FINAL PROJECT
OPTIMIZATION OF PROCESSING PARAMETER FOR
RECYCLED POLYPROPYLENE-NANOCLAY ON TENSILE
STRENGTH
A thesis submitted in
fulfilment of the requirement for the award of the
Degree Bachelor of Mechanical Engineering
Arranged by :
ANIS FIRMANSAH
D20A143006
MECHANICAL ENGINEERING DEPARTMEN INTERNATIONAL
PROGAM
UNIVERSITAS MUHAMMADIYAH SURAKARTA
2019
i
UNIVERSITAS MUHAMMADIYAH SURAKARTA
UNIVERSITI TUN HUSSEIN ONN MALAYSIA
STATUS CONFIRMATION FOR UNDERGRADUATE
OPTIMIZATION OF PROCESSING PARAMETER FOR RECYCLED
POLYPROPYLENE-NANOCLAY ON TENSILE STRENGTH
ACADEMIC SESSION: 2018/2019
I, ANIS FIRMANSAH agree to allow this Undergraduate Project Report to be kept
at theLibrary under the following terms:
1. This Undergraduate Project Report is the property of the Universitas
Muhammadiyah Surakarta.
2. The library has the right to make copies for educational purposes only.
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between higher educational institutions.
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OFFICIAL SECRET ACT 1972)
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Date: 09 – 8 - 2019 Date: 09 – 8 - 2019
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OPTIMIZATION OF PROCESSING PARAMETER FOR RECYCLED
POLYPROPYLENE-NANOCLAY ON TENSILE STRENGTH
ANIS FIRMANSAH
A thesis submitted in
fulfilment of the requirement for the award of the
Degree in Bachelor of Mechanical Engineering
Engineering Faculty Majoring in Mechanical Engineering
Universitas Muhammadiyah Surakarta
AUGUST 2019
iii
VALIDATION SHEET
This Final Report has been checked, accepted and legalized by supervisor,
knowing by head of Mechanical Engineering Department Universitas
Muhammadiyah Surakarta.
Composed by:
Name : ANIS FIRMANSAH (D20A143006)
Approved on :
Day:
Date:
Head of Mecahnical Eng. Department Supervisor
Universitas muhammadiyah surakarta
Ir. Subroto M.T Wijianto, ST, M.Eng.Sc
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ACKNOWLEDGEMENT
Alhamdulillah, all praise to Allah who gives me the strength and His blessing so that
I can complete the thesis. My appreciations are firstly dedicated to my parent who
always raises me up whenever I am feeling down. Secondly, thanks to my brother
who always have time to listen and give spirit to finish the thesis as soon as possible.
Thirdly, thanks to Mr. Wijianto S.T.,M.Eng.,Sc and Dr. Mohd Hilmi Bin Othman
who always guide me patiently. Moreover, thanks to Lab keeper for giving me
permission to work in Ceramic and Polymer Laboratory so that I can perform and
finish the research.
To all my friend, who always support me when I have doubt about the research. You
are my family in Malaysia. Finally thanks to everyone directly and indirectly, who is
supporting me for this report and anything. For me it is very helpful for making this
research done.
v
ABSTRACT
Injection moulding is one of the most efficient process in mass production that can
easily produce accurate geometry product with very short cycle time. The main
purpose of this research is to analyze the effect of processing parameter on the
quality of the product. Through this experiment, the parameters that are going to be
used are melt temperature, packing pressure, screw speed, and filling time. The
materials that will be used in this study are polypropylene and recycled
polypropylene nanoclay. According to the results, 100% polypropylene give average
tensile strength value around 28.5 MPa with best parameters are melt temperature
160°C, packing pressure 60%, screw speed 70%, filling time 2s. 50% recycled
polypropylene give tensile strength value around 28.6 MPa with 160°C, 70%, 60%,
3s. 75% recycled polypropylene nanoclay give 28.2 MPa tensile strength value with
165°C, 60%, 70%, 3s. 25% recycled polypropylene nanoclay give 28.54 MPa tensile
strength value with 165°C, 60%, 70%, 3s. The last recycled polypropylene nanoclay
100% give tensile strength value of 27.9 MPa with melt temperature 160°C, 70%,
50%,1s. Each composition for tensile shown different value according to their
recycled PPNC percentage.
