Research On Design And Process Optimization Method Of Injection Mold For High-quality Automobile Brake Plug-in

With the development of the automobile industry,the competition for high-end technology at home and abroad has become increasingly fierce,which places higher demands on my country’s automobile injection molds.At present,many companies mostly rely on experience to design molds and adjust process parameters,which can no longer meet the needs of the industry.However,the combination of CAD/CAE technology and mold design can not only improve design efficiency,but also early discover design problems and products.Defects,thereby improving mold design,optimizing process parameters,and effectively improving production efficiency and product quality.This paper takes the automobile brake plug-in as the research object,combined with CAD/CAE software to design the product injection mold,and uses the response surface method and the standard particle swarm algorithm to combine,with the warpage as the optimization target,the injection molding process parameters are optimized.The main contents of this article are as follows:First,it introduces the research of domestic and foreign scholars on injection mold design and process parameter optimization,briefly describes the injection molding process,and analyzes the material characteristics of the material used in automobile brake inserts:ABS.In order to ensure the accuracy of the subsequent melt flow simulation,the CAE software Moldflow2015 was used to pre-process and mesh the product 3D model,and repair the mesh to achieve a matching rate of more than 90%.Secondly,according to the characteristics,size,and production requirements of automobile brake plug-ins,UG NX10.0 and Moldflow are used to complete the mold structure design,and a set of high-quality injection molds suitable for this product are designed.The mold structure mainly includes: mold core design,side core pulling mechanism and insert design,pouring system design,cooling system design,etc.In combination with the product appearance requirements,the gate and cooling system schemes were compared,and the appropriate gate number and cooling pipe arrangement form were determined,so that the product pouring was balanced and the cooling effect was optimal.Finally,a set of hot runner to cold runner gating system,two-plate parting side core-pulling mechanism and submerged gate injection mold were designed.Finally,in order to ensure the quality of product molding,with the amount of warpage as the optimization goal,response surface method and standard particle swarm algorithm are used to optimize injection process parameters.Four process parameters are selected:mold temperature,melt temperature,holding pressure,and holding time as test factors.The response surface method-central composite test(CCD)is used for test design,and the response surface model is established,and the local maximum is obtained.The amount of excellent warpage is 1.18 mm.In order to obtain the global optimal process parameter combination,the response surface model is used as the algorithm model,and the standard particle swarm optimization algorithm is used to optimize the process parameter combination when the warpage is 1.0323mm: mold temperature 60℃,melt temperature280℃,The holding pressure is 95 MPa,the holding time is 8.296 s,and combined with Moldflow for simulation verification comparison,the error is small,only 2.27%.After actual injection molding production,qualified products were obtained,which verified the reliability of the standard particle swarm algorithm for optimizing product warpage.