v
TABLE OF CONTENT
Abstrak
i Abstract
ii Acknowledgement
iii Dedication
iv Table of Content
v List of Tables
ix List of Figures
xi List of Abbreviations
xiii
1. INTRODUCTION
1
1.1 Introduction
1 1.2
Background of Problem 2
1.3 Problem Statement
3 1.4
Objectives of Project 3
1.5 Scope of Project
3 1.6
Overview of Thesis 4
1.7 Activity Planning
5
2. LITERATURE REVIEW
6
2.1 Introduction
6 2.2
Injection moulding 6
2.2.1 Machine component 7
2.3 Mould
10 2.4
Polypropylene 12
2.5 Process Parameter
13 2.5.1 Temperature
13 2.5.2 Pressure
14 2.5.3 Time
14 2.5.4 Distance
14 2.5.5 Parameter Effect
15
vi 2.6
Type of Defect 17
2.6.1 Cause and Effect Diagram for Injection Moulding 17
2.6.2 Understanding the Defect 17
2.7 Surface Texture and Roughness
20 2.8
Measuring Mechanical Properties of Material 21
2.8.1 Tensile Test 21
2.9 Summary
22
3. METHODOLOGY
23
3.1 Introduction
23 3.2
Research Flow 25
3.3 Raw Material
25 3.3.1 Propylene Resin
25 3.3.2 The Characteristic of Polypropylene
26 3.4
Injection Moulding Process 27
3.4.1 The Injection Moulding Machine 27
3.4.2 Moulding Process 28
3.5 Mould
31 3.6
Injection Moulding Process Parameter 33
3.7 Surface Roughness
33 3.7.1 Surface Roughness Characteristics
34 3.7.2 Method to Analyze Surface Roughness
35 3.7.3 Portable Surface Roughness Tester
35 3.7.4 Surface Roughness Test Process Flow
37 3.8
Tensile Strength Testing 38
3.8.1 Method to Analyze Tensile Strength 39
3.8.2 Universal Tensile Machine UTM 40
3.8.3 Tensile Test Process Flow 41
3.9 Machining of Locating Ring
42 3.10 Design of Experiment
43 3.10.1 Taguchi Method
43 3.10.2 Selection Parameter
43 3.10.3 Response Variable
44
vii 3.10.4 Orthogonal Array Design
44
4. RESULT AND DICUSSION ON SURFACE QUALITY
45
4.1 Introduction
45 4.2
Design of Experiment DOE 45
4.3 Control Factor
46 4.4
Result of Experiment 47
4.4.1 Visual Inspection 49
4.5 Discussion on Surface Quality of Product
49 4.5.1 Introduction to Product Defect
49 4.5.2 Sprue Sticking
50 4.5.3 Part Sticking
51 4.5.4 Flashing
52 4.5.5 Blush
53 4.5.6 Sink Mark
54 4.5.7 Nozzle Drolling
55
5. RESULT AND DISCUSSION ON SURFACE ROUGHNESS AND
TENSILE STRENGTH 57
5.1 Surface Roughness Analysis
57 5.1.1 Generate Main Effect Result
57 5.1.2 Main Effect Plot for SN Ratios
58 5.1.3 Main Effect Plot for Means
60 5.1.4 Analysis of Variance for Means ANOVA
52 5.1.5 Predicted Value of Surface Roughness
63 5.2
Tensile Strength Analysis 65
5.2.1 Result of Tensile Strength Test 65
5.2.2 Main Effect Plot for Means SN Ratios 67
5.2.3 Main Effect Plot for Mean 69
5.2.4 Predicted Value of Tensile Strength 70
6. CONCLUSION
