Effects of Molding Parameters on MIM’s Material Distribution using Numerical Simulation Method

In the competitive world in the global market, manufacturing industry is striving to produce products at high quality, shorter time and low cost. This can be achieved through proper design activities, with assist of finite element analysis (FEA) and computer aided design (CAD). The objective of this project is to study the effect of the molding parameters on the physical characteristics of surgery tool via MIM based on design of experiment (Taguchi method). This numerical results show the behavior of feedstock entering the mould during injection process and the possibility defects that might occur. The quality of the injected product depends on the selection of the feedstock as well as the parameters for injection molding such as injection temperature (A), mold temperature (B), flow rate (C) and injection pressure (D). From the analysis of Taguchi, the optimal levels of process parameters for the shortest filling time is [A3(200ºC), B1(80ºC), C3(20 cm^3 /s), D3(260 MPa)]. Set of optimal parameters for the smallest shrinkage percentage difference is [A1(180ºC), B3(100ºC), C3(20 cm^3 /s), D2(255 MPa)]. The most influence injection molding parameters are injection temperature and injection pressure. Follow by the flow rate.