Research On Injection Molding Simulation And Warpage Compensation Of Automotive Fan

Huge warpage of molded parts has puzzled plastic molding companies at all the times. With the development of finite element technique and computer technology, numerical simulation has become an effective tool for optimal designing and analyzing the process gradually. Computer aided engineering in the field of injection molding can help us to minimize the warpage and other molding related defects by calculating the deformation accurately produced in plastic parts under the given injection molding conditions and optimizing the process. Keeping in view the warpage results obtained by numerical simulation, we can compensate it along the reverse direction and create a new model to be injection molded. It would be an effective method to reduce the warpage of plastic parts.The present study is focused on exploring the reasons of huge warpage and how to reduce it for PA66/GF30. The wrong orientation of glass fiber causes the warpage; however, remodeling the gate and increasing the wall thickness can cause the glass fiber to settle in the right orientation. CAE software"Moldflow Insight Plastics"was used to simulate the molding process for an automotive fan, got the warpage data, and then created a new model with the reverse direction to compensate warpage. To get the dimensional data of the fan leaves is a difficult task, which was carried out by using a laser scanning equipment"ATOS".Modeling the fan afresh is based on the data of molded fan surface created by the reverse engineering software"Imageware 11.0"which uses the point clouds obtained from ATOS. Visual Basic has been used to interpolate points on the front and the rear B-splines; compare the sample data with the original data of fan.Using the method of compensated fan model to design the injection tooling, the economical efficiency of plastic molding companies can be heightened greatly.