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ABSTRAK
Cetakan injeksi adalah salah satu proses paling efisien dalam produksi massal yang
dapat dengan mudah menghasilkan produk geometri yang akurat dengan waktu
siklus yang sangat singkat. Tujuan utama dari penelitian ini adalah untuk
menganalisis pengaruh parameter pemrosesan terhadap kualitas produk. Melalui
percobaan ini, parameter yang akan digunakan adalah suhu leleh, tekanan
pengepakan, kecepatan sekrup, dan waktu pengisian. Bahan-bahan yang akan
digunakan dalam penelitian ini adalah polypropylene dan polypropylene- nanoclay
daur ulang. Menurut hasil, 100% polypropylene memberikan nilai kekuatan tarik
rata-rata sekitar 28,5 MPa dengan parameter terbaik adalah suhu leleh 160 °C,
tekanan pengepakan 60%, kecepatan sekrup 70%, waktu pengisian 2s. Polypropylene
daur ulang 50% memberikan nilai kekuatan tarik sekitar 28,6 MPa dengan 160 °C,
70%, 60%, 3s. 75% daur ulang nanoclay polypropylene memberikan nilai kekuatan
tarik 28,2 MPa dengan 165 °C, 60%, 70%, 3s. 25% polypropylene-nanoclay daur
ulang memberikan nilai kekuatan tarik 28,54 MPa dengan 165 °C, 60%, 70%, 3s.
100% polypropylene-nanoclay daur ulang terakhir memberikan nilai kekuatan tarik
27,9 MPa dengan suhu leleh 160 °C, 70%, 50%, 1s. Setiap komposisi untuk uji tarik
menunjukkan nilai yang berbeda sesuai dengan persentase PPNC daur ulang masing-
masing komposisi.
vii
TABLE OF CONTENTS
APROVAL SHEET .................................................................................... i
TITLE .......................................................................................................... ii
VALIDATION SHEET .............................................................................. iii
ACKNOWLEDGEMENT .......................................................................... iv
ABSTRACT ................................................................................................ v
ABSTRAK .................................................................................................. vi
TABLE OF CONTENTS ............................................................................ vii
LIST OF TABLE ........................................................................................ ix
LIST OF FIGURES..................................................................................... xi
LIST OF SYMBOLS AND ABBREVIATIONS ....................................... xii
LIST OF APPENDICES ............................................................................. xiiii
CHAPTER 1 INTRODUCTION............................................................. 1
1.1 Background Study........................................................... 1
1.2 Problem Statement .......................................................... 2
1.3 Objectives ....................................................................... 3
1.4 Scope of Study ................................................................ 3
1.5 Expected Result .............................................................. 3
CHAPTER 2 LITERATURE REVIEW.................................................. 4
2.1 Injection Molding ........................................................... 5
2.2 Injection Molding Machine ........................................... 7
2.3 Mold ............................................................................... 8
2.4 Material Chosen ............................................................. 9
2.5 Injection Molding Parameter ........................................ 11
2.6 Recent Trend of Injection Molding .............................. 14
viii
2.7 PPNC Mechanical Properties.......................................... 14
2.8 Optimization of Injection Molding ................................. 17
CHAPTER 3 METHODOLOGY ............................................................ 19
3.1 Project Planning .............................................................. 21
3.2 Material Preparation for Injection Molding .................... 22
3.3 Mechanical Properties..................................................... 25
3.4 Optimization of Parameter .............................................. 26
3.5 Optimal Part Condition ................................................... 28
CHAPTER 4 RESULTS AND DISCUSSION ....................................... 29
4.1 Analysis Tensile Strength ............................................... 30
4.2 Conceptual Signal to Noise Ratio Approach .................. 32
4.3 Signal to Noise Ratio Response ...................................... 35
CHAPTER 5 CONCUSSION AND RECOMMENDATIONS .............. 45
5.1 Conclusion ...................................................................... 45
5.2 Recommendation ............................................................ 46
REFERENCE ........................................................................................... 44
APPENDIX ........................................................................................... 47
ix
LIST OF TABLES
Table 2.1 : General properties of Polypropylene ....................................................... 10
Table 2.2 : Comparison of unmodified PP with other materials: Disadvantages ..... 11
Table 2.3 : Tensile strength test result of specimen .................................................. 15
Table 2.4 : Flexural strength test result ..................................................................... 15
Table 3.1 : General Properties of Polypropylene ....................................................... 22
Table 3.2 : Mixtures percentages of PP and recycled PPNC ..................................... 22
