Nik Mizamzul Mehat - Academia.edu (original) (raw)

Papers by Nik Mizamzul Mehat

Research paper thumbnail of Investigating the Effects of Injection Moulding Process Parameters on Multiple Tensile Characteristics of Plastic Spur Gear via Experimental Approach

Advanced Materials Research, 2013

This paper presents the original development of an experimental approach in studying the multiple... more This paper presents the original development of an experimental approach in studying the multiple tensile characterizations as key quality characteristics for several different plastic gear materials related to various parameters in injection moulding process. In this study, emphases are given on a new low-cost mechanism for the testing of the injection moulded plastic spur gear specimens with various teeth module. The testing fixture are developed and validated to provide uniform state of tension with series of plastic gear specimens produced in accordance with the systematically designed of experiment. The effects of changes in the process parameters including melt temperature, packing pressure, packing time and cooling time at three different levels on the elongation at break and ultimate strength of plastic gear is evaluated and studied through the proposed experimental approach.

Research paper thumbnail of Optimizing Of Injection Moulding Process Parameters For Recycled Plastic Material Using Taguchi Method

A large amount of plastic parts presently produced, makes it imperative to search for alternative... more A large amount of plastic parts presently produced, makes it imperative to search for alternative for recycling or making use of these materials, since they are not biodegradable. Injection moulding, one of the most prevalent plastics processing techniques facilitates these recycled materials to be substituted for virgin material in producing plastic parts. However, the deterioration in mechanical properties of the part made of recycled plastic is the major drawback that limits the usage of recycled plastic. One of the foremost causes is variation in processing parameters. It is of critical importance to effectively control all the influencing processing parameters during the manufacturing process by an appropriate optimization method. Therefore, the main goal of conducting this research is to primarily investigate the effects of injection moulding parameters on the mechanical properties of plastic part made of recycled plastics in various of compositions

Research paper thumbnail of Evaluation on the feasibility of using bamboo fillers in plastic gear manufacturing via the Taguchi optimization method

Journal of Physics: Conference Series, Oct 1, 2017

Research paper thumbnail of The Influence of Plastic Extrusion Blow Molding Parameters on Waste Reduction

Growing demands of plastics deriving environmental and social concern on the plastics contained i... more Growing demands of plastics deriving environmental and social concern on the plastics contained in municipal waste. Comprehending to this fact, this study emphasizes on minimization of plastic wastes during extrusion blow molding process by controlling the processing parameters including parison thickness, chiller temperature, melting temperature and extruder speed. L8 Taguchi orthogonal array (OA), signal to noise (S/N) ratio and analysis of variance (ANOVA) were conducted to investigate the influence of numerous blow moulding processing parameters on the plastic wastes.

Research paper thumbnail of Reducing the Shrinkage in Plastic Injection Moulded Gear via Grey-Based-Taguchi Optimization Method

The application of plastic moulded gears in contrast of metal base gears are limited to functiona... more The application of plastic moulded gears in contrast of metal base gears are limited to functionally less important component due to its weak mechanical properties and divergent mechanism of failures. Shrinkage behaviour is one of the crucial problem in plastic moulded gear which negatively impacting the dimensional stability and accuracy of the involute profile, concentricity, roundness, tooth spacing uniformity and the size of the gear. Integrating the grey relational analysis and Taguchi method, the shrinkage behavior in tooth thickness, addendum and dedendum circles of moulded gear is investigated via optimization of processing parameters. From the results of analysis and optimization, the optimal combination of processing parameters for the moulded gear to achieve minimum shrinkage was predicted as A 2 , B 2 , C 3 , and D 1. The melt temperature showed the strongest comparability sequence among the four important injection moulding process parameters investigated in this study followed by packing pressure, cooling time and packing time.

