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Chinese Journal of Engineering
Volume 2014 (2014), Article ID 351206, 11 pages
Research Article

Hybrid Integration of Taguchi Parametric Design, Grey Relational Analysis, and Principal Component Analysis Optimization for Plastic Gear Production

1Department of Mould Technology, Kolej Kemahiran Tinggi MARA, Balik Pulau, Genting, 11000 Balik Pulau, Penang, Malaysia
2School of Mechanical Engineering, Universiti Sains Malaysia, Engineering Campus, 14300 Nibong Tebal, Penang, Malaysia

Received 27 September 2013; Accepted 17 November 2013; Published 14 January 2014

Academic Editors: M. Chen, C. Del Gaudio, H. Lu, S. Simani, and B. Sun

Copyright © 2014 Nik Mizamzul Mehat et al. This is an open access article distributed under the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.


The identification of optimal processing parameters is an important practice in the plastic injection moulding industry because of the significant effect of such parameters on plastic part quality and cost. However, the optimization design of injection moulding process parameters can be difficult because more than one quality characteristic is used in the evaluation. This study systematically develops a hybrid optimization method for multiple quality characteristics by integrating the Taguchi parameter design, grey relational analysis, and principal component analysis. A plastic gear is used to demonstrate the efficiency and validity of the proposed hybrid optimization method in controlling all influential injection moulding processing parameters during plastic gear manufacturing. To minimize the shrinkage behaviour in tooth thickness, addendum circle, and dedendum circle of moulded gear, the optimal combination of different process parameters is determined. The case study demonstrates that the proposed optimization method can produce plastic-moulded gear with minimum shrinkage behaviour of 1.8%, 1.53%, and 2.42% in tooth thickness, addendum circle, and dedendum circle, respectively; these values are less than the values in the main experiment. Therefore, shrinkage-related defects that lead to severe failure in plastic gears can be effectively minimized while satisfying the demand of the global plastic gear industry.