CUSUM
Injection Molding For Beginners
Lesson 7
Presented by: QE NPI Andres Ruelas
Created by: QE NPI Andres Ruelas Injection Molding Beginners Email us at info@[Link]
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CUSUM
• Copyright © 2021 by Pablo Andres Ruelas Juarez
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Created by: QE NPI Andres Ruelas Injection Molding Beginners Email us at info@[Link]
[Link] Thank you for Growing with us! [Link]
Instructor: Andres Ruelas CUSUM
• Quality and New Product Introduction Engineer
• Medical sector (Cardinal Health, Medtronic, Stryker, Teleflex)
• Specialized in molding, extrusion, sealing with Urania and Multivac
equipment, and automatic inspection systems
• 7 published textbooks, available at Amazon
• Quality Engineering for Recent College Graduates (Engineering / Quality)
• Guía Para la inversión utilizando Cetes Directo (Finance / Costs)
• Minitab Masters Fundamentals / Validations (Engineering / DOE)
• Cetys University: Diploma in Medical Manufacturing Engineering
• Cetys University: Diploma in Cost Engineering
• Cetys University: Diploma in Project Management
• Eje Institute: Seminar in Scientific Molding
• Minitab YouTube channel with more than 250,000 views and 4,200 training
hours given
Created by: QE NPI Andres Ruelas Injection Molding Beginners Email us at info@[Link]
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Author of the Following Courses CUSUM
Created by: QE NPI Andres Ruelas Injection Molding Beginners Email us at info@[Link]
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Workbook – Step 15. Rheology Curves CUSUM
In section 15 we optimize the
injection speed following a rheology
curve study. To create it setup the
machine with the pack and hold
phase off.
Next vary the machine at different
injection speeds and record the fill
time and peak injection pressure
reached.
Created by: QE NPI Andres Ruelas Injection Molding Beginners Email us at info@[Link]
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Workbook – Step 15. Rheology Curves CUSUM
In this example for a speed of 1.25
inch/second we record a fill time of
1.78 and an injection pressure peak of
625 psi.
Note: Simulator will not provide a fill
time for 1st phase unless there is a
pack/hold time. In real world
conditions you can make the study
with pack and hold on or off. Depends
on what makes peak 1st injection
pressure easier to identify.
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Workbook – Step 15. Rheology Curves CUSUM
Continue for each of the different injection speeds. Make sure that no burn
marks appear.
If at any point in the study burn marks appear stop the rheology curve study at
that speed. Since anything above this setting will yield bad parts.
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Workbook – Step 15. Rheology Curves CUSUM
To interpret we must look at the % Change column and the graph. The ideal
speed is a cosmetically acceptable setting (no burn marks) on which the
%Change is less than 30% the previous value. In this case we can select either
3.125 inch/sec or 3.75 inch/sec, either is acceptable.
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Workbook – Step 15. Rheology Curves CUSUM
Since we know moving from a low speed to a higher speed results in burn
marks we want to be as far away as possible from high speeds so we will opt
for 3.125. Note that 3.75 is acceptable but we don’t know how much higher
than this is unacceptable unless we continue. Is 3.75 acceptable but 3.8 burns
the parts? We don’t know at this point, so we want to be far away from 3.75.
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Workbook – Step 16. Pack/Hold Pressure CUSUM
All future studies are made with an injection speed of 3.125 inch/sec. For
section 16 we will optimize our Pack and Hold pressures with a cosmetic
process window study. Set the machine to the parameters identified so far.
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Workbook – Step 16. Pack/Hold Pressure CUSUM
Now set the machine at different pack/hold pressures and record the final
shot cushion, the peak cavity pressure (Simulator doesn’t have these sensors),
the peak machine pressure and visually inspect if parts pass or fail.
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Workbook – Step 16. Pack/Hold Pressure CUSUM
Now after executing the study we observe that parts within 2000 to 3000 pass
our inspection. Ideally we would now select a mid point of 2500 psi to serve as
our nominal pack/hold pressure.
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CUSUM
End of Lesson 7
Presented by: QE NPI Andres Ruelas
Created by: QE NPI Andres Ruelas Injection Molding Beginners Email us at info@[Link]
[Link] Thank you for Growing with us! [Link]