Composites Research

The Korean Society for Composite Materials (한국복합재료학회)
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Optimization of an Injection Molding Process for Polycarbonate Car Switch Buttons Using the Taguchi Method

실험계획법에 의한 폴리카보네이트 차량 스위치 버튼의 사출성형공정 최적화

  • Kim, Cheol (Kyungpook National University, Department of Mechanical Engineering) ;
  • Park, Jaewoo (Kyungpook National University, Department of Mechanical Engineering)
  • Received : 2015.07.30
  • Accepted : 2016.02.24
  • Published : 2016.02.29
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Abstract

The quality of polymeric automotive parts depends highly on an injection molding process, which causes various defects, such as warpage, sink marks, weld lines, shrinkage, residual stress, etc. This study is to determine the optimum processing parameters, such as packing pressure, mold temperature, melting temperature, and packing time for the manufacture of polycarbonate buttons in cars on the basis of FEM, the Taguchi method, and analysis of variance (ANOVA). As a result, the optimum processing parameters of buttons made of polycarbonate material were obtained as follows: 140 MPa of packing pressure, $105^{\circ}C$ of mold temperature, $292.5^{\circ}C$ of melting temperature and 1 second of packing time. A gain of S/N (signal to noise) ratio, 10.2, was obtained with the optimum values. Moreover, the melting temperature was found to be the most significant factor followed by the mold temperature.

고분자 재료로 된 자동차부품들은 주로 사출성형으로 제작되며, 이 과정에서 뒤틀림, 침전 흔적, 용입선, 수축, 잔류응력 등의 결함이 발생한다. 본 연구를 통해서 이들 결함을 제거할 수 있는 차량용 폴리카보네이트 버튼의 사출성형 공정변수를 실험계획법을 이용하여 최적화 하였다. 공정변수로는 충전압력, 금형온도, 용융온도, 충전시간을 고려했으며 FEM, 다구치법, ANOVA를 사용하여 해석하고 최적화 하였다. 최적화 결과, 충전압력은 140 MPa, 금형온도는 $105^{\circ}C$, 용융온도는 $292.5^{\circ}C$, 충전시간은 1초, 등의 공정변수 값을 얻었으며, 10.2의 S/N 비를 얻었다. 수지의 용융온도가 가장 큰 영향을 미치며, 그 다음으로 금형의 온도였다.

Keywords

References

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