The Simulation And Process Optimization Of Gas-assisted Injection Molding

During the work of this thesis, the author thoroughly researched the Gas-assisted Injection Molding (GAIM). For settling the problems of GAIM, the process design of GAIM was concluded, the rule of affection for GAIM process by gas channel structure and gas process parameters was revealed, furthermore, the setting functions of gas process parameters were created.In the GAIM process design research, with in-depth analysis of GAIM procedure and gas penetration behavior, as well as combined with current achievements, the GAIM components thickness and structure design criterions, gas channel layout and dimension design standards, GAIM molds design rules and process parameters setting method were summarized.In this thesis, several typical GAIM models were created with different gas channel dimensions. By the MPI (Moldflow Plastics Insight) simulation of these models, a series of data were recorded. Through integrated analysis of these data, the affection rule of GAIM by gas channel equivalent radius, gas injection pressure and gas injection time were concluded. Moreover, with the mathematic deduction of the simulation setting parameters and result data, the expression between gas delay time and gas channel dimensions; the function between gas injection pressure and gas delay time with gas channel dimensions; as also, the gas penetration length formula with variables of gas channel dimensions, gas delay time were derived. With these expressions, we can easily figure out the optimized gas injection parameters and predict the gas channel penetration length.Finally, a couple of verify experiments were executed and the above conclusions were proved to be relatively correct and helpful for the design of GAIM process.