| With the increasing development in the plastic industry and the automotive, aerospace and household appliances, large plastic parts are widely applied. It puts forward higher requirement in the design of the large-scale injection mold. In this paper, hot runner technology, CAE technology and the optimization technology are applied to design the key structure such as the gating system and cooling system, and process parameters during the injection mold design of some engineering mechanical instrument panel injection mold.In the gating system design of the injection mold, multiple point gates and hot sprue were employed to make plastic melt fill uniformly. Based on the software Moldflow, different gate projects were simulated and analyzed. It was concluded that four point gates is optimal. Then rheological theory was utilized to compute the dimension of the gating system. By continuously adjusting the dimension the balance of the injection system was realized.In the cooling system design of the injection mold, the core adopts partition type, and the cavity adopts straight-through cooling mode. Heat transfer theory was employed to preliminary design the cooling system of the injection mold. Based on the above results, different cooling projects were simulated and analyzed with Moldflow. It was concluded that the optimal cooling system can satisfy the demand of balanced cooling and shorter the cooling time.During the design of process parameters, Taguchi method was first employed to optimize the process parameters to reduce warpage. Then, based on the result of Taguchi orthogonal experiment, the BP neural network is used to build the relationship between parameters and warpage. Finally, the genetic algorithm was employed to optimize the model, and obtained the global optimum process parameters.This research work gives the optimized design of the injection mold for the engineering mechanical instrument panel, and provides references for the design of other large-scale injection mold. |
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