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Sustainable manufacturing has become essential amongst industries of all types due to the diminishing non-renewable sources and an ever- increasing demand for environmentally friendly products. Injection moulding is one of the most widely used processes for the production of plastic products and is a large consumer of energy. Energy efficiency has...
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In the process of micro-milling, the appearance of the edge-size-effect of micro-milling tools cannot be ignored when the cutting parameters are smaller than the cutting edge arc radius (r0) of the micro-milling tool or close to it, and it could easily lead to low cutting efficiency and poor surface quality of the micro-slot. Through micro-milling...
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... In industry, good design, proper process, maintenance, and accurate analysis are the result of efficient production, efficient use of energy resources, and suitable equipment maybe it seems outside but also specialized technical manpower. Any parameter that limits the system production directly or indirectly is a topic of efficiency [55][56][57]. Utilization is applied to all basic units of manufacturing, such as temperature stabilization, pressure maintenance, heat exchangers, mixers, conveyors, valves, and power generation units. Evaluation of each machine process under general headings will reveal a different definition for production [58][59][60][61]. ...
Energy efficiency is considered an important indicator after the efficiency term is one framework of economic planning. The review results show that the gained energy is completely different in industries due to the production line, raw material, used fuel, system automation, application of thermodynamic rules, and energy recovery applications. The thermal parameters of the machining system are the main indicators to determine the system's efficiency. Dynamic behavior, effectiveness, and thermal capacity limitation are some parameters used for the optimization of machining energy efficiency. The temperature, pressure, flow rate, and other operating conditions as a function of time are the physical quantities to determine the dynamic behavior. The machining tools are intensive energy-consuming types of equipment and mostly consume electricity in manufacturing industries.
The general approach for cost-effective planning is to set a complete energy-efficient system. Mass, energy, and exergy analyses are the general bases for the efficiency consideration of heat generation. But the easiest and most expeditious energy recovery is observed in effective machining like micromechanical systems and hybrid systems, up to 20% of overall losses can be recovered. If the general usage of steam to produce electricity is considered, controlling the existing configuration will improve energy efficiency by applying quantitative optimization of the electricity usage. This quantity can be increased by an extra 20%. To optimize the entire cogeneration or trigeneration machining system, a holistic approach is needed that improves the system's energy efficiency by up to 65%. The energy efficiency is increased in the range from 3 to 35% by innovative EMS. Air leaks are causing the highest energy losses in CA systems. More than 90% energy efficiency can be achieved with an appropriate CAES system mostly in isothermal and high-pressure conditions for machining purposes. Moreover, the recovered energy will mitigate GHGs. And it is strict that, any developing plan of countries which contains an energy efficiency strategy, is necessary to sustain a habitable earth.
... Under the GMP methodology, there are two different concepts: The first one seeks to improve manufacturing processes in terms of human safety and health, to produce satisfactory products in specific markets, such as the food or pharmaceutical sectors. The second one is the intervention of the processes, to achieve quality products by optimizing the resources used for manufacturing, which ensures the competitiveness of the company (Meekers et al. 2018;Park and Nguyen 2014). ...
In this work, the impact of good manufacturing practices (GMP) on the specific energy consumption (SEC) of plastic injection molding process, in 9 representative companies in Colombia, was studied. The GMP applied to the injection molding process and the degree to which they are adopted by the companies were defined. Afterwards, the SEC of 17 representative injection molding processes in those companies were evaluated. Finally, the impact of applying the GMP and their effect on SEC were studied. The degree of application of GMP on the analyzed companies ranges from 35 to 72%. A single SEC value could not be established for all the injection systems, because it depends on the injected weight and the productivity of each mold-machine-material combination. Nevertheless, a characteristic curve was defined for different systems. A relationship between the application of GMP and SEC was found. It was observed that all GMP contributed to improve the SEC, with different significance, ranging the relevance from 6 to 14%. Finally, it was concluded, taking in consideration a representative company, that “Plasticizing” and “Drive Units” were the most relevant categories to impact the SEC.