Research paper thumbnail of Investigation on the effects of processing parameters on shrinkage behaviour and tensile properties of injection moulded plastic gear via the Taguchi method

Journal of Physics: Conference Series, Oct 1, 2017

Research paper thumbnail of Investigating the effects of PDC cutters geometry on ROP using the Taguchi technique

Journal of Physics: Conference Series, Oct 1, 2017

At times, the polycrystalline diamond compact (PDC) bit's performance dropped and affects the rat... more At times, the polycrystalline diamond compact (PDC) bit's performance dropped and affects the rate of penetration (ROP). The objective of this project is to investigate the effect of PDC cutter geometry and optimize them. An intensive study in cutter geometry would further enhance the ROP performance. The relatively extended analysis was carried out and four significant geometry factors have been identified that directly improved the ROP. Cutter size, back rake angle, side rake angle and chamfer angle are the stated geometry factors. An appropriate optimization technique that effectively controls all influential geometry factors during cutters manufacturing is introduced and adopted in this project. By adopting L 9 Taguchi OA, simulation experiment is conducted by using explicit dynamics finite element analysis. Through a structure Taguchi analysis, ANOVA confirms that the most significant geometry to improve ROP is cutter size (99.16% percentage contribution). The optimized cutter is expected to drill with high ROP that can reduce the rig time, which in its turn, may reduce the total drilling cost.

Research paper thumbnail of Effect of processing parameters on the shrinkage behaviour of injection moulded polypropylene gear

IOP Conference Series: Materials Science and Engineering

The polymer gears are widely used as basic motion transfer elements in many industries. Continuou... more The polymer gears are widely used as basic motion transfer elements in many industries. Continuous improvement on the quality performance of polymer gears is very important for their ability to meet present demand. So that, controlling the parameters setting in polymers gears are very importance in order to get the best gears quality. In this study, the influences of injection moulding processing parameters on shrinkage of polypropylene gears was investigated by using Taguchi approach. It was found that the optimal processing parameters for addendum circle shrinkage, dedendum circle shrinkage and tooth thickness shrinkage are A1B1C3D3E1F2G3, A3B1C3D3E3F1G3, and A1B3C3D2E3F2G1 respectively. This results showed that pattern of fluctuation showed either an improvement or reduction in quality characteristics upon the change of process parameters setting.

Research paper thumbnail of Optimization of Laminated Composites Characteristics via integration of Chamis Equation, Taguchi method and Principal Component Analysis

IOP Conference Series: Materials Science and Engineering

To date, composite material has drawn significant attention due to its extended properties in var... more To date, composite material has drawn significant attention due to its extended properties in various application. Many factors need to be considered in designing the composites which might leads to complex decision making. Therefore, this study focuses on analyzing and optimizing various factors including combination of material, volume fraction of fiber, ply angle, ply quantity, ply thickness and load applied via integration of the Taguchi method / Principal component analysis along with analytical analysis of Chamis equation. The finite element was adopted in conducting the analysis. Three responses were considered for the laminated composites namely displacement, stress and strain. The findings from the main effects analysis showed that the set of optimum parameters was identified as load applied of 2000N, ply thickness of 0.08 mm, ply quantity of 12 plies, ply angle of 0,90,0 °, material combination of boron/epoxy as well as volume fraction of 65%.

Research paper thumbnail of Optimization of Recycled Glass Fibre-Reinforced Plastics Gear via Integration of the Taguchi Method and Grey Relational Analysis

IOP Conference Series: Materials Science and Engineering

The increase in demand for industrial gears has resulted in the increase in usage of plastic-matr... more The increase in demand for industrial gears has resulted in the increase in usage of plastic-matrix composites particularly glass fibre-reinforced plastics as the gear materials. The usage of these synthetic fibers is to enhance the mechanical strength and the thermal resistance of the plastic gears. Nevertheless, the production of large quantities of these synthetic fibre-reinforced composites poses a serious threat to the ecosystem. Comprehending to this fact, the present work aimed at investigating the effects of incorporating recycled glass fibre-reinforced plastics in various compositions particularly on dimensional stability and mechanical properties of gear produced with diverse injection moulding processing parameters setting. The integration of Grey relational analysis (GRA) and Taguchi method was adopted to evaluate the influence of recycled glass fibre-reinforced plastics and variation in processing parameters on gear quality. From the experimental results, the blending ratio was found as the most influential parameter of 56.0% contribution in both improving tensile properties as well as in minimizing shrinkage, followed by mould temperature of 24.1% contribution and cooling time of 10.6% contribution. The results obtained from the aforementioned work are expected to contribute to accessing the feasibility of using recycled glass fibre-reinforced plastics especially for gear application.

