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.

3. The library is allowed to make copies of this report for educational exchange

between higher educational institutions.

4. ** Please Mark (√)

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importance to Malaysia as STIPULATED under the

OFFICIAL SECRET ACT 1972)

RESTRICTED (Contains restricted information as determined by

the Organization/institution where research was

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FREE ACCESS

Approved by

(WRITER’S SIGNATURE) (SUPERVISOR’S SIGNATURE)

Permanent Address:

TARUMAN RT 01 RW 13

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INDONESIA

Date: 09 – 8 - 2019 Date: 09 – 8 - 2019

NOTE:

** If this Undergraduate Project Report is classified as CONFIDENTIAL or

RESTRICTED, please attach the letter from the relevant

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ii

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

iv

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.

vi

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