Search results for: molding water content

Authors: John E. Sani, Moses George

Abstract:

The paper presents the result of a laboratory study carried out on lateritic soil to determine the effects of dimensional size on the volumetric shrinkage strain (VSS) using three mould sizes i.e. split former mould, proctor mould and California bearing ratio (CBR) mould at three energy levels; British standard light (BSL), West African standard (WAS) and British standard heavy (BSH) respectively. Compactions were done at different molding water content of -2 % to +6 % optimum moisture content (OMC). At -2% to +2% molding water content for the split former mould the volumetric shrinkage strain met the requirement of not more than 4% while at +4% and +6% only the WAS and BSH met the requirement. The proctor mould and the CBR mould on the other hand gave a lower value of volumetric shrinkage strain in all compactive effort and the values are lower than the 4% safe VSS value.

Keywords: lateritic soil, volumetric shrinkage strain, molding water content, compactive effort

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Authors: Ssu-Han Chen, Der-Baau Perng

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Molding process in IC manufacturing secures chips against the harms done by hot, moisture or other external forces. While a chip was being molded, defects like cracks, dilapidation, or voids may be embedding on the molding surface. The molding surfaces the study poises to treat and the ones on the market, though, differ in the surface where texture similar to defects is everywhere. Manual inspection usually passes over low-contrast cracks or voids; hence an automatic optical inspection system for molding surface is necessary. The proposed system is consisted of a CCD, a coaxial light, a back light as well as a motion control unit. Based on the property of statistical textures of the molding surface, a series of digital image processing and classification procedure is carried out. After training of the parameter associated with above algorithm, result of the experiment suggests that the accuracy rate is up to 93.75%, contributing to the inspection quality of IC molding surface.

Keywords: molding surface, machine vision, statistical texture, discrete Fourier transformation

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Authors: Ali Ramezani

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Balancing feeding system of plastic injection molding has overriding importance as it minimizes the process’s product defects such as weld line, shrinkage, sink marks and warpage. This article presents the difference between optimization of feeding system in identical multi-cavity molding and family molding using Moldflow Plastic Insight software. In this work, the effect of dimension, shape, position and type of gates and runners on the products quality was studied. The optimization was carried out by analyzing plastic injection molding process parameters, including melt temperature, mold temperature, cooling time, cooling temperature packing time and packing pressure. It was found that symmetrical feeding system is the most efficient shape for diminishing defects in identical multi-cavity molding. However, the same results were not concluded for family molding due to the differences between volume, mass, thickness and shape of cavities.

Keywords: balancing feeding system, family molding, multi-cavity, Moldflow, plastic injection

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Authors: Burcu Kaya, Jan-Martin Kaiser, Karl-Friedrich Becker, Tanja Braun, Klaus-Dieter Lang

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Quality of the molded packages is strongly influenced by the process parameters of the transfer molding. To achieve a better package quality and a stable transfer molding process, it is necessary to understand the influence of the process parameters on the package quality. This work aims to comprehend the relationship between the process parameters, and to identify the optimum process parameters for the transfer molding process in order to achieve less voids and wire sweep. To achieve this, a DoE is executed for process optimization and a regression analysis is carried out. A systematic approach is represented to generate models which enable an estimation of the number of voids and wire sweep. Validation experiments are conducted to verify the model and the results are presented.

Keywords: dielectric analysis, electronic packages, epoxy molding compounds, transfer molding process

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Authors: Ehsan Gholami, Vincent Demers

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Low-pressure powder injection molding is an emerging technology for cost-effectively producing complex shape metallic parts with the proper dimensional tolerances, either in high or in low production volumes. In this study, the molding properties of cobalt-chrome-based feedstocks were evaluated for use in a low-pressure powder injection molding process. The rheological properties of feedstock formulations were obtained by mixing metallic powder with a proprietary wax-based binder system. Rheological parameters such as reference viscosity, shear rate sensitivity index, and activation energy for viscous flow, were extracted from the viscosity profiles and introduced into the Weir model to calculate the moldability index. Feedstocks were experimentally injected into a spiral mold cavity to validate the injection performance calculated with the model.

