Designing experiments: 3 level full factorial design and variation of processing parameters methods for polymer colors

Abstract

In this work, we investigate the effects of variation of processing parameters on the quality of dispersion of polycarbonate compound. In order to achieve appropriate pigments dispersion, we performed compounding process parameters optimizations, by investigating three processing parameters, temperature, screw speed, and feed rate. We utilized experimental design for the optimization of process parameters based upon three levels full factorial response surface methodology was utilized. The experimental designs, statistical and numerical optimization were performed using design expert software. Statistical equation was developed to understand individual parameters interactions on the values of color. The model was established as statistically significant based on diagnostic tests performed. Our analysis of variance (ANOVA) illustrates that the parameters of color (dL*, da* and db*) are affected by the three investigated parameters. The process parameters required to attain color values in a minimum desirable deviation dE* of 0.8 were found through optimization to be equal to 245.26 oC, 741.27 rpm, and 24.72 kg/hr. Furthermore, we also demonstrate variations of the processing variables while other parameters remained constant (General Trends). Both strategies generated process parameters that were statistically significant.