Research On Warpage And Correction Of Injection Molded Products For Automotive Radiator Water Chamber

The automobile water chamber is a functional structural part.The shape of this kind of plastic part has the characteristics of thinwalled,long-striped,and asymmetrical.The structural shape is complex and requires high precision in its dimensional stability,sealing,and flatness of the assembly surface.The warpage deformation of its products in actual production is much larger than that of conventional products,and the warpage deformation law is also difficult to accurately analyze,so it has become the main reason for the quality problems of such products.The traditional solution of the factory mainly relies on the experience and skills of engineers and technicians to determine the better injection molding process parameters,and then through trial molds,adjustments,and retrials,the quality of the products is guaranteed through many iterations,and a lot of time and materials are wasted,And the quality of plastic parts is also unstable;In view of the problem of warpage,scholars at home and abroad mainly focus on optimizing simulation analysis of injection molding process parameters.However,because injection molding is a complex process with multiple variables,distributed parameters,nonlinearity,strong coupling,and manual participation,The accuracy of control has not yet reached the ideal state.The pre-deformation compensation method can effectively control the warpage deformation,but there are few related researches on complex products such as automobile water chambers.This paper intends to use the pre-deformation compensation method to control the warpage deformation of automobile water chamber products.First of all,the process conditions such as injection time,melt temperature,mold temperature,holding pressure time,holding pressure,etc.of the automobile water chamber are determined through actual test molds,and a set of process conditions combination is finally determined.Then,perform CAE numerical simulation analysis on the automobile water chamber model under this process condition,including filling time,pressure during V/P conversion,clamping force,cooling water circuit temperature,product temperature,warpage analysis,etc.,so as to study and analyze The trend and magnitude of warpage deformation of plastic parts.Finally,using the pre-deformation compensation method based on CAE simulation simulation technology,select different pre-deformation coefficients λ to determine the reverse compensation amount of the automobile water chamber through Moldflow simulation and calculation,and provide a reference for the actual production of pre-deformation,and Carry out mold-opening trial production to verify its effectiveness.By comparing the CAE simulation and actual measurement data of the automobile water chamber without pre-deformation,it is verified that the simulated deformation and the actual deformation have the same trend and the values are more consistent.The theoretical simulation maximum deformation of the measuring point is-1.5mm and-1.37 mm,and the actual measurement maximum deformation is-1.38 mm and-1.43 mm.The maximum difference between the corresponding points of the two is0.25 mm.The result analysis shows that the simulation analysis is performed.Correct and effective.After selecting the pre-deformation coefficient λ,simulate and analyze the 5 pre-deformation models.After data analysis,select the λ=1pre-deformation model.The theoretical simulation maximum deformation of the measuring point is 0.25 mm and 0.17mm;Finally,the actual maximum deformation of the corresponding point can be controlled at0.24 mm and 0.21 mm through the actual verification of the mold opening.It shows that this method can effectively control the warpage and deformation of the automobile water chamber,ensure product quality,and at the same time can improve the success rate of one-time mold opening,reduce costs and improve efficiency.