Research Of Plastic Car Door Integrated Molding

On the one hand, plasticizing car body can effectively reduce the car weight, lowerfuel consumption, so as to achieve the purpose of low-carbon environment. On the otherhand, because the composite has good formability, some parts formed by rotationalmolding are more complex and beautiful than some formed by Stamping forming, sothat the car’s functions can be better optimized and enhanced. Rotary molding withmolding equipment is simple, low cost molds, suitable for processing large hollow parts,products, uniform thickness, dimensional stability, no molding seams and many otheradvantages. With the advent of materials for rotational molding, such as polyethylene,the rotational molding industry has been rapid development.Since the rotational molding process has many advantages above, rotationalmolding process has been chosen as the way the door molding.In this paper, the research process including five parts:First, reverse the door of the prototype, get a three-dimensional door model. Onecan know the whole structure of the door, on the other hand can be used as a referencewhen design new door;Second, compare current performance and price with a variety of commonly usedplastic material screwed on the market, and choose a material for molding car door,then determine the wall thickness of the car door;Third, design three-dimensional model of the car door conforming to the rotationalmolding process by UG software, based on the rules of car door design, and to reversedthe three-dimensional model of the prototype car door as a reference, combinedrotational molding process characteristics and door product thickness.Fourth, Simulate and analyze the stiffness of the door and To make sure the doorstiffness meet the requirements by Hypermesh analysis software.Fifth, design car door rotational molds and tool sets, based on rotational moldingcharacteristics and the three-dimensional model of the door designed. According to thecharacteristics of the door size, structural characteristics and selected rotary moldingmachine, determine a reasonable parting line, select the appropriate manner mold, moldtooling fixture and a reasonable method of surface treatment.According to the three-dimensional model of the door and calculated as follows:the car door weight has reduced about17.3%compared to the design prototype sheetmetal door, played a lightweight purposes.