Table 3.3 : The factor and level selected ................................................................... 26
Table 3.4 : Orthogonal Array selected (L934) ............................................................ 27
Table 4.1 : Tensile strength value for 100% Polypropylene ...................................... 30
Table 4.2 : Tensile strength value for 50% Polypropylene, 50% recycled
Polypropylene nanoclay ..................................................................................... 30
Table 4.3 : Tensile strength value for 75% Polypropylene, 25% recycled
Polypropylene nanoclay ..................................................................................... 31
Table 4.4 : Tensile strength value for 25% Polypropylene, 75% recycled
Polypropylene nanoclay ..................................................................................... 31
Table 4.5 : Tensile strength value for 0% Polypropylene, 100% recycled
Polypropylene-nanoclay. .................................................................................... 31
Table 4.6 : Signal to Noise Value for 100% Polypropylene ...................................... 33
Table 4.7 : Signal to Noise Value for Polypropylene 50%, recycled Polypropylene
nanoclay 50% ..................................................................................................... 34
Table 4.8 : Signal to Noise Value for Polypropylene 75%, recycled Polypropylene
nanoclay 25% ..................................................................................................... 34
Table 4.9 : Signal to Noise Value for Polypropylene 25%, recycled Polypropylene
nanoclay 75% ..................................................................................................... 34
Table 4.10 : Signal to Noise Value for recycled Polypropylene nanoclay 100% ...... 34
Table 4.11 : The response values table of S/N ratio for tensile strength
(Polypropylene 100%) ....................................................................................... 36
x
Table 4.12 : The response values table of S/N ratio for tensile strength
(Polypropylene 50% + recycled Polypropylene Nanoclay 50%) ....................... 37
Table 4.13 : The response values table of S/N ratio for tensile strength
(Polypropylene 75% + recycled Polypropylene Nanoclay 25%) ....................... 37
Table 4.14 : The response values table of S/N ratio for tensile strength
(Polypropylene 25% + recycled Polypropylene Nanoclay 75%) ....................... 38
Table 4.15 : The response values table of S/N ratio for tensile strength
(Polypropylene 0% + recycled Polypropylene Nanoclay 100%) ....................... 38
Table 4.16 : Best combination parameter of processing condition for Polypropylene
.......................................................................................................................... 42
Table 4.17 : Best combination parameter of processing condition for Polypropylene
50% and recycled Polypropylene-nanoclay 50% ............................................... 43
Table 4.18 : Best combination parameter of processing condition for Polypropylene
75% and recycled Polypropylene-nanoclay 25% ............................................... 43
Table 4.19 : Best combination parameter of processing condition for Polypropylene
25% and recycled Polypropylene-nanoclay 75% ............................................... 44
Table 4.20 : Best combination parameter of processing condition for Polypropylene
0% and recycled Polypropylene-nanoclay 100% ............................................... 44
xi
LIST OF FIGURES
Figure 2.1 : Depiction of the injection molding process (Kazmer, 2016) .................. 6
Figure 2.2 : Injection molding process timing (Kazmer, 2016) ................................. 6
Figure 2.3 : Schematic of injection molding machine (Groover, 2007). ................... 7
Figure 2.4 : Details of two plate mold (Groover, 2007)............................................. 8
Figure 3.1 : Dogbone shape ....................................................................................... 21
Figure 3.2 Granulator machine .................................................................................. 23
Figure 3.3 Crushed recycled PPNC ........................................................................... 23
Figure 3.4 Weigher..................................................................................................... 24
Figure 3.5 Injection moulding machine ..................................................................... 25
Figure 3.6 Universal testing machine......................................................................... 25
Figure 4.1 : The tensile S/N ratio for 100% of PP ..................................................... 40
Figure 4.2 : The tensile S/N ratio for 50% PP............................................................ 40
Figure 4.3 : The tensile S/N ratio for 75% PP............................................................ 41
Figure 4.4 : The tensile S/N ratio for 25% PP............................................................ 41
Figure 4.5 : The tensile S/N ratio for 0% PP.............................................................. 42
xii
LIST OF SYMBOLS AND ABBREVIATIONS
ANOVA - Analysis of Variance
h - Maximum Height
L
Lc
t
no.
S
Z
S/N
b
b1
Lave
ta
Tmold
Tambient
α
-
-
-
-
-
-
-
-
-
-
-
-
-
-
Length
Actual Mold Cavity Length
Thickness
Number
Shrinkage
Warpage
Signal of Noise Ratio
Width of Narrow section
Width Overall
Length Average
Average Plate Thickness
Mold Temperature in °F
Ambient Temperature in °F
Coefficient of Thermal Expansion for Steel Mold
xiii
LIST OF APPENDICES
APPENDIX TITLE PAGE
A Gantt Chart for PSM 1 & 2 51