Analysis And Process Optimization Of Injection Molding Defect For Lightweight Car Radiator Connector Based On MOLDFLOW

The material of the light car radiator connector is PA66.The components are porous complicated shape with the wall being uneven thickness and the ears in the same side.In the process of trial production,molding defects such as filling dissatisfaction,weld marks and warpage deformation sometimes occur,especially the warpage deformation becomes a technical problem that plagues the enterprise,affecting product quality and acceptance.At present,when there are quality problems in the injection parts,most traditional enterprises rely on the experience of technicians to adjust the process parameters and improve the mold structure,which wastes a lot of time and increases the design and manufacturing costs,In this paper,for the problems of product quality defects diuring the test,the molding process was simulated by Moldflow,a CAE finite element numerical simulation software for injection molding.Different improvement schemes were proposed for the original mold casting system and cooling system.Different scenarios were simulated to select the best gating system and cooling system.For the process paraneters,five factors,which have great influence on the quality of injection molding,were selected as the factors affecting the warpage deformation.The five process parameters were:mold temperature,melt temperature,injection time,holding time and holding pressure.With the minimum amount of warpage deformation as the optimization goal,several simulation experiments were carried out to study their influence on the light car radiator connector.The mathematically poor method is used to determine the order of the influence of the process parameters on the amount of warpage deformation.After the simulation verification,the results show that the warpage deformation amount drops to 0.8448 mm,and the weld line is signifleantly shortened and reduced.After obtaining the optimal injection molding process parameters,the company conducts on the spot test and workpiece inspection.The improved light-duty radiator connector has a full and full appearance,and there is no obvious weld line mark,and the average amount of warpage deformation.The average value is 0.8468mm and the maximun warpage deformation is 0.8551mm,which satisfies the design requirements of the radiator connector.By combining CAE computer simulation technology with traditional design mold technology,the direct and intuitive numerical simulation of the injection molding process can accurately predict the quality problems that may occur during the injection molding process,reduce the number of process tests,reduce costs,and shorten trial production.The cycle has substantial guiding significance for the traditional injection molding process.