Research paper thumbnail of PDC cutter optimization using response surface methodology with orthogonal arrays

Research paper thumbnail of Investigation on Wear Behavior of Bamboo Filler Reinforcement of Injection Moulded Plastic Gear

Key Engineering Materials

Research paper thumbnail of Investigating the Effects of Injection Molding Parameters on the Mechanical Properties of Recycled Plastic Parts Using the Taguchi Method

Http Dx Doi Org 10 1080 10426914 2010 529587, Jan 31, 2011

ABSTRACT The growing amount of plastic parts produced nowadays makes the search for alternatives ... more ABSTRACT The growing amount of plastic parts produced nowadays makes the search for alternatives in recycling and the further use of these nonbiodegradable materials imperative. The degradation of the mechanical properties of recycled plastic products poses the primary limitation for the usage of recycled plastic. One of the foremost causes of mechanical property degradation is variation in processing parameters. An appropriate optimization method that effectively controls all influential processing parameters during manufacturing is therefore critical. This study investigates the effects of injection molding parameters on the mechanical properties of recycled plastic parts. The preliminary experiment is conducted by using Moldflow Plastic Insight (MPI) integrated with the L18 Taguchi orthogonal array (OA). The significant processing parameters obtained from the preliminary experiment were used to conduct the principal experiment. By adopting L9 Taguchi OA, the parts made from recycled plastic were produced by injection molding. ANOVA confirms that the most significant factor for flexural modulus of a recycled toolbox tray is injection time (∼40.49% percentage contribution). For stress at yield, the most significant factor is melt temperature with percentage contribution of about 43.34%.

Research paper thumbnail of Hybrid Integration of Taguchi Parametric Design, Grey Relational Analysis, and Principal Component Analysis Optimization for Plastic Gear Production

Chinese Journal of Engineering, 2014

The identification of optimal processing parameters is an important practice in the plastic injec... more The identification of optimal processing parameters is an important practice in the plastic injection moulding industry because of the significant effect of such parameters on plastic part quality and cost. However, the optimization design of injection moulding process parameters can be difficult because more than one quality characteristic is used in the evaluation. This study systematically develops a hybrid optimization method for multiple quality characteristics by integrating the Taguchi parameter design, grey relational analysis, and principal component analysis. A plastic gear is used to demonstrate the efficiency and validity of the proposed hybrid optimization method in controlling all influential injection moulding processing parameters during plastic gear manufacturing. To minimize the shrinkage behaviour in tooth thickness, addendum circle, and dedendum circle of moulded gear, the optimal combination of different process parameters is determined. The case study demonstra...

Research paper thumbnail of Practical Applications of Taguchi Method for Optimization of Processing Parameters for Plastic Injection Moulding: A Retrospective Review

ISRN Industrial Engineering, 2013

Determining the optimal processing parameter is routinely performed in the plastic injection moul... more Determining the optimal processing parameter is routinely performed in the plastic injection moulding industry as it has a direct and dramatic influence on product quality and costs. In this volatile and fiercely competitive market, traditional trial-and-error is no longer sufficient to meet the challenges of globalization. This paper aims to review the research of the practical use of Taguchi method in the optimization of processing parameters for injection moulding. Taguchi method has been employed with great success in experimental designs for problems with multiple parameters due to its practicality and robustness. However, it is realized that there is no single technique that appears to be superior in solving different kinds of problem. Improvements are to be expected by integrating the practical use of the Taguchi method into other optimization approaches to enhance the efficiency of the optimization process. The review will shed light on the standalone Taguchi method and inte...

Research paper thumbnail of Modeling and Analysis of Injection Moulding Process Parameters for Plastic Gear Industry Application

ISRN Industrial Engineering, 2013

The performance of plastic gears in wide variety of power and motion transmission applications is... more The performance of plastic gears in wide variety of power and motion transmission applications is rather limited due to weak mechanical properties and divergent mechanism of failures. A methodical simulation is carried out to analyze the gear performance with various gating system types, gate locations, and processing parameters via grey-based Taguchi optimization method. With the obtained optimum results in simulation stage, the flow patterns of polymer melt inside the mould during filling, packing, and cooling processes are studied and the plastic gear failures mechanism related to processing parameters are predicted. The output results in the future can be used as guidance in selecting the appropriate materials, improving part and mould design, and predicting the performance of the plastic gear before the real process of the part manufacturing takes place.

