Thin-wall Plastic Parts Warp Controlling By Researching Forming Process And Mold Optimization

Thin-wall molding injection is a new technology for forming the thin-wall plasticparts that is based on the traditional injection molding technology. The thin-wall plasticparts can economize material, lower cost, improve production efficiency, reduce theweight and easy to carry. However, with the thickness of plastic parts become thinner. Itis much more difficult to fill the cavity because the melt is frozen so quickly that easilylead to unqualified plastic parts and produced different degrees of defects, and the warpdeforming is the main defect in the manufacturing process. And regarding the thin-wallplastic parts warp deforming as a measure of the plastic parts is good or bad quality.Consequently, this paper focuses on the warp deforming of thin-wall plastic parts byinjection molding Moldflow and ANSYS mold deformation simulation analysis,Comprehensive study of the influence of warpage deformation. Achieve the purpose ofreducing the warp deforming of plastic parts by optimizing the molding processparameter. The main studying of this thesis is listed as follows:The thin wall plastic parts with average thickness of1mm is taken as the researchobject, the warpage influence of plastic parts is comprehensively analysised by Taguchiexperiments with Moldflow software. And the optimization of injection moldingprocess parameters is achieved. Through CAE simulation, the warping deformation isvalidated to be0.86mm, which is the minimum amount of thin-wall plastic parts.The thin-wall injection molding is researched under the mechanical load andtemperature effects of thermal coupling with ANSYS. According to the result of moldtemperature field distribution, optimize the layout mold cooling system, the temperaturefield uniform. According to the result of thermal stress field contours of the mold gotthe size and location of the cavity deformation prone to deformation, the mold can bechecked strength and rigidity and optimization of the overall structure of the mold.Considering the effect of temperature and stress field of the mold, reducing factors dueto mold plastic deformation and warping effects of uneven cooling, making simulationresults more accurate.The melt temperature, mold temperature, packing pressure, packing time andcooling plan is chosen to act as the factor of warp deforming of thin-wall plastic parts. Using Taguchi experiments combined with Moldflow and ANSYS softwarecomprehensive analysis the warpage influence of plastic parts and optimization ofinjection molding process parameters and Using the experimental data analysis of meanvalue analysis and variance analysis, getting the warp deforming of the optimalcombination of process parameters is A3B3C4D1E3, This method can reduce the warpdeforming of plastic parts and achieve the purpose of optimizing mold structure.