CAE Analysis And Optimized Design Of The Injection Mold With Different Cavity Based On The Moldflow Software

Due to the plastic parts in the mold with different cavity of the upper and lowercover of remote control are different, in injection molding, it is difficult to ensure thatthe each cavity of mold is filled by molten plastic at the same moment. therefore thefilling time and pressure are unbalanced, may lead to large pressure-holding, residualstress,fill dissatisfaction, warpage and many other injection molding defects. CAEanalysis technology which was used to optimize the mold design and molding processparameters, can solve these problems effectively. Moldflow software was used tosimulate the injection molding process on the remote upper and lower cover, thecooling system and gating system of the mould could be optimized cooling systemthe simulation results, thus the mold have achieved a good filling balance. moldingprocess parameters were optimized by the Taguchi method, which reduced warpingdeformation of the upper and lower cover of remote control and improved the qualityof the products.Based on gate type and gate location analysis,four kinds of gate scheme wasdesigned, then according to comparison and analysis of filling balance by Moldflowsoftware, the optimal gate scheme of the mold with different cavity of the upper andlower cover of remote control was determined ultimately.According to the optimal gate scheme, the gating system of the mold withdifferent cavity of the upper and lower cover of remote control was build. then thesizes of runners and gates were optimized based on repeated simulation analysis byMoldflow, the final results of filling analysis show that filling time differencebetween the upper and lower cover is only0.0001s and pressure difference of the endof filling is less than5MPa, thus the mold have achieved a good balance.The initial cooling system of the mold was build according to the structure ofplastic part and mold. the results of cooling analysis by Moldflow show that therewere heat accumulation problem in moving half of the remote upper cover, so thescheme is improved by adding the water-stop sheet cooling system, which reduce theheat accumulation area and the cooling time. the optimal cooling system was determined ultimately.Three levels of four factors orthogonal experiment scheme was selected bytaking the maximum warpage as the optimization objective, the optimal combinationof process parameters,which is Mold temperature50℃、the melt temperature240℃、holding pressure65Mpa and holding time10s, was determined by range analysis of9times warp simulation results. Then, the warpage decreased16.6%than beforeoptimization.Final, the mold assembly drawing was designed by AutoCAD software and3dmodel of cavity, core, inserts and lifter were build in PRO/E.