Keywords: binder, feedstock, moldability, powder injection molding, viscosity

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Authors: Tzai-Shiung Li, Wen-Bin Young

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The wind turbine blade sustains various kinds of loadings during the operating and parking state. Due to the increasing size of the wind turbine blade, it is important to arrange the composite materials in a sufficient way to reach the optimal utilization of the material strength. In the fabrication process of the vacuum assisted resin transfer molding, the fiber content of the turbine blade depends on the vacuum pressure. In this study, a design of the fiber layup for the vacuum assisted resin transfer molding is conducted to achieve the efficient utilization the material strength. This design is for the wind turbine blade consisting of shell skins with or without the spar structure.

Keywords: resin film infiltration, vacuum assisted resin transfer molding process, wind turbine blade, composite materials

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Authors: M. M. Mekkakia, M. P Luong, A. Arab

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These controlling the water content of compaction are a major concern of fundamental civil engineers. Also, the knowledge of the fundamentals of the behaviour of compacted clay soils is essential to predict and quantify the effects of a change in water content. The study of unsaturated soils is a very complex area which several studies are directed to in recent years. Our job work is to perform tests of Proctor, Oedometer and shear, on samples of unsaturated clay in order to see the influence of water content on the compressibility and the shear strength. The samples were prepared at different amounts of water from water content to optimum water contents close to saturation. This study thus allowed us to measure and monitor the parameters of compressibility and shear strength as a function of water content.

Keywords: laboratory tests, clay, unsaturated soil, atterberg limits, compaction, compressibility, shear

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Authors: Vigen Arakelian

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This paper deals with the study of devices for displacement of the mould base of blow-molding machines. The displacement of the mould in the studied case is carried out by a linear actuator, which ensures the descent of the mould base and by extension springs, which return the letter in the initial position. The aim of this paper is to study the inverse dynamics of the device for displacement of the mould base of blow-molding machines and to determine its optimum parameters for higher rate of production. In the other words, it is necessary to solve the inverse dynamic problem to find the equation of motion linking applied forces with displacements. This makes it possible to determine the stiffness coefficient of the spring to turn the mold base back to the initial position for a given time. The obtained results are illustrated by a numerical example. It is shown that applying a spring with stiffness returns the mould base of the blow molding machine into the initial position in 0.1 sec.

Keywords: design, mechanisms, dynamics, blow-molding machines

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Authors: B. S. So, Y. H. Yoon, J. O. Jung, K. S. Bae

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Metal Injection Molding (MIM) is a technology that combines powder metallurgy and injection molding. Particularly, it is widely applied to the manufacture of precision mobile parts and automobile turbocharger parts because compact precision parts with complicated three-dimensional shapes that are difficult to machining are formed into a large number of finished products. The swing valve is a valve that adjusts the boost pressure of the turbocharger. Since the head portion is exposed to the harsh temperature condition of about 900 degrees in the gasoline GDI engine, it is necessary to use Inconel material with excellent heat resistance and abrasion resistance, resulting in high manufacturing cost. In this study, we developed a swing valve using a metal powder injection molding based hybrid material (Inconel 713C material with heat resistance is applied to the head part, and HK30 material with low price is applied to the rest of the body part). For this purpose, the process conditions of the metal injection molding were optimized to minimize the internal defects, and the effectiveness was confirmed by the fracture strength and fatigue test.

