OPTIMIZATION OF THE INJECTION MOLDING PROCESS FOR SHORT-FIBER-REINFORCED COMPOSITES

A fast and effective methodology integrating the finite-element and Taguchi methods is presented to determine the optimal design conditions of the injection molding process for short-fiber-reinforced polycarbonate composites. The finite-element-based flow simulation software, M-flow, was employed to simulate the molding process to obtain the fiber orientation distributions required. The Taguchi optimization technique was used to identify the optimal settings of injection molding parameters to maximize the shear layer thickness. The effects of four main parameters - the filling time, melt temperature, mold temperature, and injection speed - on the fiber orientation or the shear layer thickness were investigated and discussed. It is found that the dominant parameter is the filling time. The best levels of the four parameters to acquire the thickest shear layer are also identified.