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The injection molding of plastic parts consists of a series of events that include mold closing, injection of molten plastics into closed mold, cooling of molten plastics, mold opening, and ejecting of molded parts. Of these events, the cooling process comprise 75% of the injection molding cycle time. Consequently, identifying the material and processing variables and/or their interactions that significantly influence the cooling process is of utmost importance in understanding and optimizing the cooling process and in preventing part warpage. Many studies have investigated different aspects of the cooling process in injection molding including the role of the thermal diffusivities of the materials being processed. These studies have examined the role of thermal diffusivity by incorporating it into equations for estimating cooling times. Thermal diffusivity measures how fast thermal energy travels through materials and thus affects the rate of thermal energy (heat transfer) removal during the cooling process. It appears that the thermal diffusivity of a plastic plays a crucial role in the cooling process given that the ratio of the thermal diffusivities of the materials generally involved in the cooling process, plastics, coolant (water), and steel is 1:1.6:50 (plastics:water:steel). This implies that thermal diffusivity of plastics may be the controlling or limiting variable in the cooling process. Therefore in this study, by using the design of experiments (DOE), it is expected to examine the roles processing and material variables play in the cooling process, and in plastics part warpage. These variables include plastics thermal diffusivity, coolant flow rates, cooling time, coolant temperature, and injection back pressure. The goals of this study are twofold: firstly, to provide a hands-on platform for students in the MET program to integrate materials covered in a design of experiments course with the topics covered in a plastics course in addressing technical issues that may arise in the injection molding of plastics, and secondly, to provide a framework for a lab in the trouble-shooting of injection molding processing problems using the design of experiments as a vehicle.

Senior Project: Using Design of Experiment (DOE) to Identify Material and Processing Variables that Impact Part Warpage in Injection Molding