Keywords: hybrid metal injection molding, swing valve, turbocharger, double injection

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Authors: Mehani Mouna, Segni Ladjel

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Medicinal and aromatic plants are promising and are characterized by the biosynthesis of odorous molecules that make up the so-called essential oils (EO), which have long been known for their antiseptic and therapeutic activity in folk medicine. The objective of this study was to evaluate the influence of drying in the shade on the water content and on the content of essential oils extracted from leaves of Eucalyptus camendulensis for better quality control of medicinal and aromatic plants. The water content of the Eucalyptus camendulensis plant material decreases during the drying process. It increased from 100 % to 0.006 % for the drying in the shade after ten days. The moisture content is practically constant at the end of the drying period. The drying in the shade increases the concentration of essential oils of Eucalyptus camendulensis. When the leaves of Eucalyptus camendulensis plant are in the shade, the maximum of the essential oil content was obtained on the eighth days; the recorded value was 1.43% ± 0.01%. Beyond these periods, the content continuously drops in before stabilizing. The optimum drying time is between 6 and 9 days.

Keywords: Eucalyptus camendulensis, drying, essential oils, water, content

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Authors: T. S. Ijimdiya, K. J. Osinubi

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This study examines the influence of compactive efforts on hydraulic conductivity behaviour of compacted black cotton soil treated with bagasse ash which is necessary in assessing the performance of the soil - bagasse ash mixture for use as a suitable barrier material in waste containment application. Black cotton soil treated with up to 12% bagasse ash (obtained from burning the fibrous residue from the extraction of sugar juice from sugarcane) by dry weight of soil for use in waste containment application. The natural soil classifies as A-7-6 or CH in accordance with the AASHTO and the Unified Soil Classification System, respectively. The treated soil samples were prepared at molding water contents of -2, 0, +2, and +4 % of optimum moisture contents and compacted using four compactive efforts of Reduced British Standard Light (RBSL), British Standard light (BSL), West African Standard (WAS) and British Standard Heavy (BSH). The results obtained show that hydraulic conductivity decreased with increase in bagasse ash content, moulding water content and compaction energy.

Keywords: bagasse ash treatment, black cotton soil, hydraulic conductivity, moulding water contents, compactive efforts

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Authors: Obeida Aiche, Mohamed Khiatine, Medjnoun Amal, Ramdane Bahar

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Soil compaction is one of the most challenging tasks in the construction of road embankments, railway platforms, and earth dams. Stability and durability are mainly related to the nature of the materials used and the type of soil in place. However, nature does not always offer the engineer materials with the right water content, especially in arid and semi-arid regions where obtaining the optimum Proctor water content requires the addition of considerable quantities of water. The current environmental context does not allow for the rational use of water, especially in arid and semi-arid regions, where it is preferable to preserve water resources for the benefit of the local population. Low water compaction can be an interesting approach as it promotes the reuse of earthworks materials in their dry or very dry state. Thanks to techniques in the field of soil compaction, such as vibratory compactors, which have made it possible to increase the compaction energy considerably, it is possible for some materials to obtain a satisfactory quality by compacting at low water contents or at least lower than the optimum determined by the Proctor test. This communication deals with the low water content compaction of soils in the semi-arid zone of the Chlef region in Algeria by increasing the compaction energy.

Keywords: compaction, soil, low water content, compaction energy

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Authors: Suwarno, M. Helmi Prakoso

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Mineral oil is commonly used for high voltage transformer insulation. The insulation quality of mineral oil is affecting the operation process of high voltage transformer. There are many contaminations which could decrease the insulation quality of mineral oil. One of them is water. This research talks about the effect of water content on dielectric properties, physic properties, and partial discharge pattern on mineral oil. Samples were varied with 10 varieties of water content value. And then all samples were tested to measure the dielectric properties, physic properties, and partial discharge pattern. The result of this research showed that an increment of water content value would decrease the insulation quality of mineral oil.

Keywords: dielectric properties, high voltage transformer, mineral oil, water content

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Authors: Chung-Chih Lin, Chien-Liang Wu

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The detection of the polymer melt state during manufacture process is regarded as an efficient way to control the molded part quality in advance. Online monitoring rheological property of polymer melt during processing procedure provides an approach to understand the melt state immediately. Rheological property reflects the polymer melt state at different processing parameters and is very important in injection molding process especially. An approach that demonstrates how to calculate rheological property of polymer melt through in-process measurement, using injection molding as an example, is proposed in this study. The system consists of two sensors and a data acquisition module can process the measured data, which are used for the calculation of rheological properties of polymer melt. The rheological properties of polymer melt discussed in this study include shear rate and viscosity which are investigated with respect to injection speed and melt temperature. The results show that the effect of injection speed on the rheological properties is apparent, especially for high melt temperature and should be considered for precision molding process.