... Mianehrow et al. (2017) assessed the impact of different machine-related and process-related parameters on energy consumption and provided insights into how to reduce the maximum electrical demand. Meekers et al. (2018) achieved reduce energy consumption by the impact of parameters such as cooling time on the injection process. Quantitative models were commonly established to capture the relationship between energy consumption and process parameters. ...
The high energy intensity and rigorous quality demand of injection molding have received significant interest under the background of the soaring production of global plastic industry. As multiple parts can be produced in a multi-cavity mold during one operation cycle, the weight differences of these parts have been demonstrated to reflect their quality performance. In this regard, this study incorporated this fact and developed a generative machine learning-based multi-objective optimization model. Such model can predict the qualification of parts produced under different processing variables and further optimize processing variables of injection molding for minimal energy consumption and weight difference amongst parts in one cycle. Statistical assessment via F1-score and R² was performed to evaluate the performance of the algorithm. In addition, to validate the effectiveness of our model, we conducted physical experiments to measure the energy profile and weight difference under varying parameter settings. Permutation-based mean square error reduction was adopted to specify the importance of parameters affecting energy consumption and quality of injection molded parts. Optimization results indicated that the processing parameters optimization could reduce ~ 8% energy consumption and ~ 2% weight difference compared with the average operation practices. Maximum speed and first-stage speed were identified as the dominating factors affecting quality performance and energy consumption, respectively. This study could contribute to the quality assurance of injection molded parts and facilitate energy efficient and sustainable plastic manufacturing.
... The authors proposed a methodology that seeks to identify and eliminate energy inefficient processes, as well as eliminate non-value adding activities (e. g., non-productive energy consumption) with the aim of improving the overall efficiency of the manufacturing process. A close look at the process is made by [4], which analyses the optimisation of the injection process to reduce energy consumption without reducing product quality. The impacts of cooling time, screw rotational speed, mould temperature and nozzle temperature were studied. ...
... According to their findings, the operations that consume the most energy are plasticising and cooling. These findings are in agreement to a certain degree with the outcomes found in [4]. One of the concrete proposals of this study [5] is to reduce the cooling time as much as possible without compromising the quality of the product. ...
... This suggests that attention should be paid to other elements in addition to the injection moulding machine, as they significantly increase the power demand. This observation is consistent with what [4] discovered concerning the influence of the chiller. However, a more detailed analysis is required to assess the influence of this element in this case. ...
... These processes are beneficial for large volume production as mould development for a specific component is quite costly. In contrast, other techniques are also available which are cheaper for low volume production, such as fused deposition modelling (FDM) or fused filament fabrication (FFF) [2]. FDM uses 3D CAD data for creating a physical model with the help of CAD softwares and 3D printing machines. ...
Fused deposition modelling (FDM) is an additive-based manufacturing technique used by various industries due to its effectiveness & ability to make complicated geometries possible. This technique requires sufficient knowledge about the process and its parameters including their effect on the component’s mechanical characteristics. Thus, it is crucial to review the available articles on this topic not only to identify the practical and useful aspects, limitations, and process variables but also to understand how the results of the literature are relevant to be used for real applications and further studies. A systematic literature review is carried out based on the type of 3D printing materials. The printing parameters which influence the mechanical characteristics of the FDM specimens are discussed based on the results presented in the literature. From the present study, it has been found that the process variables such as orientation, raster angle, raster width, layer height, and contours directly affect the quality of the 3D-printed parts. It has also been found that the effect of these process variables also varies with the type of thermoplastic materials. The present article will help researchers to select FDM processed material and appropriate process variables for further research.
... It utilizes machine learning techniques in defect detection, and it is more efficient and improves the industry's productivity. e initial cost of an online monitoring system can be pretty expensive, but they are profitable in the long run [48]. ...
... For reducing defects in injection molding, control on operating parameters is required [48]. ese operating parameters include injection speed and pressure, mold temperature, and mold design [16]. ...