Research paper thumbnail of A Study of Hybrid Optimization of Injection Moulding Process Parameters for Plastic Gear

Advanced Materials Research, 2012

This paper presents a hybrid optimization method for optimizing the injection moulding process pa... more This paper presents a hybrid optimization method for optimizing the injection moulding process parameters for plastic gear. This proposed method combines the Taguchi robust design, grey relational analysis (GRA) and principal component analysis (PCA) in designing the experiments and analyzing the behaviour of shrinkage in addendum circles (AC), dedendum circles (DC) and tooth thickness (TT) of the moulded gear. The proposed hybrid optimization method appears to be a necessity to overcome the shortcomings in multiple quality characteristics optimization as well as provides a statistical solution in defining a weight for each quality characteristic.

Research paper thumbnail of Optimized Injection Molding of Unfilled and Glass Filled PA6 Gears

International Journal of Manufacturing Engineering, 2014

Shrinkage behavior is a crucial problem in manufacturing plastic molded gear. This is because it ... more Shrinkage behavior is a crucial problem in manufacturing plastic molded gear. This is because it negatively affects the dimensional stability and accuracy of the involute profile, as well as the concentricity, roundness, tooth spacing uniformity, and size of the gear. By integrating the Taguchi robust design, Grey relational analysis, and principal component analysis, we investigated the dimensional stability related to the shrinkage of tooth thickness, addendum circle, and dedendum circle of molded gear via the optimization of processing parameters and glass fiber reinforcement. The results revealed that the optimal combination of the processing parameters of the molded gear to achieve minimum shrinkage is melt temperature of 260°C, packing pressure of 60%, packing time of 5 s, and cooling time of 30 s. The melt temperature showed the highest comparability sequence among the four key process parameters examined, followed by packing pressure, cooling time, and packing time. Meanwhil...

Research paper thumbnail of Quality control and design optimisation of plastic product using Taguchi method: a comprehensive review

International Journal of Plastics Technology, 2012

ABSTRACT The Taguchi method is a powerful approach for solving quality problems in various aspect... more ABSTRACT The Taguchi method is a powerful approach for solving quality problems in various aspects of the engineering field. Due to the increase of plastic parts consumption in each day, continuing customer satisfaction and economic viability in a competitive plastic industry environment are gaining tremendous attention. Thus, Taguchi method offers a simple yet systematic approach to optimize design for performance, enhancing the product quality and reduce the cost as well. A lot of studies have been conducted on the efficiency of this method. However a total comprehensive review of the implementation of the Taguchi method particularly in the plastic industry is limited. This paper presents an extensive review of past literature on the application of the Taguchi method in plastic industries focusing on product quality enhancing and obtaining the desired properties for new materials. From the review, it can be concluded that the Taguchi method has made extensive contribution to the plastic industry by bringing focused and awareness to robustness to improving quality.

Research paper thumbnail of Improving the Performance of Reprocessed ABS Products from the Manufacturing Perspective via the Taguchi Method

International Journal of Manufacturing Engineering, 2013

Additives are costly and can have negative environmental effects. Thus, searching for other alter... more Additives are costly and can have negative environmental effects. Thus, searching for other alternatives to improve recycling plastics without using additives is necessary. This study aims to improve the hoop tensile strength, elongation at break, and shrinkage of the ring stopper made from an acrylonitrile butadiene styrene blend comprising 40% recyclates through the optimization of processing parameters using the Taguchi method. By adopting the L9 Taguchi orthogonal array, four controllable factors each at three levels are tested to determine the optimal combination of factors and levels in the injection moulding process. Considering the multiple quality characteristics involved in this study, we investigate the effects of processing parameters on hoop tensile strength, elongation at break, and shrinkage of the ring stopper both separately and simultaneously because changing a parameter can result in the improvement or deterioration of each quality response and of the overall prod...

