Optimization of removal process parameters of polyvinyl butyral cooling channel in rapid silicone rubber molds using the Taguchi method

In practice, the cooling channel (CC) is commonly used in the injection molding (IM) because the cooling is an important stage in the IM process. Traditionally, the acetone solution is widely used to remove CC inside the rapid tool. However, it is harmful to the operator and not environmentally friendly and ecological method. Besides, the conventional method of removing polyvinyl butyral (PVB) CC inside the silicone rubber mold (SRM) depends on trial-and-error approach in the laboratory. However, the distinct drawbacks include energy consuming and random efforts. In this study, a sustainable manufacturing method is proposed to remove PVB CC inside the SRM. The Taguchi method is used to optimize the removal process parameters of PVB CC inside SRM. It was found that the advantages of using an ethanol solution to remove PVB CCC include low environmental pollution, low energy consumption, and environmentally friendly and ecological approach. The most important control factor affecting the removal time of PVB CC inside SRM is the ethanol temperature, followed by the ethanol concentration, ethanol flow rate, and hose diameter. The contribution ratio for ethanol concentration, ethanol temperature, ethanol flow rate, and hose diameter is about 15.56%, 60.03%, 13.71%, and 10.71%, respectively. The optimum process parameters for removing PVB CC inside SRM involve ethanol concentration of 92%, ethanol temperature of 70 °C, alcohol flow rate of 1.15 L per minute, and hose diameter of 3 mm. The confirmation tests showed the saving efficiency of removal time is approximately 16 to 66%. The finding of this study is very practical and provides useful application for removing PVB CC inside the rapid tool.