Keywords: injection molding, melt viscosity, shear rate, monitoring

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Authors: R. N. Khare, J. P. Sahu, Rajesh Kumar Tamrakar

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Tests were conducted to determine the property of soil with variation of H2SO4 content for soils under different stage. The soils had varying amounts of plasticity’s ranging from low to high plasticity. The unsaturated soil behavior was investigated for different conditions, covering a range of compactive efforts and water contents. The soil characteristic curves were more sensitive to changes in compaction effort than changes in compaction water content. In this research paper two types of water (Ground water Ph =7.9, Turbidity= 13 ppm; Cl =2.1mg/l and surface water Ph =8.65; Turbidity=18.5; Cl=1mg/l) were selected of Bhilai Nagar, State-Chhattisgarh, India which is mixed with a certain type of soil. Results shows that by the presence of ground water day by day the particles are becoming coarser in 7 days thereafter its size reduces; on the other hand by the presence of surface water the courser particles are disintegrating, finer particles are accumulating and also the dry density is reduces. Plasticity soils retained the smallest water content and the highest plasticity soils retained the highest water content at a specified suction. In addition, soil characteristic for soils to be compacted in the laboratory and in the field are still under process for analyzing the bearing capacity. The bearing capacity was reduced 2 to 3 times in the presence of H2SO4.

Keywords: soil compaction, H2SO4, soil water, water conditions

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Authors: Leila Ben Haj Said, Sihem Bellagha, Karim Allaf

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The present study deals with the dehydrofreezing assisted by instant controlled pressure drop (DIC) treatment of apple fruits. Samples previously dehydrated until different water contents (200, 100, and 30% dry basis (db)) and DIC treated were frozen at two different freezing velocities (V+ and V-), depending on the thermal resistance established between the freezing airflow and the sample surface. The effects of sample water content (W) and freezing velocity (V) on freezing curves and characteristics, exudate water (EW) and texture variation were examined. Lower sample water content implied higher freezing rates, lower initial freezing points (IFP), lower practical freezing time (PFT), and lower specific freezing time (SFT). EW (expressed in g exudate water/100 g water in the product) of 200% and 100% db apple samples was approximately 3%, at low freezing velocity (V-). Whereas, it was lower than 0.5% for apple samples with 30% db water content. Moreover, the impact of freezing velocity on EW was significant and very important only for high water content samples. For samples whose water content was lower than 100% db, firmness (maximum puncture force) was as higher as the water content was lower, without any insignificant impact of freezing velocity.

Keywords: dehydrofreezing, instant controlled pressure drop DIC, freezing time, texture

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Authors: M. Shirinbayan, J. Fitoussi, N. Abbasnezhad, A. Lucas, A. Tcharkhtchi

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Sheet Molding Compounds (SMCs) with special microstructures are very attractive to use in automobile structures especially when they are accidentally subjected to collision type accidents because of their high energy absorption capacity. These are materials designated as standard SMC, Advanced Sheet Molding Compounds (A-SMC), Low-Density SMC (LD-SMC) and etc. In this study, testing methods have been performed to compare the mechanical responses and damage phenomena of SMC, LD-SMC, and A-SMC under quasi-static and high strain rate tensile tests. The paper also aims at investigating the effect of an initial pre-damage induced by fatigue on the tensile dynamic behavior of A-SMC. In the case of SMCs and A-SMCs, whatever the fibers orientation and applied strain rate are, the first observed phenomenon of damage corresponds to decohesion of the fiber-matrix interface which is followed by coalescence and multiplication of these micro-cracks and their propagations. For LD-SMCs, damage mechanisms depend on the presence of Hollow Glass Microspheres (HGM) and fibers orientation.