Research paper thumbnail of Investigating the Effects of Injection Moulding Process Parameters on Multiple Tensile Characteristics of Plastic Spur Gear via Experimental Approach

Advanced Materials Research, 2013

This paper presents the original development of an experimental approach in studying the multiple... more This paper presents the original development of an experimental approach in studying the multiple tensile characterizations as key quality characteristics for several different plastic gear materials related to various parameters in injection moulding process. In this study, emphases are given on a new low-cost mechanism for the testing of the injection moulded plastic spur gear specimens with various teeth module. The testing fixture are developed and validated to provide uniform state of tension with series of plastic gear specimens produced in accordance with the systematically designed of experiment. The effects of changes in the process parameters including melt temperature, packing pressure, packing time and cooling time at three different levels on the elongation at break and ultimate strength of plastic gear is evaluated and studied through the proposed experimental approach.

Research paper thumbnail of Optimizing Of Injection Moulding Process Parameters For Recycled Plastic Material Using Taguchi Method

A large amount of plastic parts presently produced, makes it imperative to search for alternative... more A large amount of plastic parts presently produced, makes it imperative to search for alternative for recycling or making use of these materials, since they are not biodegradable. Injection moulding, one of the most prevalent plastics processing techniques facilitates these recycled materials to be substituted for virgin material in producing plastic parts. However, the deterioration in mechanical properties of the part made of recycled plastic is the major drawback that limits the usage of recycled plastic. One of the foremost causes is variation in processing parameters. It is of critical importance to effectively control all the influencing processing parameters during the manufacturing process by an appropriate optimization method. Therefore, the main goal of conducting this research is to primarily investigate the effects of injection moulding parameters on the mechanical properties of plastic part made of recycled plastics in various of compositions

Research paper thumbnail of Evaluation on the feasibility of using bamboo fillers in plastic gear manufacturing via the Taguchi optimization method

Journal of Physics: Conference Series, Oct 1, 2017

Research paper thumbnail of The Influence of Plastic Extrusion Blow Molding Parameters on Waste Reduction

Growing demands of plastics deriving environmental and social concern on the plastics contained i... more Growing demands of plastics deriving environmental and social concern on the plastics contained in municipal waste. Comprehending to this fact, this study emphasizes on minimization of plastic wastes during extrusion blow molding process by controlling the processing parameters including parison thickness, chiller temperature, melting temperature and extruder speed. L8 Taguchi orthogonal array (OA), signal to noise (S/N) ratio and analysis of variance (ANOVA) were conducted to investigate the influence of numerous blow moulding processing parameters on the plastic wastes.

Research paper thumbnail of Reducing the Shrinkage in Plastic Injection Moulded Gear via Grey-Based-Taguchi Optimization Method

The application of plastic moulded gears in contrast of metal base gears are limited to functiona... more The application of plastic moulded gears in contrast of metal base gears are limited to functionally less important component due to its weak mechanical properties and divergent mechanism of failures. Shrinkage behaviour is one of the crucial problem in plastic moulded gear which negatively impacting the dimensional stability and accuracy of the involute profile, concentricity, roundness, tooth spacing uniformity and the size of the gear. Integrating the grey relational analysis and Taguchi method, the shrinkage behavior in tooth thickness, addendum and dedendum circles of moulded gear is investigated via optimization of processing parameters. From the results of analysis and optimization, the optimal combination of processing parameters for the moulded gear to achieve minimum shrinkage was predicted as A 2 , B 2 , C 3 , and D 1. The melt temperature showed the strongest comparability sequence among the four important injection moulding process parameters investigated in this study followed by packing pressure, cooling time and packing time.

