CAE Optimization Of Melt Filling About Large-sized And Exact Injection Mold

Conventional injection mold sometimes must be tested and mended many times before using, because mold designing and manufacturing mostly depend on the intuition and experience of the mold designers and the skill of the workers. It brings longer cycle of mold manufacturing and product exploiting, and more cost. But the product quality is not always better. Especially in designing of large-sized molds, exact molds, new molding processes, and in using new plastic materials, the efficiency is especially low to design with experience and the method of trial and error.Compared with conventional mold designing, the technique of CAE is highly useful in enhancing productivity, improving quality of mold and product, reducing cost and taking from the workload, and so on. The technique of CAE about injection molding is based on polymer processing rheology and conductive calorifics. It simulates the actual process of melt filling, packing and cooling by setting up mathematic and physical models about melt flowing and heat transmitting in the mold cavity, and working out the results by the theory of numerical value analysis. It can also list the processing parameters quantificationally such as pressure, time, temperature, speed, etc, and reflect the results visually by computer figures.This paper has optimized the structure of the large-sized automobile instrument panel mold with hot runner and the thermoset plastic injection mold of exact gasmeter. In the part of thermoplastic automobile instrument panel mold, we designed the 3D model by computer, used the software of Moldflow to measure off the mesh with finite method, did the filling, packing, cooling and warp analysis, and accomplished the optimization about filling system, cooling system and processing parameters. Ultimately, much problems which should occur in the production were overcome, and the hot runner mold was designed with the best case. It is another important part about thermoset plastic injection molding and warm runner designing in this paper. We have simulated the filling process about thermoset plastic injection molding for the first time, compared the influence to the filling process with different runners, gates, and parameters. Finally the better mold structure and processing parameters were adopted. It is undoubtedly helpful to solve the processing problems, reduce the cost, enhance the productivity, and increase the benefit.The associated exertion of computer aided 3D modeling and the technology of CAE/CAM and RP&M can simulate the process of melt filling, mold opening and clamping and fabricate the product prototype rapidly. In addition, the technology of RP&M is used. These give us eyeable information about product and mold, forecast the problems which may occur in produce, and avoid mold repairing caused by lack of experience. So that it can reduce the cost of product innovation and exploitation, shorten the cycle of mold manufacturing, and increase the feasibility of mold application. To ensure the quality and enhance the productivity, we have accomplished the optimization of mold structure and the simulation of melt filling and mold opening. In the end, the best case to solve processing problems and optimize mold structure and processing parameters is excogitated.