The Injection Molding Quality Analysis And Optimization Of Operating Lever Based On Moldflow

Plastic products will always have various molding defects in the process of injection molding.Especially,the long injection part with complex shape,uneven wall thickness and more prominent shapessuch as operating lever,inevitably generates many weld lines,fill insufficiently and larger warpage.When injection molding parts are defective,the traditional practices in enterprises at present depend on the rich experience accumulated by engineers and technicians,constantly trying to adjust injection molding process parameters,and repair moulds and trial moulds repeatedly,so the mold making cycle is long and the cost is high.The lead-in of CAE technology before mold manufacturing can directly simulate the mold design plan on the computer,predict possible defects,and improve the mold design accordingly.Thus,the design and production of the mold can be effectively guided.Aiming at the problems such as fill insufficiently,weld line and warpage in injection molding of a car's operating lever,numerical simulation of the whole injection molding process is carried out by injection molding CAE simulation software Moldflow.According to the simulation results,the improvement scheme of the original gating system and cooling system is put forward.By comparing the quality indexes of filling conditions,weld lines and warping deformation under different schemes,the optimal design scheme of gating system and cooling system is obtained.Then the influence of the five processing parameters on the warpage are studied using Taguchi experiment design and numerical simulation.The range result showthe order of the influence of the process parameters on warpage is:pressure holding time>injection time>mold temperature>melt temperature>packing pressure,and the optimum combination of process parameters is A₂B₁C₄D₅E₅,that is,the melt temperature is 177?,the mould temperature is 60?,the injection time is 5.5s,the packing pressure is 90%filling pressure,and the pressure holding time is 10s.The simulation results show that the warpage was reduced to 1.628mm,in line with the assembly requirements,and the welding is shortened and dimmed.Finally,practice experiment is carried out in the factory with optimized gating system,cooling system and process parameters.The product is filled fully and no obvious weldinglines.Warpage deformation is also measured in the range of assembly,which is in line with customer quality requirements.