Research paper thumbnail of Investigation on the effects of processing parameters on shrinkage behaviour and tensile properties of injection moulded plastic gear via the Taguchi method

Journal of Physics: Conference Series, Oct 1, 2017

Research paper thumbnail of Investigating the effects of PDC cutters geometry on ROP using the Taguchi technique

Journal of Physics: Conference Series, Oct 1, 2017

At times, the polycrystalline diamond compact (PDC) bit's performance dropped and affects the rat... more At times, the polycrystalline diamond compact (PDC) bit's performance dropped and affects the rate of penetration (ROP). The objective of this project is to investigate the effect of PDC cutter geometry and optimize them. An intensive study in cutter geometry would further enhance the ROP performance. The relatively extended analysis was carried out and four significant geometry factors have been identified that directly improved the ROP. Cutter size, back rake angle, side rake angle and chamfer angle are the stated geometry factors. An appropriate optimization technique that effectively controls all influential geometry factors during cutters manufacturing is introduced and adopted in this project. By adopting L 9 Taguchi OA, simulation experiment is conducted by using explicit dynamics finite element analysis. Through a structure Taguchi analysis, ANOVA confirms that the most significant geometry to improve ROP is cutter size (99.16% percentage contribution). The optimized cutter is expected to drill with high ROP that can reduce the rig time, which in its turn, may reduce the total drilling cost.

Research paper thumbnail of Effect of processing parameters on the shrinkage behaviour of injection moulded polypropylene gear

IOP Conference Series: Materials Science and Engineering

The polymer gears are widely used as basic motion transfer elements in many industries. Continuou... more The polymer gears are widely used as basic motion transfer elements in many industries. Continuous improvement on the quality performance of polymer gears is very important for their ability to meet present demand. So that, controlling the parameters setting in polymers gears are very importance in order to get the best gears quality. In this study, the influences of injection moulding processing parameters on shrinkage of polypropylene gears was investigated by using Taguchi approach. It was found that the optimal processing parameters for addendum circle shrinkage, dedendum circle shrinkage and tooth thickness shrinkage are A1B1C3D3E1F2G3, A3B1C3D3E3F1G3, and A1B3C3D2E3F2G1 respectively. This results showed that pattern of fluctuation showed either an improvement or reduction in quality characteristics upon the change of process parameters setting.

Research paper thumbnail of Optimization of Laminated Composites Characteristics via integration of Chamis Equation, Taguchi method and Principal Component Analysis

IOP Conference Series: Materials Science and Engineering

To date, composite material has drawn significant attention due to its extended properties in var... more To date, composite material has drawn significant attention due to its extended properties in various application. Many factors need to be considered in designing the composites which might leads to complex decision making. Therefore, this study focuses on analyzing and optimizing various factors including combination of material, volume fraction of fiber, ply angle, ply quantity, ply thickness and load applied via integration of the Taguchi method / Principal component analysis along with analytical analysis of Chamis equation. The finite element was adopted in conducting the analysis. Three responses were considered for the laminated composites namely displacement, stress and strain. The findings from the main effects analysis showed that the set of optimum parameters was identified as load applied of 2000N, ply thickness of 0.08 mm, ply quantity of 12 plies, ply angle of 0,90,0 °, material combination of boron/epoxy as well as volume fraction of 65%.

Research paper thumbnail of Optimization of Recycled Glass Fibre-Reinforced Plastics Gear via Integration of the Taguchi Method and Grey Relational Analysis

IOP Conference Series: Materials Science and Engineering

The increase in demand for industrial gears has resulted in the increase in usage of plastic-matr... more The increase in demand for industrial gears has resulted in the increase in usage of plastic-matrix composites particularly glass fibre-reinforced plastics as the gear materials. The usage of these synthetic fibers is to enhance the mechanical strength and the thermal resistance of the plastic gears. Nevertheless, the production of large quantities of these synthetic fibre-reinforced composites poses a serious threat to the ecosystem. Comprehending to this fact, the present work aimed at investigating the effects of incorporating recycled glass fibre-reinforced plastics in various compositions particularly on dimensional stability and mechanical properties of gear produced with diverse injection moulding processing parameters setting. The integration of Grey relational analysis (GRA) and Taguchi method was adopted to evaluate the influence of recycled glass fibre-reinforced plastics and variation in processing parameters on gear quality. From the experimental results, the blending ratio was found as the most influential parameter of 56.0% contribution in both improving tensile properties as well as in minimizing shrinkage, followed by mould temperature of 24.1% contribution and cooling time of 10.6% contribution. The results obtained from the aforementioned work are expected to contribute to accessing the feasibility of using recycled glass fibre-reinforced plastics especially for gear application.

