Study On Molding Experiments Of The Filling Ability And Numerical Simulation For Thin-Wall Plastic Parts

The process and method of traditional injection molding are all ready consummate, which are different from that in thin-wall injection molding. It is much more difficult to fill the cavity because the melt is frozen very quickly when the thickness become smaller. Also, the flow behavior of the polymer melt in thin-wall injection molding is different from that in traditional condition. Many problems are unsolved.In this research, a mold of a simple mobile phone back cover is used. The thicknesses of the cover part are 0.5mm and 0.6mm. (In order to consider the influence of thickness, additional machining is made to modify the thickness during the experiments) The research is based on the simulation of Moldflow and the experiments are arranged using method of Taguchi. Range analysis and ANOVA analysis are used in data processing. Effective factors such as injection rate, injection pressure, melt temperature, mold temperature, thickness of the part and injection volume are studied and the interactions between melt temperature and injection rate, injection rate and injection pressure are involved. The results are given in the form of contribution rates.According to the results of range analysis and ANOVA analysis, almost the same conclusions are got. In range analysis, the sequence of the effective factors is part thickness, melt temperature, injection volume, injection pressure, mold temperature and injection rate. In ANOVA analysis, the sequence of the effective factors is part thickness, injection volume, melt temperature, injection pressure and mold temperature. The tiny difference is ascribed to experiment error. The part thickness is the most significant factor with a contribution rate of 36.94% followed by melt temperature and injection volume with 12.45% and 12.79%. Injection pressure is also important with a contribution rate of 6.72%. Mold temperature is not important and there is not any interaction between them.This research can be used for reference in study on influence of factors and their interactions in thin-wall injection molding. It is also helpful in further research in thin-wall injection molding.