Taguchi and ANOVA-based analysis of injection parameters affecting automotive reflector surface and optical efficiency

In this study, the effect of injection parameters on sink marks and photometric properties in the production of reflector used in automobiles was investigated. Mold filling analysis was performed with Moldflow software and sinkmarks and warpage were determined before production. Afterwards, the reflector was produced. The effects of injection parameters such as melt temperature, mold temperature, injection speed, injection pressure, holding time and cooling time on sink marks and photometry were investigated by Taguchi and Anova analysis. In the mold filling simulation, a sink mark of 0.05 mm was formed, while an average of 0.053 mm of sink mark was formed in the experimental results. It was found that the most effective parameter on the sink mark was melt temperature, while cooling time was found for photometry. In the experiment, the lowest sink marks value was 0.053 mm in avarage, and the highest photometry value (923.33 mcd/lux) was measured in the same test. The lowest photometry value was measured as 700.33 mcd/lux and the sink marks value in this experiment was 0.082 mm. The sink marks on the reflector surface change the illumination angles by disrupting the surface planarity, and the reflector’s reflective properties are also affected by this.