Research paper thumbnail of PDC cutter optimization using response surface methodology with orthogonal arrays

Research paper thumbnail of Investigation on Wear Behavior of Bamboo Filler Reinforcement of Injection Moulded Plastic Gear

Key Engineering Materials

Research paper thumbnail of Investigating the Effects of Injection Molding Parameters on the Mechanical Properties of Recycled Plastic Parts Using the Taguchi Method

Http Dx Doi Org 10 1080 10426914 2010 529587, Jan 31, 2011

ABSTRACT The growing amount of plastic parts produced nowadays makes the search for alternatives ... more ABSTRACT The growing amount of plastic parts produced nowadays makes the search for alternatives in recycling and the further use of these nonbiodegradable materials imperative. The degradation of the mechanical properties of recycled plastic products poses the primary limitation for the usage of recycled plastic. One of the foremost causes of mechanical property degradation is variation in processing parameters. An appropriate optimization method that effectively controls all influential processing parameters during manufacturing is therefore critical. This study investigates the effects of injection molding parameters on the mechanical properties of recycled plastic parts. The preliminary experiment is conducted by using Moldflow Plastic Insight (MPI) integrated with the L18 Taguchi orthogonal array (OA). The significant processing parameters obtained from the preliminary experiment were used to conduct the principal experiment. By adopting L9 Taguchi OA, the parts made from recycled plastic were produced by injection molding. ANOVA confirms that the most significant factor for flexural modulus of a recycled toolbox tray is injection time (∼40.49% percentage contribution). For stress at yield, the most significant factor is melt temperature with percentage contribution of about 43.34%.

Research paper thumbnail of Hybrid Integration of Taguchi Parametric Design, Grey Relational Analysis, and Principal Component Analysis Optimization for Plastic Gear Production

Chinese Journal of Engineering, 2014

The identification of optimal processing parameters is an important practice in the plastic injec... more The identification of optimal processing parameters is an important practice in the plastic injection moulding industry because of the significant effect of such parameters on plastic part quality and cost. However, the optimization design of injection moulding process parameters can be difficult because more than one quality characteristic is used in the evaluation. This study systematically develops a hybrid optimization method for multiple quality characteristics by integrating the Taguchi parameter design, grey relational analysis, and principal component analysis. A plastic gear is used to demonstrate the efficiency and validity of the proposed hybrid optimization method in controlling all influential injection moulding processing parameters during plastic gear manufacturing. To minimize the shrinkage behaviour in tooth thickness, addendum circle, and dedendum circle of moulded gear, the optimal combination of different process parameters is determined. The case study demonstra...

Research paper thumbnail of Practical Applications of Taguchi Method for Optimization of Processing Parameters for Plastic Injection Moulding: A Retrospective Review

ISRN Industrial Engineering, 2013

Determining the optimal processing parameter is routinely performed in the plastic injection moul... more Determining the optimal processing parameter is routinely performed in the plastic injection moulding industry as it has a direct and dramatic influence on product quality and costs. In this volatile and fiercely competitive market, traditional trial-and-error is no longer sufficient to meet the challenges of globalization. This paper aims to review the research of the practical use of Taguchi method in the optimization of processing parameters for injection moulding. Taguchi method has been employed with great success in experimental designs for problems with multiple parameters due to its practicality and robustness. However, it is realized that there is no single technique that appears to be superior in solving different kinds of problem. Improvements are to be expected by integrating the practical use of the Taguchi method into other optimization approaches to enhance the efficiency of the optimization process. The review will shed light on the standalone Taguchi method and inte...

Research paper thumbnail of Modeling and Analysis of Injection Moulding Process Parameters for Plastic Gear Industry Application

ISRN Industrial Engineering, 2013

The performance of plastic gears in wide variety of power and motion transmission applications is... more The performance of plastic gears in wide variety of power and motion transmission applications is rather limited due to weak mechanical properties and divergent mechanism of failures. A methodical simulation is carried out to analyze the gear performance with various gating system types, gate locations, and processing parameters via grey-based Taguchi optimization method. With the obtained optimum results in simulation stage, the flow patterns of polymer melt inside the mould during filling, packing, and cooling processes are studied and the plastic gear failures mechanism related to processing parameters are predicted. The output results in the future can be used as guidance in selecting the appropriate materials, improving part and mould design, and predicting the performance of the plastic gear before the real process of the part manufacturing takes place.

