Simulation And Optimization Of Overmolding Process For Multiinsert Connector Of Automobile

Connector is one of the common components of automobile electrical systems.Its role is to connect blocking part or isolated part in the circuit and conduct current and to achieve preset function.Automobile connectors are generally produced using overmolding process,and have high requirement to molding quality and dimensional accuracy.however due to the presence of metal inserts,injection products will easy to emerge defect,such as welding lines,uneven shrinkage and even the deformation of inserts.Therefore,it is significant to study the overmolding process and optimization of multiinsert connector of automobile.This paper analyses overmolding process of multiinsert connector of automobile based Moldflow software and studies static structural of metal insert combine the simulation resurts of Moldflow with ANSYS Mechanical.It was found that the plastic products produced by the ordinary injection molding method have a large number of weld marks,the shrinkage is not extremely uniform and metal inserts also have a certain degree of deformation.These defects seriously affect the application performance of product.It is obviously difficult to solve similar problems though the optimization of injection molding process parameters and need to improve the production process.Through the in-depth study of the product structure,molding quality and the advantages and disadvantages of advanced injection molding process,it was ultimately decided to use the package plastic molding process to produce this product.This paper respectively design plastic inserts and covering product,the role of plastic insert is to locate the elongated metal insert to prevent its positional deviation or deformation.The numerical simulation of overmolding process of multiinsert connector of automobile was carried out by using Moldflow and ANSYS Mechanical software.The results show that the deformation amount of metal insert was greatly reduced and the molding quality of products can be improved.But the bonding performance of interface between plastic insertand covering products become an important factor affecting the use of product performance.It is difficult to directly evaluate the interfacial bonding property between different materials of overmolding products,and the influence of the process parameters on the difference of the average shrinkage rate of the product is studied by orthogonal experiment.The results show that the effect of holding pressure and melt temperature is significant,the influence of mold temperature and cooling time is second,the holding time has little effect on the experimental results,and the optimal parameters of bonding performance of interface can be obtained.The molding quality of the automobile connector is greatly improved by using the overmolding technology and the best process parameters.It solves the defects caused by the existence of the slender metal inserts,which not only provides some theoretical guidance for the production of similar products,but also provides a new method for the solution of similar problems.