Hybrid mold: comparative study of rapid and hard tooling for injection molding application using Metal Epoxy Composite (MEC)
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2022
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my.unimap-747532022-03-23T01:23:08Z Hybrid mold: comparative study of rapid and hard tooling for injection molding application using Metal Epoxy Composite (MEC) Radhwan, Hussin Radhwan, Hussin Safian, Sharif Nabiałek, Marcin Shayfull Zamree, Abd Rahim Mohd Tanwyn, Mohd Khushairi Mohd Azlan, Suhaimi Mohd Mustafa Al Bakri, Abdullah Mohd Hazwan, Mohd Hanid Wysłocki, Jerzy J. Bloch, Katarzyna radhwan@unimap.edu.my Faculty of Mechanical Engineering, Universiti Teknology Malaysia (UTM) Center of Excellence Geopolymer and Green Technology (CEGeoGTech), School of Materials Engineering, Universiti Malaysia Perlis (UniMAP) Faculty of Mechanical Engineering Technology, Universiti Malaysia Perlis (UniMAP) Department of Physics, Częstochowa University of Technology IMU Centre for Life-Long Learning (ICL), International Medical University Faculty of Chemical Engineering Technology, Universiti Malaysia Perlis (UniMAP) Hybrid mold Rapid tooling (RT) Metal epoxy composite (MEC) Material properties Injection molding process Link to publisher's homepage at https://www.mdpi.com/journal/materials The mold-making industry is currently facing several challenges, including new competitors in the market as well as the increasing demand for a low volume of precision moldings. The purpose of this research is to appraise a new formulation of Metal Epoxy Composite (MEC) materials as a mold insert. The fabrication of mold inserts using MEC provided commercial opportunities and an alternative rapid tooling method for injection molding application. It is hypothesized that the addition of filler particles such as brass and copper powders would be able to further increase mold performance such as compression strength and thermal properties, which are essential in the production of plastic parts for the new product development. This study involved four phases, which are epoxy matrix design, material properties characterization, mold design, and finally the fabrication of the mold insert. Epoxy resins filled with brass (EB) and copper (EC) powders were mixed separately into 10 wt% until 30 wt% of the mass composition ratio. Control factors such as degassing time, curing temperature, and mixing time to increase physical and mechanical properties were optimized using the Response Surface Method (RSM). The study provided optimum parameters for mixing epoxy resin with fillers, where the degassing time was found to be the critical factor with 35.91%, followed by curing temperature with 3.53% and mixing time with 2.08%. The mold inserts were fabricated for EB and EC at 30 wt% based on the optimization outcome from RSM and statistical ANOVA results. It was also revealed that the EC mold insert offers better cycle time compared to EB mold insert material. 2022 2022-03-23T01:20:25Z 2022-03-23T01:20:25Z 2021-02 Article Materials, vol. 14(3), 2021, 15 pages 1996-1944 http://dspace.unimap.edu.my:80/xmlui/handle/123456789/74753 https://doi.org/10.3390/ma14030665 en MDPI AG |
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| topic |
Hybrid mold Rapid tooling (RT) Metal epoxy composite (MEC) Material properties Injection molding process |
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Hybrid mold Rapid tooling (RT) Metal epoxy composite (MEC) Material properties Injection molding process Radhwan, Hussin Radhwan, Hussin Safian, Sharif Nabiałek, Marcin Shayfull Zamree, Abd Rahim Mohd Tanwyn, Mohd Khushairi Mohd Azlan, Suhaimi Mohd Mustafa Al Bakri, Abdullah Mohd Hazwan, Mohd Hanid Wysłocki, Jerzy J. Bloch, Katarzyna Hybrid mold: comparative study of rapid and hard tooling for injection molding application using Metal Epoxy Composite (MEC) |
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Link to publisher's homepage at https://www.mdpi.com/journal/materials |
| author2 |
radhwan@unimap.edu.my |
| author_facet |
radhwan@unimap.edu.my Radhwan, Hussin Radhwan, Hussin Safian, Sharif Nabiałek, Marcin Shayfull Zamree, Abd Rahim Mohd Tanwyn, Mohd Khushairi Mohd Azlan, Suhaimi Mohd Mustafa Al Bakri, Abdullah Mohd Hazwan, Mohd Hanid Wysłocki, Jerzy J. Bloch, Katarzyna |
| format |
Article |
| author |
Radhwan, Hussin Radhwan, Hussin Safian, Sharif Nabiałek, Marcin Shayfull Zamree, Abd Rahim Mohd Tanwyn, Mohd Khushairi Mohd Azlan, Suhaimi Mohd Mustafa Al Bakri, Abdullah Mohd Hazwan, Mohd Hanid Wysłocki, Jerzy J. Bloch, Katarzyna |
| author_sort |
Radhwan, Hussin |
| title |
Hybrid mold: comparative study of rapid and hard tooling for injection molding application using Metal Epoxy Composite (MEC) |
| title_short |
Hybrid mold: comparative study of rapid and hard tooling for injection molding application using Metal Epoxy Composite (MEC) |
| title_full |
Hybrid mold: comparative study of rapid and hard tooling for injection molding application using Metal Epoxy Composite (MEC) |
| title_fullStr |
Hybrid mold: comparative study of rapid and hard tooling for injection molding application using Metal Epoxy Composite (MEC) |
| title_full_unstemmed |
Hybrid mold: comparative study of rapid and hard tooling for injection molding application using Metal Epoxy Composite (MEC) |
| title_sort |
hybrid mold: comparative study of rapid and hard tooling for injection molding application using metal epoxy composite (mec) |
| publisher |
MDPI AG |
| publishDate |
2022 |
| url |
http://dspace.unimap.edu.my:80/xmlui/handle/123456789/74753 |
| _version_ |
1729704801837514752 |