Research On Deformation Compensation And Numerical Simulation Of Plastics Warpage

In recent years, with the widely use of plastics, customers put forward higher requirements to quality of plastics products. Warpage is one of the most basically flaws in the injection process. It can affect appearance and using performance. Severe warpage can make plastics useless. Engineers have paid attention to control warpage of plastics.At present the researches on warpage mainly concentrate on warpage theory and adjusting of injection process parameters. However, in production process, if warpage occurs, it is difficult to eliminate warpage only by adjusting injection process parameters. An effective method to control warpage is to modify mold structure where warpage occurs. The deformation compensation can counteract the warpage. But how to get the compensation value is difficult. Sometimes it doesn't work only by reference of experience.In this paper, the research object is a piece of plastic which warpes badly during its injection process. Warpage was simulated in Moldflow software. Combined with the experimentation, the relationship between simulated warpage and experimental warpage was found. Then the value of deformation compensation was predicted according to this relation. Subsequently the plastic was anti-deformed and the warpage was simulated again in Moldflow. In this simulation the deformation compensation is proved acceptable. In order to make the compensation more secure, combined the assembly of the plastic, the compensation was adjusted moderately to get the final compensation value. According to the final data, the plastic was anti-deformed again and the warpage was simulated again. From the simulation, the final compensation was proved acceptable. Then the mold was modified according to the final compensation and an experiment was made again. This experiment indicated that the deformation compensation is successful.In the progress of the experiments and simulations, there is difference between values of simulated warpage and experimental warpage. But Moldflow can exactly predict the warpage situation and warpage trend. So, Moldflow has strong guidance function to control warpage during the plastics products forming.