Gating System Balanced Design And Process Parameters Optimization On The Asymmetric Shell Injection Molded Parts

Asymmetric shell injection molded parts molding belongs to a multi-cavity non-balanced layout of the flow channel system forming, due to the mold cavity is inconsistent, It is difficult to ensure the consistency of the cavity pressure and temperature in the actual filling process, therefore may lead to fill dissatisfaction, flash, warpage, etc. injection molding defects. The quality of injection product not only affects the appearance of the mobile phone, but also affects the overall assembly and quality, and even affect mobile phone development and production cycle and cost. Using MoldFlow software to analyze and test mode, not only can predict forming defects, improve product quality, but also reduce development time and cost savings, which can rapidly seize the market for new prod uct development.To solve the defects of the asymmetric thin shell of mobile phone in the two cavity of the mold, the finite element model of the middle and bottom shell of the mobile phone was build based on the flow and warp mechanism analysis. The best gate location was found by two gate laction schemes analysis of the middle and bottom shell of the mobile phone.The imbalance gating system was build and was optimized. The theoretical model and the equation of the imbalance gating system was researched.then, the imbalance gating system was researched by Moldflow analysis software as the basis of academic reference.After the establishment of the cooling system, flow, warping, cooling analysis of the products was carried on to predict injection defects such as Contraction deformation, Warping deformation. Product scrap rate was reduced.As the shrinkage and warpage of the amount of optimization objectives, the three levels of the four factors was selected, using the Taguchi method combinations of process parameters, then A verification test was performed to prove the effective of Taguchi technique after the optimum levels of process parameters are determined, which reduced the maximum shrink deformation and warping deformation,and provide the basis for the reasonable decision of production process parameters.