Prepared by : Ng Siew Kai

DOE

Process Parameters Window

For XXX

Prepared by : Ng Siew Kai

1.0 Objective :

To optimize and determine injection parameters window for

XXX.

2.0 Machine/ Material:

Machine : 11

Resin : PC ABS CYCOLOY 1100HF 76701

Tool # : 1

No. of Cavities: 4

Screw Dia. : 30 mm

Prepared by : Ng Siew Kai

a) Holding Pressure (bar) : 95 +/- 10 (P7 – P11), 30 +/- 10 (P12 – P16)

b) Injection Speed (mm/s) : 20 +/- 5 (C2F – C2J), 50 +/- 5 (C1 – C2E)

c) Injection Pressure (bar) : 100 +/- 10 (C1 – C2J)

3.0 Design Of Experiment

Responses :

Critical Dimensions and Cosmetic

Other Parameter Setting :

Cooling time (sec) : 5 sec

MTC (Core/Cavity) (degC) : 90/90

Barrel (degC) : 255,260,255,255

Hot tip (Z1-Z6) (degC) : 255,255,330,310,270,270

Prepared by : Ng Siew Kai

4.0 DOE Matrix and Result

Prepared by : Ng Siew Kai

Holding Press

Inj Speed

Holding Press*Inj Speed

Inj Press

Holding Press*Inj Press

Inj Speed*Inj Press

Source

1

1

1

1

1

1

Nparm

1

1

1

1

1

1

DF

0.00231540

0.01242676

0.00004186

0.00144991

0.00039621

0.00016471

Sum of Squares

4.1053

22.0332

0.0742

2.5708

0.7025

0.2920

F Ratio

0.1800

0.0425

0.8108

0.2500

0.4902

0.6430

Prob > F

Effect Tests

D48.25

Holding Press

Inj Speed

Holding Press*Inj Speed

Inj Press

Holding Press*Inj Press

Inj Speed*Inj Press

Source

1

1

1

1

1

1

Nparm

1

1

1

1

1

1

DF

0.00096361

0.00834632

0.00021632

0.00000450

0.00003872

0.00000113

Sum of Squares

18.8587

163.3455

4.2336

0.0881

0.7578

0.0220

F Ratio

0.0491

0.0061

0.1759

0.7946

0.4758

0.8957

Prob > F

Effect Tests

D59.12

5.0 ANOVA : D48.25 & D59.12

From the Anova:

Injection Speed is significant factor for D48.25 and Holding Pressure and Injection Speed are significant

factors D59.12

Prepared by : Ng Siew Kai

Holding Press

Inj Speed

Holding Press*Inj Speed

Inj Press

Holding Press*Inj Press

Inj Speed*Inj Press

Source

1

1

1

1

1

1

Nparm

1

1

1

1

1

1

DF

0.00000000

0.00000000

0.12500000

0.12500000

0.00000000

0.00000000

Sum of Squares

0.0000

0.0000

1.8000

1.8000

0.0000

0.0000

F Ratio

1.0000

1.0000

0.3118

0.3118

1.0000

1.0000

Prob > F

Effect Tests

Shining

Holding Press

Inj Speed

Holding Press*Inj Speed

Inj Press

Holding Press*Inj Press

Inj Speed*Inj Press

Source

1

1

1

1

1

1

Nparm

1

1

1

1

1

1

DF

0.00000000

0.12500000

0.12500000

0.12500000

0.12500000

0.00000000

Sum of Squares

0.0000

0.4500

0.4500

0.4500

0.4500

0.0000

F Ratio

1.0000

0.5714

0.5714

0.5714

0.5714

1.0000

Prob > F

Effect Tests

Burr

5.1 ANOVA : Shining & Burr

From the Anova:

Holding Pressure, Injection Speed and Injection Pressure are not significant factors for Shining and

Burr.

Prepared by : Ng Siew Kai

D48.2

5

48.3868

48.2065

48.29777

D59.1

2

59.2773

59.1756

59.23004

Shin

ing

1.06484

-0.2871

0.388889B

urr

1.44912

-1.0047

0.222222

Holding Press

-1 10

Inj Speed-1 1

0

Inj Press

-1 1

0

Prediction Profiler

From the Main Effect Plot :

• Increase in Injection Speed will increase D48.25.

• Increase in Holding Pressure and Injection Speed will increase D59.12

5.3 Main Effect Plot

Prepared by : Ng Siew Kai

6.0 Parameters Window / Preliminary Conclusion

Holding Pressure (bar) : 103-105 (P7 – P11), 38-40 (P12 – P16)

Injection Speed (mm/s) : 15-18 (C2F – C2J), 45-48 (C1 – C2E)

Injection Pressure (bar) : 90-97 (C1 – C2J)

Process window narrow due to Shining and Burr defects. No concern for the critical

dimension.