The Numerical Simulation And The Mold Design Of Double-Color Air-Conditioning Shell

With the improvement of people’s living standard, people’s requirement for the usability and appearance of the products are higher and higher. Double-color products are walking into our daily life gradually. Double-color injection molding products is the combination of the material with different color or different material to meet people’s requirement for the colorful plastic products. With the development of industrialization, double-color products are used for a variety of plastic products, such as the white household appliances, electronic products, automobile decoration and articles for daily life. Double-color products are widely used in these fields.Double-color injection molding technology is that two kinds of material or different color material was injected by two independent injection unit of an injection molding machine passing through the nozzle into the mold cavity to form a plastic product. Double color products outer shell changed the traditional plastic products spraying process. It can reduce the cost and the pollution. Through the material combination of different materials greatly improve the products quality and aesthetic. As a kind of advanced molding process, double-color injection molding technology is at the starting stage in China, the use of advanced computer simulation and optimization is very few studies in double-color injection molding, this subject is taking advantage of CAE technology to optimize the parameter of injection molding process and injection mould structure, getting a high quality double color air-conditioning shell finally. Although CAE software can conduct the real simulation of double-color injection, the influencing factors of double-color is twice as much traditional injection and there are many uncertain factors of remelt area included. It still need more research.Taking the characteristic of double-color products into consideration to design by three-dimensional software Pro/E, according the characteristic of the double-color injection processing, we will chose double-color injection machine with moving mould rotation of Fu Qiang Xin. As our requirements for the appearance of the double-color are very high, we chose hot runner gating system with needle valve gate, it will have no effect on the second injection as there are no injection mark on the surface of the products. The mold structure that we take is changing the position of the fixed mould and moving mould,we can use two set of mold,by doing this we can make sure the surface gloss of the double-color products and the high production efficiency.The mathematical model was set up based on numerical simulation, Taking advantage of the Moldflow2015 software to conduct the injection process of double-color air-conditioning panel, choose the sequence as thermoplastic overlap injection to optimize the position and number of the gate,finally the best project is four gates in two lines, building runner system based on mold structure. To conduct orthogonal test based on the best project we get and take the warping as the indicator, to optimize the process parameter by simulation analysis and get the best combination of the processing parameter by range analysis, the marshalling sequence of the influencing factors:packing pressure>packing time>cooling time>mold temperature>injection time>melt temperature, we can conduct experiments based on the combination of the best processing parameter.