Design optimization of feed system for injection molded polymer gear. (2021)

• Record Type: Journal Article
• Authors: Solanki, Bikram Singh; Singh, Harpreet; Sheorey, Tanuja
• Is Part Of: Materials today. Volume 47:Part 11(2021)
• Page Start: 3418
• Page End: 3424
• Publication Date: 2021
• Subjects: Polymer -- Gear -- Injection molding -- Feed system -- Shrinkage -- Warpage; Materials science -- Congresses -- Periodicals; 620.1
• DOI: 10.1016/j.matpr.2021.07.289
• Languages: English
• ISSNs: 2214-7853

Abstract

Abstract: The shrinkage, residual stresses, and warpage are the prime defects during polymer injection molding. Furthermore, the effective control of these defects has become a challenge if the part thickness is higher. Especially, producing the part like gear which needs to withstand against complex load conditions must be defect free. The quality of the molded part is predominantly influenced by filling pattern of the cavity which is highly depends upon the feed system. Therefore, the effective design of feed system is one of the prime consideration for the polymer injection molding. In the present work, sprue end diameter, runner diameter, and gate end diameter of the feed system were selected as three factors at three levels to minimize the defects in spur gear. The L9 orthogonal array of Taguchi method was selected to design the experiments in Minitab software. Using these sets of experiments, the numerical studies were conducted in Autodesk Moldflow Insight 2019.05. The minimum volumetric shrinkage of 8.937%, warpage of 0.2176 mm and stress of 49.85 MPa were found at sprue end diameter of 7.27 mm, runner diameter of 4.58 mm and gate end diameter of 1.5 mm. The result confirmed that the gate end diameter has highest contribution towards the various gear defects.