Energy Consumption Analysis of ABS Plastic Parts Injected in a Hybrid Injection Moulding Machine

The energy analysis of injection moulding processes is influenced by complex interactions amongst the moulded part, its material, the injection machine, the process parameters and the environmental conditions. The availability of energy usage analyses that comprehend information on specific materials and machine kind is limited. This paper reports a study that estimates and analyses the power usage profile (PUP), the specific energy consumption (SEC), and the energy distribution at an operation level of two different injected parts made of acrylonitrile-butadiene-styrene and produced in a hybrid injection moulding machine. The methodology followed by the authors incorporates an experiment carried out in an industrial facility. A large sample size, and data-acquisition and data post-processing processes to obtain an accurate PUP and SEC are used. A breakdown of the energy consumed by the injection moulding process of the parts studied at an operation level using Sankey diagrams is discussed. The study results are used to identify strategies to reduce the energy consumed by the processes. The methodology employed, and the strategies reported could be used with other plastic parts regardless of the material and machine used. The results reported are new experimental data useful input for theoretical models.