Numerical Simulation And Process Optimization In The Design Of Injection Mould

Polymer materials which were represented by plastic and rubber have fine processing characteristic and operational performance, were being used widely in many fields, such as cars, home appliances and instruments, and present the tendency of plastic in place of steel and wood. The research object of this dissertation was an intermediate thick-walled sauna stool, an export enterprise product. The dissertation mainly applied CAD technique and hot runner system to design the structure of injection mold, and analysed injection molding process by CAE technique and the optimization technology of injection molding process, and the main content is below:Firstly, giving a full account of the characteristics of the plastic sauna steel’s design, the model of the injection molding machine which will be used in injection molding process was determined. Based on the theory of rheology, mechanics and heat transfer, preliminarily design process were present for the injection mold, such as mould cavity, the pouring system, exhaust system, demolding mechanism, cooling system, mould frame. For some deep holes of the injection mold, in order to make the mold’s exhaust and machining convenient and extend the life of the mold, inserts were applied in corresponding places. After that, UG MoldWizard software was utilized to finish the model of the whole injection mold.Secondly, Moldflow Insight 2010 software was utilized to conduct analysis of molding window, filling, packing, cooling and warping. Based on the result of filling analysis and the expectation of rapid separation between pouring system and the product, two hot runner pouring system in different place were optimized based on comparative analysis. The orthogonal test method was implemented to deal with the result of cooling analysis, and the influence degree of cold water’s temperature, speed rate to cooling time, mold temperature and products’ hottest temperature were obtained respectively. Based on the multi-index variance method, combinative values of cold water and speed rate were optimized, which can help the cooling system have the best cooling effect. At last, considering the influence of different holding pressure curve to the quality of products’ molding injection process, an optimal pressure curve was acquired to ensure minimal warp deformation.On this basis, Taguchi orthogonal test method was utilized to research the influence of processing parameters to product quality, and S/N ratio was considered to be standard for measuring the importance of factors. The influence degree of processing parameters during injection molding process to t the warp deformation was analysed with ANOVA, and the optimal combinative values of processing parameters ensuring minimal warp deformation was analysed with ANOM. At last, the reliability of combined values of the best processing parameters were verified through numerical simulation and on-site mould testing.