Warpage minimisation on side arm using response surface methodology (RSM)
Abstract
Catheter manufacturing process requires the use of mould called side arm through latex dipping process. Manufacturing process of a nylon PA66 - side arm via an injection moulding often leads to undesirable warpage. This research tends to determine the
optimum processing parameters that can be used for manufacturing side arms in minimizing the warpage issues. The considered processing parameters were packing pressure, packing time, cooling time, mould temperature and melt temperature. Apart
from that, this research also tries to find the most significant factor affecting the warpage. The side arm model was developed via computer aided drafting (CAD)
software and the whole analyses on the warpage was executed via a simulation software
while the parameters concerned were optimised through response surface methodology.
As a result, the optimised parameter settings are 76.57 MPa, 0.60 s, 8.30 s, 34.45 °C and
275.00 °C acquired for packing pressure, packing time, cooling time, mould
temperature and melt temperature respectively. On top of that, cooling time has been
found to be the most influential parameter affecting the warpage with contribution
factor of 4.01 % compared to others. The warpage based on parameter settings
recommended by the simulation software has also been compared with that after the
optimisation. It can be concluded that the warpage after optimisation is 22.8 % reduced
compared to the original recommended setting.