One of the most suitable methods for the mass production of complicated shapes is injection molding due to its superior production rate and quality. The key to producing higher quality products in injection molding is proper injection speed, pressure, and mold design. Conventional methods relying on the operator’s expertise and defect detection techniques are ineffective in reducing defects. Hence, there is a need for more close control over these operating parameters using various machine learning techniques. Neural networks have considerable applications in the injection molding process consisting of optimization, prediction, identification, classification, controlling, modeling, and monitoring, particularly in manufacturing. In recent research, many critical issues in applying machine learning and neural network in injection molding in practical have been addressed. Some problems include data division, collection, and preprocessing steps, such as considering the inputs, networks, and outputs, algorithms used, models utilized for testing and training, and performance criteria set during validation and verification. This review briefly explains working on machine learning and artificial neural network and optimizing injection molding in industries.
... The lack of uniformity in the cooling and, therefore, on the surface and internal temperatures of the piece can cause visible problems during its ejection or at a later time such as residual stresses, differential shrinkage, warpages, etc. In light of this, several authors have proposed different solutions regarding the geometry of the conformal channels with the aim of decreasing the cycle time, seeking energy savings in the process, and an improvement in the line of sustainability [6][7][8][9][10]. ...
The paper presents a hybrid cooling model based on the use of newly designed fluted conformal cooling channels in combination with inserts manufactured with Fastcool material. The hybrid cooling design was applied to an industrial part with complex geometry, high rates of thickness, and deep internal concavities. The geometry of the industrial part, besides the ejection system requirements of the mold, makes it impossible to cool it adequately using traditional or conformal standard methods. The addition of helical flutes in the circular conformal cooling channel surfaces generates a high number of vortexes and turbulences in the coolant flow, fostering the thermal exchange between the flow and the plastic part. The use of a Fastcool insert allows an optimal transfer of the heat flow in the slender core of the plastic part. An additional conformal cooling channel layout was required, not for the cooling of the plastic part, but for cooling the Fastcool insert, improving the thermal exchange between the Fastcool insert and the coolant flow. In this way, it is possible to maintain a constant heat exchange throughout the manufacturing cycle of the plastic part. A transient numerical analysis validated the improvements of the hybrid design presented, obtaining reductions in cycle time for the analyzed part by 27.442% in comparison with traditional cooling systems. The design of the 1 mm helical fluted conformal cooling channels and the use of the Fastcool insert cooled by a conformal cooling channel improves by 4334.9% the thermal exchange between the cooling elements and the plastic part. Additionally, it improves by 51.666% the uniformity and the gradient of the temperature map in comparison with the traditional cooling solution. The results obtained in this paper are in line with the sustainability criteria of green molds, centered on reducing the cycle time and improving the quality of the complex molded parts.
... They found that temperature was the most significant contributing factor to minimising shrinkage inflow, surface roughness, and cross-flow directions in the parts. During an investigation into the effect of cooling time, mould temperature, screw rotational speed, and nozzle temperature on energy consumption during injection moulding, Meekers et al. [9] discovered that cooling time, along with nozzle temperature, had the greatest impact on energy consumption. Taifor et al. [10] investigated ABS material gear injection moulding simulation with optimization of moulding parameters and found that the number of runners, melting temperature, and orientation of the injection process were the most important contributing factors to the final product quality. ...