Research paper thumbnail of A Study of Hybrid Optimization of Injection Moulding Process Parameters for Plastic Gear

Advanced Materials Research, 2012

This paper presents a hybrid optimization method for optimizing the injection moulding process pa... more This paper presents a hybrid optimization method for optimizing the injection moulding process parameters for plastic gear. This proposed method combines the Taguchi robust design, grey relational analysis (GRA) and principal component analysis (PCA) in designing the experiments and analyzing the behaviour of shrinkage in addendum circles (AC), dedendum circles (DC) and tooth thickness (TT) of the moulded gear. The proposed hybrid optimization method appears to be a necessity to overcome the shortcomings in multiple quality characteristics optimization as well as provides a statistical solution in defining a weight for each quality characteristic.

Research paper thumbnail of Optimized Injection Molding of Unfilled and Glass Filled PA6 Gears

International Journal of Manufacturing Engineering, 2014

Shrinkage behavior is a crucial problem in manufacturing plastic molded gear. This is because it ... more Shrinkage behavior is a crucial problem in manufacturing plastic molded gear. This is because it negatively affects the dimensional stability and accuracy of the involute profile, as well as the concentricity, roundness, tooth spacing uniformity, and size of the gear. By integrating the Taguchi robust design, Grey relational analysis, and principal component analysis, we investigated the dimensional stability related to the shrinkage of tooth thickness, addendum circle, and dedendum circle of molded gear via the optimization of processing parameters and glass fiber reinforcement. The results revealed that the optimal combination of the processing parameters of the molded gear to achieve minimum shrinkage is melt temperature of 260°C, packing pressure of 60%, packing time of 5 s, and cooling time of 30 s. The melt temperature showed the highest comparability sequence among the four key process parameters examined, followed by packing pressure, cooling time, and packing time. Meanwhil...

Research paper thumbnail of Quality control and design optimisation of plastic product using Taguchi method: a comprehensive review

International Journal of Plastics Technology, 2012

ABSTRACT The Taguchi method is a powerful approach for solving quality problems in various aspect... more ABSTRACT The Taguchi method is a powerful approach for solving quality problems in various aspects of the engineering field. Due to the increase of plastic parts consumption in each day, continuing customer satisfaction and economic viability in a competitive plastic industry environment are gaining tremendous attention. Thus, Taguchi method offers a simple yet systematic approach to optimize design for performance, enhancing the product quality and reduce the cost as well. A lot of studies have been conducted on the efficiency of this method. However a total comprehensive review of the implementation of the Taguchi method particularly in the plastic industry is limited. This paper presents an extensive review of past literature on the application of the Taguchi method in plastic industries focusing on product quality enhancing and obtaining the desired properties for new materials. From the review, it can be concluded that the Taguchi method has made extensive contribution to the plastic industry by bringing focused and awareness to robustness to improving quality.

Research paper thumbnail of Improving the Performance of Reprocessed ABS Products from the Manufacturing Perspective via the Taguchi Method

International Journal of Manufacturing Engineering, 2013

Additives are costly and can have negative environmental effects. Thus, searching for other alter... more Additives are costly and can have negative environmental effects. Thus, searching for other alternatives to improve recycling plastics without using additives is necessary. This study aims to improve the hoop tensile strength, elongation at break, and shrinkage of the ring stopper made from an acrylonitrile butadiene styrene blend comprising 40% recyclates through the optimization of processing parameters using the Taguchi method. By adopting the L9 Taguchi orthogonal array, four controllable factors each at three levels are tested to determine the optimal combination of factors and levels in the injection moulding process. Considering the multiple quality characteristics involved in this study, we investigate the effects of processing parameters on hoop tensile strength, elongation at break, and shrinkage of the ring stopper both separately and simultaneously because changing a parameter can result in the improvement or deterioration of each quality response and of the overall prod...