Keywords: SMC, Sheet Molding Compound, LD-SMC, Low-Density SMC, A-SMC, Advanced Sheet Molding Compounds, HGM, Hollow Glass Microspheres, damage

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Authors: Jian Wang, Lu Yang, Jiong Peng

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Internal circulation two-platen clamping system for injection molding machine (IMM) has many potential advantages on energy-saving. In order to estimate its properties, experiments in this paper were carried out. Displacement and pressure of the components were measured. In comparison, the model of hydraulic clamping system was established by using AMESim. The related parameters as well as the energy consumption could be calculated. According to the analysis, the hydraulic system was optimized in order to reduce the energy consumption.

Keywords: AMESim, energy-saving, injection molding machine, internal circulation

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Authors: Zachary N. Wing

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Compared to autoclave based processes, Resin Transfer Molding (RTM) offers several key advantages. This includes high internal and external complexity, less waste, lower volatile emissions, higher production rates, and excellent surface finish. However, the injection of high pressure-high temperature resin presents a tooling challenge in cases where trapped geometries exist. Tooling materials that can sustain these conditions and be easily removed would expand the use of RTM. We have performed research on developing an RTM suitable tooling material called 'RTMCore' for use in forming trapped geometries. RTMCore tooling materials can withstand the injection of high temperature-high pressure resin but be easily removed with tap water. RTM properties and performance capabilities are reviewed against other washout systems. Our research will cover the preliminary characterization of tooling system properties, mechanical behavior, and initial results from an RTM manufacturing trial. Preliminary results show the material can sustain pressures greater than 13 MPa and temperatures greater than 150°C.

Keywords: RTM, resin transfer molding, trapped geometries, washout tooling

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Authors: Ersin Sener, Ibrahim Demir, Hasan Aykut Karaboga, Kadir Kilinc

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Bayesian methods, which have very wide range of applications, are implemented to the data obtained from the production of F class fly ash-based geopolymer bricks’ experimental design. In this study, dependent variable is compressive strength, independent variables are treatment type (oven and steam), treatment time, molding time, temperature, water absorbtion ratio and density. The effect of independent variables on compressive strength is investigated. There is no difference among treatment types, but there is a correlation between independent variables. Therefore, hierarchical Bayesian path analysis is applied. In consequence of analysis we specified that treatment time, temperature and density effects on compressive strength is higher, molding time, and water absorbtion ratio is relatively low.

Keywords: experimental design, F class fly ash, geopolymer bricks, hierarchical Bayesian path analysis

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Authors: Asma A. Parlin, K. Nakamura, N. Watanabe, T. Komai

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Understanding the effective diffusion of benzene vapor in the soil-atmosphere interface is important as an intrusion of benzene into the atmosphere from the soil is largely driven by diffusion. To analyze the vertical one dimensional effective diffusion of benzene vapor in porous medium with high water content, diffusion experiments were conducted in soil columns using Andosol soil and Toyoura silica sand with different water content; for soil water content was from 0 to 30 wt.% and for sand it was from 0.06 to 10 wt.%. In soil, a linear relation was found between water content and effective diffusion coefficient while the effective diffusion coefficient didn’t change in the sand with increasing water. A numerical transport model following unsteady-state approaches based on Fick’s second law was used to match the required time for a steady state of the gas phase concentration profile of benzene to the experimentally measured concentration profile gas phase in the column. The result highlighted that both the water content and porosity might increase vertical diffusion of benzene vapor in soil.