In this fast growing world, the demand for fast-moving consumer goods (FMCG) and half of the goods are manufactured through the use of plastic. To cater to those, plastic goods are manufactured using different types of moulding process. Plastic injection moulding (PIM) is a technique of injecting molten plastic into a mould to form it. They are widely used to manufacture FMCG products like containers, remote cases, or other small, complex profiles. But sometimes these complex profile mouldings lack dimensional accuracy. The current study provides an understanding of the clear thermoplastic Polymethyl Methacrylate (PMMA) material moulding for FMCG items utilizing an injection moulding machine. The transparent top sheath used in male/female deodorants can be considered in this investigation. For the purpose of minimizing weld-line width and sink-marks depth during injection moulding of commercial grade transparent thermoplastic (Polymethyl Methacrylate), eight plastic injection moulding criteria were considered , namely melting temperature, mould temperature, cooling time, injection pressure, back pressure, holding pressure, ambient temperature, and holding time. In accordance with Taguchi's Design, the 27 experiments were piloted, and the factors were optimized using the Taguchi-based WASPAS method (Weighted Aggregated Sum Product Assessment), the Ant Lion optimization algorithm, and analysis of variance to determine the most dominant parameter in the minimization of weld-line width and sink-mark depth of the plastic injection moulded part. It was discovered that the cooling time of the plastic injection moulded component is the most important element affecting the weld-line width as well as the depth of the sink-mark on the surface of the part.
... Aus ökologischer Perspektive ist die Kühlzeit eng mit dem Energiebedarf des Produktionsprozesses verbunden [21,22]. Dies bedeutet, dass der Energiebedarf mit der Länge der Kühlzeit ansteigt, da u.a. ...
Augmented Reality bietet Chancen zur lernwirksamen Nutzung in Lernprozessen der dualen Ausbildung. Die Virtualisierung von simulierten Fehlerfolgen aus Handlungsfehlern erweitert betriebliche Arbeitsprozesse der Kunststofftechnik um eine augmentierte Dimension. Üblicherweise durch Ausbildungspersonal verhinderte Fehlerkonsequenzen lassen sich damit in Lernprozessen nutzen. Der Beitrag zeigt, wie Zielkonflikte didaktischer Leitideen z.B. der Nachhaltigkeit auf Grundlage von Arbeitsanalysen einer Füllstudie beim Spritzgießen für die Ableitung von Zielstellungen und Gestaltung eines betrieblichen Ausbildungsprozesses genutzt werden. Beispiel-haft werden die Zielkonflikte anhand der Kühlzeit im Produktionsprozess beschrieben. Darauf aufbauend wird eine konkrete Zielstellung des Lernprozesses diskutiert. Das didaktische Konzept eignet sich sehr gut zur Förderung reflektierter Handlungskompetenz. Es eignet sich zur Fehlerdarstellung in Augmented Reality in betrieblichen Lernprozessen. Ein Transfer auf andere technische Ausbildungsbereiche mit deren Zielkonflikten ist möglich.
... Several process parameters affect the speed or time of the production, the surface morphology and mechanical properties of the product, which intend to enhance the quality of the product [1]. These various parameters are mould temperature, injection pressure, holding pressure, cooling arrangement, cooling time, melt temperature, and injection speed [2][3][4]. Due to the inappropriate selection of these parameters, various defects like-flow line, sink marks [5], vacuum voids, weld line [6], short shot, flash, warpage [7], surface delamination, burn marks [8], jetting are caused in the product. Many studies have been done on the effect of these process parameters on mechanical properties and microstructure of the material [9][10][11]. ...
Injection moulding is used significantly in modern days for manufacturing of plastic materials, mainly due to its effectiveness of mass production, modulation of complex geometry, and high precision objects. The process is influenced by various parameters like mould temperature, injection pressure, holding pressure , cooling arrangement, cooling time, injection speed and melt temperature, resulting in effective manufacturing with a quality product. The current study is focused on analysing the influence of injection pressure and holding pressure on the fabrication of Delrin specimens. Delrin is one of the most commonly used plastic for wear-related issues, mainly due to its higher wear resistance and sliding properties. In this study, the effect of injection pressure and holding pressure is analysed on the mechanical and tribo-logical properties of Delrin specimen, for which pin on disc and universal testing machine are used, respectively. Experimental results showed that the wear resistance, tensile strength and compressive strength of Delrin specimens were increased with respect to the injection pressure up to a specific limit but continuously increased with the holding pressure.
