Based Injection Molding Process Parameter Optimization and Adaptive Process Quality Control

Abstract

The parameter setting will decide the quality of the injection molded product. The quality of injection molded parts may be altered by environment changes, different material batches and improper processing parameter settings etc., resulting in unstable product quality in the long-term production process. This research aims at machine tooling and established a science based standard process parameter setting process for injection molding machine based on the least sensors, so that the production process is stable even without the use of the adaptive process control system. This study define the appropriate velocity to pressure (V/P) switchover point, injection speed and packing pressure according to the characteristics of the nozzle pressure, and define the appropriate clamping force by the peak value of the clamping force. The next step is to combine the sensors with an adaptive process control system to minimize product weight variation and stabilize product quality. Finally, experiments were carried out with different materials to verify the effectiveness of the system and to be suitable for different machines, and to prove the feasibility of industrialization.