A Study on the Optimization for Metal Injection Molding Process

The objective of this paper is study the optimization for metal injection molding process by using the design of experiments (DOE) and numerical analysis. In order to determine optimal process parameters, experiment and computerized analysis have been performed for various process conditions. Proper coded and uncoded regression equations and optimization for responses (flow front temperature, part weight, filling time, cycle time, and volumetric shrinkage) achieved from studying and verifying interrelation of the factors. About 70% of whole binder extracted within about 10 minutes and temperature of solvent is higher, the debinding rate is fast. 50 degrees C was the most suitable condition for solvent extraction because of crack occurrence on green body at 55 degrees C. It took about 14.5 hours to perform secondary thermal debinding, which was only about 35% of the entire time taken compared with single thermal debinding process, even if it considers solvent extraction time required. Therefore, the applied method greatly reduces the debinding time. The excellent process capability showed that the PPM total and Z.Bench were 9,946.8 and 2.33 showing good quality rate of around 99.01% and sigma level of 3.83. As a result, the process and optimization have been improved, and the proposed approach could be successfully reflected on the metal injection molding.