Warpage Optimisation on the Moulded Part with Conformal Cooling Channels using Response Surface Methodology (RSM) and Genetic Algorithm (GA) Optimisation Approaches

In the injection moulding process, quality and productivity are important and must be controlled for each product that have been produced in moulding industries. To control the quality of the moulded part, many researchers have introduced various of optimisation methods to get an appropriate combination of processing parameters setting. On the other hand, to improve the productivity of injection moulding process, some researchers have introduced the application of conformal cooling channels in mould fabrication which have been proven will shorten the moulding cycle time. Thus in this paper, the application of Response Surface Methodology (RSM) with Genetic Algorithm (GA) optimisation methods on the moulded part with a conformal cooling channels moulds will be presented. A front panel housing made from ABS has been selected as a specimen and the performance of the proposed optimisation method have been applied on the Milled Groove Square Shape (MGSS) conformal cooling channels. Based on the simulation results, melt temperature is the most significant factor contribute to the warpage condition and warpage have optimised by 28%. The finding shows that the application of optimisation work on the conformal cooling channels offers the better quality and productivity of the moulded part produced.