Keywords: benzene vapor-phase, effective diffusion, subsurface soil medium, unsteady state

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Authors: Miriam I. Lautenschläger, Max H. Scheiwe, Kay A. Weidenmann, Frank Henning, Peter Elsner

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Due to increasing environmental awareness jute fibers are more often used in fiber reinforced composites. In the Sheet Molding Compound (SMC) process, the mold cavity is filled via material flow allowing more complex component design. But, the difficulty of using jute fibers in this process is the decreased capacity of fiber movement in the mold. A comparative flow study with jute nonwoven reinforced SMC was conducted examining the influence of the fiber volume content, the grammage of the jute nonwoven textile and a mechanical modification of the nonwoven textile on the flowability. The nonwoven textile reinforcement was selected to support homogeneous fiber distribution. Trials were performed using two SMC paste formulations differing only in filler type. Platy-shaped kaolin with a mean particle size of 0.8 μm and ashlar calcium carbonate with a mean particle size of 2.7 μm were selected as fillers. Ensuring comparability of the two SMC paste formulations the filler content was determined to reach equal initial viscosity for both systems. The calcium carbonate filled paste was set as reference. The flow study was conducted using a jute nonwoven textile with 300 g/m² as reference. The manufactured SMC sheets were stacked and centrally placed in a square mold. The mold coverage was varied between 25 and 90% keeping the weight of the stack for comparison constant. Comparing the influence of the two fillers kaolin yielded better results regarding a homogeneous fiber distribution. A mold coverage of about 68% was already sufficient to homogeneously fill the mold cavity whereas for calcium carbonate filled system about 79% mold coverage was necessary. The flow study revealed a strong influence of the fiber volume content on the flowability. A fiber volume content of 12 vol.-% and 25 vol.-% were compared for both SMC formulations. The lower fiber volume content strongly supported fiber transport whereas 25 vol.-% showed insignificant influence. The results indicate a limiting fiber volume content for the flowability. The influence of the nonwoven textile grammage was determined using nonwoven jute material with 500 g/m² and a fiber volume content of 20 vol.-%. The 500 g/m² reinforcement material showed inferior results with regard to fiber movement. A mold coverage of about 90 % was required to prevent the destruction of the nonwoven structure. Below this mold coverage the 500 g/m² nonwoven material was ripped and torn apart. Low mold coverages led to damage of the textile reinforcement. Due to the ripped nonwoven structure the textile was modified with cuts in order to facilitate fiber movement in the mold. Parallel cuts of about 20 mm length and 20 mm distance to each other were applied to the textile and stacked with varying orientations prior to molding. Stacks with unidirectional orientated cuts over stacks with cuts in various directions e.g. (0°, 45°, 90°, -45°) were investigated. The mechanical modification supported tearing of the textile without achieving benefit for the flowability.

Keywords: filler, flowability, jute fiber, nonwoven, sheet molding compound

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Authors: A. Hamidi, S. Khelladi, L. Illoul, A. Tcharkhtchi

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Reactive rotational molding (RRM) is a process to manufacture hollow plastic parts with reactive material has several advantages compared to conventional roto molding of thermoplastic powders: process cycle time is shorter; raw material is less expensive because polymerization occurs during processing and high-performance polymers may be used such as thermosets, thermoplastics or blends. However, several phenomena occur during this process which makes the optimization of the process quite complex. In this study, we have used a mixture of isocyanate and polyol as a reactive system. The chemical transformation of this system to polyurethane has been studied by thermal analysis and rheology tests. Thanks to these results of the curing process and rheological measurements, the kinetic and rheokinetik of polyurethane was identified. Smoothed Particle Hydrodynamics, a Lagrangian meshless method, was chosen to simulate reactive fluid flow in 2 and 3D configurations of the polyurethane during the process taking into account the chemical, and chemiorehological results obtained experimentally in this study.

Keywords: reactive rotational molding, simulation, smoothed particle hydrodynamics, surface tension, rheology, free surface flows, viscoelastic, interpolation

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Authors: Muhammad Naeem, Amina Zubari, Abdus Salam, Syed Ali Ayub Bukhari, Naveed Ahmad Khan

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Seventy three wild Labeo bata of different body sizes, ranging from 8.20-16.00 cm total length and 7.4-86.19 g body weight, were studied for the analysis of body composition parameters (Water content, ash content, fat content, protein content) in relation to body size and condition factor. Mean percentage is found as for water 77.71 %, ash 3.42 %, fat 2.20 % and protein content 16.65 % in whole wet body weight. Highly significant positive correlations were observed between condition factor and body weight (r = 0.243). Protein contents, organic content and ash (% wet body weight) increase with increasing percent water contents for Labeo bata while these constituents (% dry body weight) and fat contents (% wet and dry body weight) have no influence on percent water. It was observed that variations in the body constituents have no association to body weight or length.

