Warpage Analysis And Optimization Based On CAE Technology For Automobile Lamp Lens

With the rapid development of automobile industry and the requirement of vehicle lightweight,plastic parts have been used in automobile on a large scale.As the largest thin-walled cover on the lamp,warping is the most common defect in injection molding process.Excessive warpage leads to poor size,difficult assembly,and other serious consequences.Therefore,it is of great economic value and social significance to study and optimize the injection molding process.In this paper,CAE software is used to simulate the injection moulding process and study the moulding mechanism of automobile lamp lens.Through the analysis of the flow mathematical model,gate type,filling effect,melt line distribution and warpage deformation,the rules are summarized and optimized.1)Analyze the application of high molecular polymers in injection molding.The mechanical properties,optical properties and molding properties of the material Makrolon 2407(PC)are introduced in particular.The viscosity curve and PVT curve of the material are also given.2)Based on CAE software,the geometric model of automobile lamp lens is meshed and optimized,then the pouring system and cooling system are established according to the actual situation.The former mainly includes the statistics and analysis of mesh generation,as well as the diagnosis,repair and re-division of meshes.3)Starting from the injection process conditions,orthogonal experiments were carried out to study the effects of parameters and interaction on warpage,taking the mould temperature,melt temperature,injection time,holding pressure,holding time and cooling time as the main influencing factors.Then single factor experiments were carried out to analyze the influence trend of each parameter on warpage.Finally,the parameters were adjusted to obtain the optimal combination to reduce the warpage.4)The actual production was arranged for verification,and the optimal process parameters made the warpage of the lamp mask controlled within 1 mm,which was very close to the theoretical prediction value,which proved the effectiveness of the scheme in the actual production.