Simulation And Optimization Of Injection Processing For PA66/GF Intake Manifold

Energy-conservation and environmental protection are drawing more people's attention and weight reduction becomes important development trend of the automobile industry. Using more plastics parts on automobiles is one of effective measures to achieve the purpose of weight reduction. This study is about the intake manifold made of plastics, which is important part round the automobile engine. Because of the big volume, complicated shape and requirement of high quality, the injection process of intake manifold is difficult and complicated and the technical parameters are strict. So it is necessary and important to research the injection process of the intake manifold. Using numerical simulation technology and method of orthogonal experiment design and single factor rotating optimization, this thesis makes a study of "lost core injection ", thus achieve the optimization of the parameters of molding process, to offer basic reference when developing production technology and mould of the plastics intake manifold. Based on the study of the status in quo and development trend of weight reduction on automobile, the application of plastics to automobile and intake manifold, then under the guidance of theory model and numerical simulation technology in the process of high polymer material, this thesis launches flowing main research work: First of all, on the basis of the three-dimensional model of the part and finite element net model, several designs of gating and running system are numerically simulated and analyzed via MPA of Moldflow. Through analyzing the index of filling quality, welding lines position and quantity etc. of each design scheme, we get the optimal gating and running system, which has 4 gates and half restriction running system. Then, by means of orthogonal experimental design, two orthogonal tables are got, one of which is about filling processing and has 3 levels and 3 factors (melt temperature, fill time and mold temperature), another one of which is about hold & cooling processing and has 3 levels and 3 factors too (hold pressure, hold time, cooling time). According to the two orthogonal tables, the processing of filling and hold & cooling are separately numerical simulated via MPI of Moldflow. And then through synthetically analyzing simulation results for much goals (much quality indexes), this thesis gets optimal parameters of the processing of filling and hold & cooling. Thereafter based on above optimal parameters craft parameter, we adopt the method of single factor rotating, namely changing each single parameter by turns, and utilize numerical simulation technology to study the influence of each parameter to shrink warping, welding lines and orientation of glass fiber, which are all the important quality targets. Finally, according to above-mentioned study mainly by numerical simulation and analysis, this thesis achieves the optimizing of "lost core injection"process of automobile plastics intake manifold.