This research paper proposes using an artificial neural network model integrated with an expected improvement function method to optimize injection molding process parameters and minimize part warpage. Input parameters like melt temperature, mold temperature, injection time, packing time and pressure were used in the ANN model with warpage as the output. The expected improvement function was then used to select new sample points to iteratively improve the ANN model, balancing global and local searches to efficiently reach an optimal solution. The method was tested on mobile phone and scanner covers and showed reductions in warpage, providing an effective approach for injection molding optimization.
This research paper proposes using an artificial neural network model integrated with an expected improvement function method to optimize injection molding process parameters and minimize part warpage. Input parameters like melt temperature, mold temperature, injection time, packing time and pressure were used in the ANN model with warpage as the output. The expected improvement function was then used to select new sample points to iteratively improve the ANN model, balancing global and local searches to efficiently reach an optimal solution. The method was tested on mobile phone and scanner covers and showed reductions in warpage, providing an effective approach for injection molding optimization.
This research paper proposes using an artificial neural network model integrated with an expected improvement function method to optimize injection molding process parameters and minimize part warpage. Input parameters like melt temperature, mold temperature, injection time, packing time and pressure were used in the ANN model with warpage as the output. The expected improvement function was then used to select new sample points to iteratively improve the ANN model, balancing global and local searches to efficiently reach an optimal solution. The method was tested on mobile phone and scanner covers and showed reductions in warpage, providing an effective approach for injection molding optimization.
Injection molding Process Parameters Optimization By using Expected Improvement Function Method and Integrated Artificial Neural Network Model.
(Review Research Paper)
Abstract: divided into following parts filling,
mold opening and post filling. For It consists of adaptive optimization reducing warpage the geometry of process which is based on ANN parts and mold structures can be model and is proposed for useful. Since the design is important optimizing. The aim is to minimize for the initial stage of the product the warpage of molding parts by and changing of design is not so easy injection molding and the design so here come the optimization, it is variables are process parameters. For the most reasonable and feasible this insertion analysis software was method which can be used for the used and different parameters like designing. In the manufacturing of melt and temperature of mold, time the plastic parts it is necessary to of injection, packing time and know and optimize the warpage pressure of packing were taken as before the stage of manufacturing. process parameters. Design of experiment with the artificial neural was used for the appropriate relationship between process Literature Review: parameters and warpage. The process Different methods and strategies were is improved by the infilling sampling adapted by different persons for criteria. It can balance both the reducing the warpage. Although the global and local search and reach warpage was reduced but the process towards solution(global optimal). So taken was costly and time taking so as samples mobile phone and scanner after all the most suitable method covers were taken for this purpose. which was seen is Taguchi method The results were in favour of which is easier and can also give us reducing the warpage in injection the crucial and important factors. molding. Even this process can only give us the combination of effective parameters and not actually give us Introduction : the optimal solution. The warpage is nonlinear process and it is estimated Injection molding is mostly used by the finite element equations. If the plastic producing processes. It can be process is complicated then it has a greater computational cost. The variables which we considered were results showed that the model which temperature of melt, temperature of was reprocessed according to the mold, time of packing, packing pressure and the cooling time. The parameters they can give less warpage was considered as the output processing cost in the warpage in this case. The number of input and optimization and uses output neurons was calculated. It is algorithm(genetic) to make it used for making the relation of the efficient. Warpage values were process parameters and the warpage detected by using the software. The which replaces the costly simulation adaptive method was performed using program analysis in the process of optimization. Now the EI method is EI function it adaptively selects the used to close the solution(Global different points for finding the Optimization. The neuron number of optimal value. The method is viewed the middle layer was determined by trials. taken as effective global The transfer function between the input optimization. layer and the hidden layer is Logsig, and the transfer function between the hidden layer and the output layer is Purelin. The train function is trainlm, Methodology: performance function is MSE, learning cycle is 50,000, learning rate is 0.05, and ANN is a power full tool for momentum factor is 0.9. nonlinear problems solution. Every Advantages (Infilling): neuron sums up the inputs. Then uses a linear or non linear function for the It can efficiently add sample points output. BPN (Back Propagation for the improvement of ANN so it Network) is a typical ANN. It is a deals with the small size data. It can feed forward architecture in which skip the large areas of larger function the output of each layer is given to values and can reduce the cost. Its the above neuron. A BPN can have selection criteria are so that the much layers but the tasks are mostly stability of ANN prediction is not accomplished in just three layers affected. BPN. For this the ranges of the Optimization Comparison for process parameters were set Sample # 01: accordingly. Upper a
nd lower limit was set for testing
before the optimization. A BPN consists of a series of inputs and outputs and the layers. The neural network predicts the relationship between the predicted and the actual output patterns of the sample. Then it generates a value of error. The process goes on unless the mean squared error is minimized. In our case a 3 layer of ANN is used with a layer which is hidden. The input boundaries. The effect of each factor on the warpage was seen by keeping the rest of the parameters at the optimum level. It was also seen that high temperature and process of injection with a shorter time is efficient. The non linear decrease in the warpage value was seen from 260 o C to 300 o C. This behaviour was Optimization Comparison for due to the bad liquidity at the lower Sample # 02: temperatures which causes quick formation of skin layer and it can cause greater shear stress with flow blocking. Although warpage value increases non linearly at the time of injection. The change of warpage values is only in time of packing duration and when time of packing is greater it is constant. If rest of the process parameters are seen such as cooling time, packing pressure and mold temperature then it can be observed that the warpage values are irregular.
Conclusion:
In the above method EI function and
integrated ANN is used to decrease the warpage of the injection molded process. Process of optimization can be started from an approximation function trained through sample points. Then the EI function helps to add the best sample points in the function according to the requirement for efficient result. The EI can take those regions which are accurate for ANN method and can very quickly approach to the solution(global Results and Discussion: optimization). In the above study the Different outputs were taken and cell and scanner cover was taken as tables were drawn which showed that sample. Ten sample points for each many parameters were in the limit were taken and every iteration gives a new sample point. The suggested 6. Cheng J, Li QS (2009) A hybrid method is good for reducing the artificial neural network method warpage and for reaching the with uniform design for structural optimization. Comput Mech optimization solution quickly. These 44(1):6171. samples have limited parameters but this method can be used for even more number of parameters. But there are two problems, development of efficient optimization algorithm. Also it is multimodal and it has sharp peaks which make the solution difficult. The other is for some certain methods which is determining some parameters, like learning rate and learning cycle.
References:
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