Warpage Optimisation on the Moulded Part with Straight-Drilled and 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. To control the quality of the moulded part, many researchers have introduced various of optimisation methods to get the suitable combination of processing parameters setting. While, 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. In this paper, the application of Response Surface Methodology (RSM) with Genetic Algorithm (GA) optimisation method on the moulded part with a straight-drilled and conformal cooling channels moulds to optimised warpage condition 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 conventional straight-drilled cooling channels and Milled Groove Square Shape (MGSS) conformal cooling channels and will be compared. Based on the simulation results, melt temperature is the most significant factor contribute to the warpage condition and warpage have optimised by 40.5% for straight-drilled cooling channels. While, for MGSS conformal cooling channels, 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.