Optimisation of Warpage on Plastic Injection Moulding Part Using Response Surface Methodology (RSM)

The warpage is often encountered which occur during injection moulding process of thin shell part depending the process condition. The statistical design of experiment method which are Integrating Finite Element (FE) Analysis, moldflow analysis and response surface methodology (RSM) are the stage of few ways in minimize the warpage values of x,y and z on thin shell plastic parts that were investigated. A battery cover of a remote controller is one of the thin shell plastic part that produced by using injection moulding process. The optimum process condition parameter were determined as to achieve the minimum warpage from being occur. Packing pressure, Cooling time, Melt temperature and Mould temperature are 4 parameters that considered in this study. A two full factorial experimental design was conducted in Design Expert of RSM analysis as to combine all these parameters study. FE analysis result gain from analysis of variance (ANOVA) method was the one of the important process parameters influenced warpage. By using RSM, a predictive response surface model for warpage data will be shown.