Rosli, Mohammad Shahir (2023) Multiple response Taguchi optimisation for injected moulded polypropylene nanoclay processing and fibre content, for building appliances. Doctoral thesis, Universiti Tun Hussein Onn Malaysia.

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Abstract

This study examines the impact of compounding gigantochloa scortechinii (GS) and polypropylene-nanoclay components through multiple response optimisations. Taguchi Orthogonal Array method is employed to optimise the injection moulding process parameters, including melt flow index, flexural strength, warpage, and shrinkage. The research started with simulation analysis of the injection moulding process to assess the suitability of the design sample according to ISO 178 (flexural bar shape). The compounding materials used in this study consisted of polypropylene, nanoclay, a compatibilizer called polypropylene graft maleic anhydride (PP-g-MA), and GS (gigantochloa scortechinii), commonly known as bamboo fibre. To facilitate comparison, three different contents of natural fibre were selected: 0wt.%GS, 3wt.%GS, and 6wt.%GS. These contents were tested under various injection moulding processing conditions such as packing pressure, melting temperature, screwing speed, and filling time. Based on the analysis of the signal- to-noise ratio, the highest S/NQP value was observed at 6wt.%GS, measuring 160.6451 dB, followed by 3wt.%GS (158.1919 dB) and 0wt.%GS (134.8150 dB). Moreover, the presence of Gigantochloa Scortechinii caused a shift in the most influential parameter, altering it from melting temperature to packing pressure. In order to validate the optimised results, a test was conducted to determine the percentage of improvement of multiple responses. Next, the test also compared the effects of GS content under the optimised injection moulding processing conditions. These optimised results served as a recommended reference and prediction approach, specifically in terms of looking at the impact of compounding polypropylene-nanoclay-gigantochloa scortechinii in the plastic manufacturing process. Essentially, the findings of this study could contribute towards broader and more efficient applications of building appliances such as frame, pavement and tiles

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