Modelling and optimization of injection molding process for PBT/PET parts using modified particle swarm algorithm

Abstract

In the present study, a systematic methodology has been presented to determine optimal injection molding conditions for minimizing warpage and shrinkage in a thin wall relay part using modified particle swarm algorithm (MPSO). Polybutylene terephthalate (PBT) and polyethylene terephthalate (PET) have been injected in thin wall relay component under different processing parameters: melt temperature, packing pressure and packing time. Further, Taguchi’s L9 (32) orthogonal array hasbeen used for conducting simulation analysis to consider the interaction effects of the above parameters. A predictive mathematical model for shrinkage and warpage has been developed in terms of the above process parameters using regression model. ANOVA analysis has been performed to establish statistical significance among the injection molding parameters and the developed model. The developed model has been further optimized using a newly developed modified particle swarm optimization (MPSO) algorithm and the process parameters values have been obtained for minimized shrinkage and warpage. Furthermore, the predicted values of the shrinkage and warpage using MPSO algorithm have been reduced by approximately 30% as compared to the initial simulation values making more adequate parts.