WARPAGE ANALYSIS ON FRONT PANEL HOUSING USING RESPONSE SURFACE METHODOLOGY (RSM)

Abstract

The work reported herein is about a study to establish the best combination of injection moulding parameters in minimising warpage over a front panel housing using a simulation software. The warpage in x and y directions were analysed using Autodesk Moldflow Insight (AMI) software where specifications of injection moulding machine (Nessei NEX 1000) and P20 as a mould material were set in this analysis. On top of that, Acrylonitrile Butadiene Styrene (ABS) was adopted as the plastic material. Four process parameters were taken as variable factors which are mould temperature, melt temperature, packing pressure and packing time. Design Expert 7.0 software was used to optimise warpage obtained from AMI analysis. The mathematical model was obtained from Design of Experiment (DOE) integrated with Response Surface Methodology (RSM) along with Center Composite Design (CCD) method. Results showed that packing pressure and melt temperature is the most significant factor leading to warpage whilst mould temperature and packing time demonstrated the least significant in both directions

Keywords

• Injection moulding
• Response Surface Methodology