Optimization Of The Gas-Assisted Injection Molding Process For The Typical Automotive Plastic Parts

In the field of the automotive plastics manufacturing, optimization of the gas-assisted injection molding process for the typical automotive plastic parts, such as the car handle, with numerical simulation, has maximized efficiency and shorted production cycle. This paper about the impact of process parameters on forming quality of the gas-assisted injection molding includes the following: 1. the ribs with various sections have been studied, to investigate trend of the impact of process parameters on forming quality of the gas-assisted injection molding. 2. the typical automotive plastic parts has been studied to get two sets of process conditions under the gas-assisted injection molding, by implementing arrangements of the orthogonal design whether considering interaction between factors or not. Then, the two sets of process conditions have been compared to find out which is more appropriate for production process.The order of presentation is as follows:Chapter 1 presents the brief review of the gas-assisted injection molding research at home and abroad, and points out which shortcomings, then put forward what this paper will study.In chapter 2, the common rib has been studied to get the best process conditions under the gas-assisted injection molding. Implementing arrangements for the preliminary orthogonal experimental design is to narrow range of process parameters, then, another improved orthogonal experimental design based on preliminary arrangements is to get the best process conditions. In the light of the above process conditions, a comparative study of different shapes of ribs are done, to investigate trend of the impact of the single process parameter on forming quality under the gas-assisted injection molding, by changing one of the parameters while the others remaining unchanged.In chapter 3, the car handles have been studied to get two sets of process conditions under the gas-assisted injection molding, by implementing arrangements of the orthogonal experimental design whether considering interaction between factors or not. The results of orthogonal experimental design will be processed by analysis of variance, and shows the impact of factors on forming quality. Finally, the two sets of process conditions have been compared to find out which is more appropriate for production process. In general, the orthogonal experimental design which considering interaction between factors is in line with the actual situation.In chapter 4, using methods in Chapter 3, the rearview mirror products have been studied to get two sets of process conditions under the gas-assisted injection molding, by implementing arrangements of the orthogonal experimental design whether considering interaction between factors or not. Finally, comparing the process conditions from numerical simulation with the actual production process is to suggest improvements for production process and improve the numerical simulation for optimization of gas-assisted injection molding.In chapter 5, all achievements of the dissertation are summarized and the further research work is put forward.