| The mold with different cavity injection mold has more cavity,and the shape and quality of the products of each cavity are not the same,so the melt is difficult at the same time with the same temperature and pressure to completely fill the various cavities in the injection molding process.So multi-cavity mold is prone to flow imbalance in the filling.It will result in short shot,flash,shrink marks,warping and other molding defects,could seriously affect product quality.One would need to go through repeated testing,change the mold,repair mode,adjust the process parameters to be get the satisfied product.But it will undoubtedly cost a lot of manpower,resources and time,and greatly increase the cost of production.With the CAE technology in the mold industry and its wide range and in-depth application,it can be a good solution to this problem.Based on the engineering practice,this paper takes CAE analysis software Moldflow as the example of the production of the upper and lower cover of the air conditioning fan of the vehicle,and uses a variety of optimization methods to solve the flow imbalance in the actual production.After analyzing the structural characteristics and forming performance of the upper and lower covers of the air conditioning fan for the vehicle,the pouring system was established according to the parameters of the original scheme.The results of the filling analysis were investigated,and the deficiency of the original scheme in the flow balance was pointed out.To provide the basis for the subsequent optimization of the casting system.The flow imbalance between the original gating system is optimized from the aspects of geometric parameters and process parameters.In the geometric parameters by analyzing the gate position combined with the structural characteristics of the product,we can get the best into the plastic area and determine the appropriate gate size;Using the Moldflow flow path equilibrium analysis,the original runner system is iteratively calculated to obtain a satisfactory optimal flow path size.In the process parameters,Moldflow combined with Minitab software to develop response surface test design optimization program,to get the optimal process parameters.Based on the optimized parameters,the original packing scheme is optimized,and the constant packing effect of the original scheme is analyzed.On the basis of this,the variable pressure packing scheme is adopted,and the important parameters such as the holding pressure,the constant pressure duration and the decay duration of the pressure reduction curve are determined according to the original packing analysis results.Thereby obtaining an optimized packing curve.By determining the geometrical parameters and process parameters after gating system optimization,it verifies that the optimization effect is remarkable and the quality of the product is good. |