Keywords: Labeo bata, body size, body composition, condition factor

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Authors: Nagri Sateesh, Kundavarapu Vengalrao, Kopparthi Phaneendra Kumar

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Vacuum assisted resin transfer molding (VARTM) is one of the manufacturing technique that is viable for production of fiber reinforced polymer composite components suitable for aerospace, marine and commercial applications. However, the repeatable quality of the product can be achieved by critically fixing the process parameters such as Vacuum Pressure (VP) and permeability of the preform. The present investigation is aimed at studying the effect of permeability for production of Glass Fiber Reinforced Plastic (GFRP) components with consistent quality. The VARTM mould is made with an acrylic transparent top cover to observe and record the resin flow pattern. Six layers of randomly placed glass fiber under five different vacuum pressures VP1 = 0.013, VP2 = 0.026, VP3 = 0.039, VP4 = 0.053 and VP5 = 0.066 MPa were studied. The laminates produced by this process under the above mentioned conditions were characterized with ASTM D procedures so as to study the effect of these process parameters on the quality of the laminate. Moreover, as mentioned there is a considerable effect of permeability on the impact strength and the void content in the laminates under different vacuum pressures. SEM analysis of the impact tested fractured GFRP composites showed the bonding of fiber and matrix.

Keywords: permeability, vacuum assisted resin transfer molding (VARTM), ASTM D standards, SEM

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Authors: Sky Chou, Joseph C. Chen

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This paper focuses on using six sigma methodologies to reach the desired shrinkage of a manufactured high-density polyurethane (HDPE) part produced by the injection molding machine. It presents a case study where the correct shrinkage is required to reduce or eliminate defects and to improve the process capability index Cp and Cpk for an injection molding process. To improve this process and keep the product within specifications, the six sigma methodology, design, measure, analyze, improve, and control (DMAIC) approach, was implemented in this study. The six sigma approach was paired with the Taguchi methodology to identify the optimized processing parameters that keep the shrinkage rate within the specifications by our customer. An L9 orthogonal array was applied in the Taguchi experimental design, with four controllable factors and one non-controllable/noise factor. The four controllable factors identified consist of the cooling time, melt temperature, holding time, and metering stroke. The noise factor is the difference between material brand 1 and material brand 2. After the confirmation run was completed, measurements verify that the new parameter settings are optimal. With the new settings, the process capability index has improved dramatically. The purpose of this study is to show that the six sigma and Taguchi methodology can be efficiently used to determine important factors that will improve the process capability index of the injection molding process.

Keywords: injection molding, shrinkage, six sigma, Taguchi parameter design

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Authors: Al-Molhem, Y.

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This work aimed to study the influence of a geotextile material under sprinkler irrigation on the availability of soil moisture content and salinity of 40 cm top soil profile. Field experiment was carried out to measure soil moisture content, soil salinity and water application efficiency under sprinkler irrigation system. The results indicated that, the mats placed at 20 cm depth leads to increasing of the availability of soil moisture content in the root zone. The results further showed increases in water application efficiency because of using the geotextile material. In addition, soil salinity in the root zone decreased because of increasing soil moisture content.

Keywords: geotextile, moisture content, sprinkler irrigation

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Authors: Herman Ruswan Suwarman, Ahmad Rivai, Mochamad Saidiman, Kuncoro Diharjo, Dody Ariawan

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The use of biodegradable composite to solve ecological and environmental problems has currently risen as a trend. With the increasing use of biodegradable composite comes an increasing need to fabricate it properly. Yet this understanding has remained a challenge for the design engineer. Therefore, this study aims to explore how to combine coconut coir as a reinforcing material and polypropylene (PP) as a biodegradable polymer matrix. By using Hotpress Molding, two methods were developed and compared. The difference between these two methods is not only the step of fabrication but also the raw material. The first method involved a PP sheet and the second used PP pellets directly. Based on the results, it can be concluded that PP pellets yield better results, where the composite was produced in a shorter time, with an evenly distributed coconut coir and a smaller number of voids.

