(Review Research Paper)

Submitted By:

Name : Raheel Abbas

Roll No : 06255

Subject : Advance Control Systems

Class : MS-76

Submitted To:

Sir Imran Shafi

Injection molding Process Parameters Optimization By using Expected
Improvement Function Method and Integrated Artificial Neural Network
Model.
(Review Research Paper)
Abstract:
It consists of adaptive optimization
process which is based on ANN
model and is proposed for
optimizing. The aim is to minimize
the warpage of molding parts by
injection molding and the design
variables are process parameters. For
this insertion analysis software was
used and different parameters like
melt and temperature of mold, time
of injection, packing time and
pressure of packing were taken as
process parameters. Design of
experiment with the artificial neural
was used for the appropriate
relationship between process
parameters and warpage. The process
is improved by the infilling sampling
criteria. It can balance both the
global and local search and reach
towards solution(global optimal). So
as samples mobile phone and scanner
covers were taken for this purpose.
The results were in favour of
reducing the warpage in injection
molding.
Introduction :
Injection molding is mostly used
plastic producing processes. It can be
divided into following parts filling,
mold opening and post filling. For
reducing warpage the geometry of
parts and mold structures can be
useful. Since the design is important
for the initial stage of the product
and changing of design is not so easy
so here come the optimization, it is
the most reasonable and feasible
method which can be used for the
designing. In the manufacturing of
the plastic parts it is necessary to
know and optimize the warpage
before the stage of manufacturing.
Literature Review:
Different methods and strategies were
adapted by different persons for
reducing the warpage. Although the
warpage was reduced but the process
taken was costly and time taking so
after all the most suitable method
which was seen is Taguchi method
which is easier and can also give us
the crucial and important factors.
Even this process can only give us
the combination of effective
parameters and not actually give us
the optimal solution. The warpage is
nonlinear process and it is estimated
by the finite element equations. If the
process is complicated then it has a
greater computational cost. The
results showed that the model which
was reprocessed according to the
parameters they can give less
processing cost in the warpage
optimization and uses
algorithm(genetic) to make it
efficient. Warpage values were
detected by using the software. The
adaptive method was performed using
EI function it adaptively selects the
different points for finding the
optimal value. The method is viewed
taken as effective global
optimization.
Methodology:
ANN is a power full tool for
nonlinear problems solution. Every
neuron sums up the inputs. Then uses
a linear or non linear function for the
output. BPN (Back Propagation
Network) is a typical ANN. It is a
feed forward architecture in which
the output of each layer is given to
the above neuron. A BPN can have
much layers but the tasks are mostly
accomplished in just three layers
BPN. For this the ranges of the
process parameters were set
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
variables which we considered were
temperature of melt, temperature of
mold, time of packing, packing
pressure and the cooling time. The
warpage was considered as the output
in this case. The number of input and
output neurons was calculated. It is
used for making the relation of the
process parameters and the warpage
which replaces the costly simulation
program analysis in the process of
optimization. Now the EI method is
used to close the solution(Global
Optimization. The neuron number of
the middle layer was determined by trials.
The transfer function between the input
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,
performance function is MSE, learning
cycle is 50,000, learning rate is 0.05, and
momentum factor is 0.9.
Advantages (Infilling):
It can efficiently add sample points
for the improvement of ANN so it
deals with the small size data. It can
skip the large areas of larger function
values and can reduce the cost. Its
selection criteria are so that the
stability of ANN prediction is not
affected.
Optimization Comparison for
Sample # 01:

Optimization Comparison for
Sample # 02:
Results and Discussion:
Different outputs were taken and
tables were drawn which showed that
many parameters were in the limit
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
due to the bad liquidity at the lower
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
optimization). In the above study the
cell and scanner cover was taken as
sample. Ten sample points for each
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.

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