Study Of Mold Design And Optimization Of Engine Cover Based On Microcellular Injection Molding

Compared with the traditional injection molding,microcellular injection molding has many advantages,such as weight reduction of part?low molding pressure and saving material.However,with the involvement of supercritical fluid,the property of melt,filling performance,holding performance,cooling performance,orientation of fiber and the deformation performance in microcellular injection molding changes.Therefore,the mold designing,mold trail,testing for molded part and optimization of process parameters based microcellular injection molding is more complicated,and thus present greater challenges for engineer.Researchers had conducted a lot of theoretical research related to microcellular injection molding,such as the nucleation of bubbles,the weight reduction ratio of part,and the improvement of surface quality of foamed part,which is helpful in guiding the design and development of mold based on microcellular injection molding.Besides,with the development of computer aided engineering(CAE),some commercial CAE software have become more and more mature in the simulation of microcellular injection molding,which could assist engineer to solve the problem in part design,mold design and the trail of process parameters related to microcellular injection molding.For an automobile engine cover from Guangdong Yizumi Precision Machinery Co.,Ltd.a mold based on microcellular injection molding is designed and made according to the process property of microcellular injection molding and the quality requirement of the engine cover.The trail of the mold shows the mold is properly designed for microcellular injection molding process for the weight reduction,appearance quality and the bubble structure of parts meet the quality requirement of the engine cover.A CAE software for injection molding,Moldex3 D,is used to simulate the trail of the mold,and the simulation results is generally consistent with the result of trail.With the help of Moldex3 D,cavity geometry and cooling system is optimized to reduce the deformation of the part.Orthogonal experiment in Moldex3 D is conducted to investigate the effect of process parameters on the deformation of part based on the optimized mold,and the process of molding is optimized.Part with allowed deformation could be produced with the optimized process parameters based the optimized mold,which may provide guiding for mold develop in the future.