Warpage Optimization And Pre-compensation For Body Side Molding Based On Co-simulation CAE Technology

Warpage is one of the most common defects in the injection molding process andthe minimization of the warpage is an important task in the injection moldingoptimization. Warpage will affect the appearance of the product and the usingperformance. Therefore, minimization of the warpage of plastic products has alwaysbeen an important goal in the field of plastic production.At present, the study on the warpage was mainly concentrated on the research ofthe optimization of injection molding process parameters. However, in the actualproduction, the warpage could not be eliminated only by adjusting the processparameters of injection molding when the product appeared serious warpingdeformation. In our practice, the pre-compensation of mold cavity was an effectivesolution to minimize the warpage. By modifying the mold cavity along the reversedirection of serious warpage parts, the deformation compensation could counteractthe warpage. To obtain the accuracy values of reverse compensation is the key factorof pre-compensation method, but how to determine the values of compensation isdifficult. Getting values of compensation only by experience is ineffective.In this study, the co-simulation technique based on Computer Aided Engineering(CAE) was used to provide theoretical basis for the mold cavity making of the Bodyside molding in practical production. The co-simulation of MOLDFLOW andABAQUS was used to analyze of the warpage of automobile rubbing strips and theobtained values was used for pre-compensation procedure. According to the valuesof pre-compensation the mold cavity was made along the reverse direction. Finally，the Body side molding produced by the modified mold meeting the requirement ofassembly accuracy. It has been proved that this method could improve the one-offmold making ability, saving cost and increasing the production efficiency.