Plastik enjeksiyon prosesinde eksik enjeksiyon hatasının engellenmesi

The Plastic injection molding machine (IMM) has been one of the most preferred manufacturing methods since its invention and continues its development in parallel with the advancing technology. The demand for faster, better quality, and cheaper parts with improved quality output is increasing day by day. Manufacturers are dealing with quality errors in production while trying to meet this demand. The most common of these quality errors are the short shot missing injection error. The special mold investment, changing of part design, and usage of distinct plastic raw materials are carried out to solve this error. The most practical temporary action taken to prevent this error in production is to increase the raw material's weight by optimizing the process parameters. Unfortunately, all of these solution methods increase the product cost. This thesis aims to develop a system for preventing short shot quality failure without using a solution to massive increase the part's cost. Firstly, the finite element analysis (FEA) for the short shot quality defect in injection machinery molding (IMM) is performed via Autodesk Moldflow Analysis. The mold flow FEA model is verified in serial production. Then, IMM is integrated into manufacturing execution system (MES) and a quality control system with cameras installed at the end of the production line. The relationship between short shot quality defect and IMM critical process parameters extracted with data analytic. The model is generated and commissioned in the production line. The integration of each production line into MES and installing a camera measurement system can adversely affect industrial deployment sustainability. Therefore, a different approach is developed with in-mold pressure/temperature sensors. The production parameters affecting the short shot quality failure are determined via the data analytics. The goal is to produce the system in the ideal range in each cycle by giving feedback to the IMM according to the in-mold sensors' data during production. The main aim of this thesis is to avoid short-shot quality failure in plastic part production. The short-shot quality defect has not been eliminated in this study. However, it has decreased from 3.7% error rates to 0.82%. This dramatic reduction results in an overall 80% improvement in short shot quality failure without increasing product cost.