Keywords: biodegradable, coconut coir, hot press molding, polypropylene

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Authors: Maria Fonseca, Ana Branco, Joao Graca, Rui Mendes, Pedro Mimoso

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The present work is focused on the production of a carbon composite element for cycling through different techniques, namely, blow-molding and high-pressure resin transfer injection (HP-RTM). The main objective of this work is to compare both processes to produce carbon composite elements for the cycling industry. It is well known that the carbon composite components for cycling are produced mainly through blow-molding; however, this technique depends strongly on manual labour, resulting in a time-consuming production process. Comparatively, HP-RTM offers a more automated process which should lead to higher production rates. Nevertheless, a comparison of the elements produced through both techniques must be done, in order to assess if the final products comply with the required standards of the industry. The main difference between said techniques lies in the used material. Blow-moulding uses carbon prepreg (carbon fibres pre-impregnated with a resin system), and the material is laid up by hand, piece by piece, on a mould or on a hard male. After that, the material is cured at a high temperature. On the other hand, in the HP-RTM technique, dry carbon fibres are placed on a mould, and then resin is injected at high pressure. After some research regarding the best material systems (prepregs and braids) and suppliers, an element was designed (similar to a handlebar) to be constructed. The next step was to perform FEM simulations in order to determine what the best layup of the composite material was. The simulations were done for the prepreg material, and the obtained layup was transposed to the braids. The selected material was a prepreg with T700 carbon fibre (24K) and an epoxy resin system, for the blow-molding technique. For HP-RTM, carbon fibre elastic UD tubes and ± 45º braids were used, with both 3K and 6K filaments per tow, and the resin system was an epoxy as well. After the simulations for the prepreg material, the optimized layup was: [45°, -45°,45°, -45°,0°,0°]. For HP-RTM, the transposed layup was [ ± 45° (6k); 0° (6k); partial ± 45° (6k); partial ± 45° (6k); ± 45° (3k); ± 45° (3k)]. The mechanical tests showed that both elements can withstand the maximum load (in this case, 1000 N); however, the one produced through blow-molding can support higher loads (≈1300N against 1100N from HP-RTM). In what concerns to the fibre volume fraction (FVF), the HP-RTM element has a slightly higher value ( > 61% compared to 59% of the blow-molding technique). The optical microscopy has shown that both elements have a low void content. In conclusion, the elements produced using HP-RTM can compare to the ones produced through blow-molding, both in mechanical testing and in the visual aspect. Nevertheless, there is still space for improvement in the HP-RTM elements since the layup of the braids, and UD tubes could be optimized.

Keywords: HP-RTM, carbon composites, cycling, FEM

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Authors: G. E. Gandomkar, E. Bekhradinassab, S. Sabbaghi, M. M. Zerafat

Abstract:

The reduction of water content in crude oil emulsions reduces pipeline corrosion potential and increases the productivity. Chemical emulsification of crude oil emulsions is one of the methods available to reduce the water content. Presence of demulsifier causes the film layer between the crude oil emulsion and water droplets to become unstable leading to the acceleration of water coalescence. This research has been performed to study the improvement performance of a chemical demulsifier by silica nanoparticles. The silica nano-particles have been synthesized by sol-gel technique and precipitation using poly vinyl alcohol (PVA) and poly ethylene glycol (PEG) as surfactants and then nano-particles are added to the demulsifier. The silica nanoparticles were characterized by Particle Size Analyzer (PSA) and SEM. Upon the addition of nanoparticles, bottle tests have been carried out to separate and measure the water content. The results show that silica nano-particles increase the demulsifier efficiency by about 40%.

Keywords: demulsifier, dehydration, silicon dioxide, nanoparticle

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