Improvement And Structure Optimization Of Injection Molding Based On Warpage

As a primary index of product quality, warpage has been paid more and more attention to by product designers and interrelated customers. Optimization of processes and structures centering on warpage deformation is one of the topices in plastic parts manufacturing.One of the most common methods to find the cause of warpage is to try some improved schemes to reduce the deflection of the product after doing simulations based on the simulation. However, this method depends much on the experience of individuals. Therefore, optimization theories and algorithms integrated with the simulations has been one of the popular topics in injection molding.This thesis is focused on the mould design optimization as well as some studies on the cause of warpage. According to the cause of deflection, optimizations of gate locations and parameters of cooling channels are taken into consideration. The main contents of this thesis are listed below.1. The main cause of warpage for plastic parts was studied, and the development and application of CAE simulation as well as the process in warpage simulations was discussed.2. Based on the simulation results, optimization was carried out to find a better gate location. The deflection simulated using the changed gate is 26% less than previous. Actual size has similar warp trend with simulation results.3. DOE and ANN are used to optimize the gate locations and channels parameters on an electric housing part. Indirect model was achieved by using BP network. After the optimization, the warpage result was reduced by 33.3%.4. Gate locations optimization for a U-shape part was achieved by combining CAE simulation of warpage with optimization algorithm. After the optimization, the warpage result was reduced by 27.4%.5. Optimization process and model proposed and achieved by different methods were studied and compared, which can be very useful for choosing the optimization methods.