Process Analysis And Optimization Of Two-cavity Injection In One Mold For Busbar Insulation Parts

As an important molding process,injection molding is widely used in the parts production of automobile,machinery,household appliances,aviation and daily necessities.The products obtained by injection molding have the advantages of excellent performance,high precision in size,beautiful appearance and so on.Using numerical simulation software to analyze injection products before testing can effectively help to improve the quality of mold design,reduce the number of mold test,and avoid quality defects.In this paper,two plastic parts of busbar insulation parts were taken as the research objects.In order to obtain the plastic part products which can meet the quality requirements,Moldflow simulation software was used to design the runner of plastic parts.The process of injection molding of plastic parts was simulated and analyzed to find out the possible causes of defects.Then the original scheme was optimized and the appropriate solution was put forward.The main contents of this paper are as follows:On the premise of modeling and meshing of plastic parts by using Moldflow simulation software,the gating system and cooling system of part A and part B were designed and established.The filling and cooling analysis were carried out respectively.In filling analysis,the flow behavior of melt in different filling stages was analyzed,and the contour distribution diagram of filling time and pressure diagram were described in detail.It can be concluded that the main problem of the original scheme is the imbalance of filling.As an inducement,the imbalance of filling will lead to some problems,such as long filling time,over-pressure,obvious weld lines and uneven shrinkage.In view of this major defect,two different optimization schemes of runners for plastic parts A and B were designed.By analyzing the indexes of these schemes,the third scheme can effectively improve the problem of filling imbalance,and has fewer weld lines and air traps.It has better appearance quality.The third scheme is the best filling scheme.Combining the simulation results in cooling analysis,it is concluded that the cooling system of plastic parts A and B can meet the requirements.Combined with the optimal filling and cooling scheme obtained by Moldflow software analysis and the actual situation of production workshop,mold testing and production verification were carried out to obtain qualified plastic parts that meet quality requirements.The research in this paper can be used for reference in the production of other injection products with two-cavity in one mold,and can effectively improve the efficiency and quality of injection production.