Achieving energy savings and process optimization in plastic injection molding: A design of experiments study

IF 9.7 1区 环境科学与生态学 Q1 ENGINEERING, ENVIRONMENTAL
Haytem Moussaoui
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Abstract

The plastic injection molding process is essential for rapidly producing intricate plastic parts, yet optimizing its energy efficiency without compromising quality remains a challenge. This paper uses the Plackett-Burman method to investigate parameter interactions and identify optimal settings to minimize energy consumption while maintaining quality with the 750-ton hydraulic injection molding machine. Analysis of variance statistically evaluates parameter impacts. Specific energy consumption and cycle time are chosen as response variables, with eight parameters as factors. Results show screw rotation speed significantly impacts Specific energy consumption (84.18%) and mold closing movement affects cycle time (29.27%). The model explains 94.2% of Specific energy consumption variability and 99.34% of cycle time variability. Specifically, the study found that with an optimal configuration of the parameters, the system achieves an average specific energy consumption of 21.7477 kWh/kg and an average cycle time of 38.174 s. Pareto analysis highlights key factors for optimization, guiding efforts to improve energy efficiency. Interaction analysis reveals factors are largely independent. The prediction profiler offers insights into achieving lower energy consumption and cycle time, aiding cost reduction and process optimization. This study provides valuable insights for enhancing efficiency and sustainability in plastic injection molding. It introduces the novel application of the Plackett-Burman design to optimize energy efficiency in plastic injection molding. These crucial insights address complexity in industrial plastics manufacturing, focusing on key factors impacting energy and cycle time.
在注塑成型中实现节能和工艺优化:实验设计研究
注塑成型工艺对于快速生产复杂的塑料零件至关重要,但如何在不影响质量的前提下优化能效仍是一项挑战。本文使用 Plackett-Burman 方法研究参数之间的相互作用,并确定最佳设置,以便在保持 750 吨液压注塑机质量的同时最大限度地降低能耗。方差分析对参数的影响进行了统计评估。选择特定能耗和周期时间作为响应变量,八个参数作为因子。结果表明,螺杆转速对特定能耗(84.18%)和合模运动对周期时间(29.27%)有明显影响。该模型可解释 94.2% 的比能耗变化和 99.34% 的周期时间变化。具体而言,研究发现,在参数配置最优的情况下,系统的平均比能耗为 21.7477 千瓦时/公斤,平均周期时间为 38.174 秒。帕累托分析突出了优化的关键因素,为提高能效提供了指导。交互分析显示,各因素在很大程度上是独立的。预测剖析器为实现更低的能耗和周期时间提供了见解,有助于降低成本和优化流程。这项研究为提高注塑成型的效率和可持续性提供了宝贵的见解。它介绍了 Plackett-Burman 设计在优化注塑成型能效方面的新应用。这些重要见解解决了工业塑料制造的复杂性,重点关注影响能源和周期时间的关键因素。
本文章由计算机程序翻译,如有差异,请以英文原文为准。
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来源期刊
Journal of Cleaner Production
Journal of Cleaner Production 环境科学-工程:环境
CiteScore
20.40
自引率
9.00%
发文量
4720
审稿时长
111 days
期刊介绍: The Journal of Cleaner Production is an international, transdisciplinary journal that addresses and discusses theoretical and practical Cleaner Production, Environmental, and Sustainability issues. It aims to help societies become more sustainable by focusing on the concept of 'Cleaner Production', which aims at preventing waste production and increasing efficiencies in energy, water, resources, and human capital use. The journal serves as a platform for corporations, governments, education institutions, regions, and societies to engage in discussions and research related to Cleaner Production, environmental, and sustainability practices.
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