The Standardized Mold Testing And Process Optimization Of Injection Molding

In order to guarantee the quality of injection molded parts,all the injection molds need to be on-site tested before mass production.Mold testing not only determines final process parameters,but also evaluates molds to provide the basis for potential mold repairing.Nowadays,mold testing on the shop floor still depends on the actual experience of workers,costing a lot of time and effort,and affecting production efficiency.Due to the lack of scientific and unified guidance,optimization of process parameters and mold evaluation suffer shortage of theoretical basis,which undermines the robustness of the process and leads to products not meeting requirements.In view of the above shortcomings,relative research is carried out from following four aspects.A set of standardized mold testing process for injection molding is proposed to complete mold evaluation and process optimization in on-site mold testing.And the feasibility of the experiment is verified by an experimental case.The experimental results show that the test mode can not only obtain the products without appearance defects,but also ensure the robustness of injection molding process.Based on the standardized mold testing process,A set of formability analysis process is proposed,which can be applied in CAE analysis stage.The feasibility of the process is verified by a CAE case.Though the formability analysis process can not replace on-site mold testing,it can provide reference to mold design and on-site mold testing.To overcome shortcomings of the constant packing pressure profile in the standardized mold testing and limitation of the existing research,a multi-objective optimization method for the packing profile is proposed.In this method,gray relational analysis is employed to evaluate the multi-index in the optimization model synthetically,and the global optimal packing profile is obtained in via response surface model and genetic algorithm.Compared with the existing methods,the optimal packing profile obtained by this method can not only satisfy the requirements of the maximum volume shrinkage of the product,but also reduce the standard deviation of the volume shrinkage of the product to the minimum,which can significantly decrease the warpage of the product.According to the standardized mold testing procedure,a set of on-site mold testing software running on PCs is designed.And then based on.NET framework,C # is utilized to implement each functional modules in the software package.The application of the software can improve automation and efficiency of on-site mold testing.