Injection Molding Process Simulation And Optimization Of Parameters Based On Moldflow

As the most common way to mold plastic products in the present stage, injection molding has found wide applications in spheres, such as daily life, electronic information, medical apparatuses and instruments and aeronautics and astronautics. However, with the increasingly fierce competition of market and continuous price hikes of raw materials, presently, enterprises are concentrating their efforts on enhancing productivity by manufacturing most optimal products as soon as possible. Moldflow, one simulation software for injection molding, can be harnessed to conduct a dynamic simulation throughout injection molding, and by doing so, predictions are made of where defects may exist so that measures can be taken before the manufacture to prevent defects from being generated. Additionally, optimized injection molding processing parameters that result from the combination of numerical simulation and orthogonal experiment play a great role in enhancing the productivity.With fan brackets as a research subject, the Moldflow software was applied to simulation analysis. Analysis of four simulation results: the filling time, weld lines, air traps and shrink, and then a comparison is made between the simulation and the reality in places where weld lines are generated. The comparison leads to a conclusion that weld lines exist in the same place in them, and further testifies to the accuracy. In the second place, a study is conducted on the fractures of the bracket that are generated from the testing after it being installed, the reasons for the fractures are found, and proper solutions are worked out.In the final place, with protection covers as a research subject, the thesis finds the application of Moldflow in an analysis and comparison of two designed gating system, by comparing filling time, pressure at V/P swithchover and clamping force etc. to generate a proper plan and then orthogonal experiment is used to optimize processing parameters. Both signal-to-noise and analysis of variance are made use of to address to what extent melt temperature, mold temperature, injection time, holding pressure time and holding pressure respectively affect the volume shrinkage and warpage of plastic parts, with the result that the most optimal processing parameters mix is worked out that minimizes volume shrinkage and warpage. Besides, predictions and simulation verification are made of the optimization result. The final result indicates that the use of optimized processing parameters mix minimizes the volume shrinkage and warpage of plastic parts, thereby verifying the accuracy of the optimized processing parameters.The research findings show that the use of Moldflow can simulate injection molding in an accurate manner, and that the combination of Moldflow simulation and orthogonal experiment can optimize molding processing parameters. These fruits guide the formulation of processing documents and the development of products in real manufacture.