Research On Auto Shroud Warpage

Due to the complexity consists in the shroud's structure and the environment of injection forming, it is hard to control the quality of moldings. Product defects are especially representing as flash, short shot and warpage, which is the hardest to control.The traditional solutions for warpage are: optimizing the process parameters of forming, modifying the mold structures or conducting post-treatment of products. These kinds of solutions have two shortages:1. The correction of all size errors which produced during forming process will be remained to following-process engineers. It causes irrational division of labor and time wasted in partial sections. All these bring impact to products development cycle.2. Neither the optimization of process conditions nor modification of mold structure is always applicable. Different design for similar parts always recalls different optimization and correction. In order to solve these problems, a new method is presented by this paper: 1st conduct the optimization for typical products structure based on mechanics theory. 2nd generate the optimized structure and verify them by computer simulation. 3rd generate complete design of shroud with the conception of optimized typical structures get by the above steps. A sample has been designed and verified by moldflow software and shows the success of optimization.This method provides several suggestions for shrouds'designing with general applicability which brings convenience for similar products development. Meanwhile, it will greatly reduce the pressure for producing section and shorten the product development cycle for the consideration of the warpage at the prophase of products design.