Injection Molding Process Simulation And Mold Design For Plastic Wire Clip Of Overhead Contact Line

Plastic wire clip is one of the important bearing components of the overhead contact line, it is made of nylon by injection molding. Due to the wall thickness of the wire clip structure is different and the forming characteristic of the nylon material is complex, it is easy to generate serious warping deformation in the wire clip manufacturing.In this paper, the plastic wire clip of the overhead contact line was chosen to be the object for research. Basing on the Moldflow simulation, different injection molding process schemes were designed and compared. An injection molding process which can reduce warping deformation to meet the requirement was obtained. According to the optimized injection molding process scheme, the injection mold design of the plastic wire clip was completed.The main achievements in this researching work are as follows:(1) The Frianyl A63V2WEISS9003/T of PA66is recommended to be the production material of the plastic wire clip according to simulation results.(2) By conducting different injection molding process simulations, the effect of different factors to the warping deformation of the plastic wire clip was assessed and the results show that:melt temperature>injection time>holding pressure>holding time; The injection molding process parameters were also confirmed:the melt temperature is295degree centigrade, the injection time is5seconds, the holding pressure of first and second stages are95percent of injection pressure and80percent of injection pressure respectively. The holding time of first and second stages are17.5seconds and5.75seconds respectively. The injection pressure is4MPa and the clamping force is2.27tons. The molding cycle is119.8seconds.(3) According to simulation results, the injection mold design and manufacturing of the plastic wire clip were both completed. Based on the optimized injection molding process scheme, some samples were obtained. The average maximum warping deformation of the samples was0.904mm and it meet the requirement.The research method of this paper is universal, it can provide some reference in process designing of other plastic components. The research results obtained can be applied to industrial production directly and it shows high engineering application value.