A STUDY OF WARPAGE FOR A NEWLY INSERT INJECTION-MOLDED FRAME USING TAGUCHI AND RESPONSE SURFACE METHOD

Abstract

In the present study, a numerical investigation of warpage in injection-molded integrated mold frame units was carried out based on Taguchi method and Response Surface Methodology (RSM). In order to minimize and integrate the components of back light unit for a liquid crystal display, an integrated mold frame unit was developed by integrating conventional mold frame, metal reflector, and bezel together. Employing an insert injection molding, a slim composite part with a high strength could be successfully obtained. For a reliable mass production, it is required to minimize warpage defect by numerical investigation. The influences of parameters were analyzed based on Taguchi technique and RSM, as a result, packing pressure played the most significant role. Furthermore, the optimum conditions for all processing parameters were proposed. The present investigation can be used in a development and a reliable manufacturing of novel functional products with high precision and minimal material consumption.