Optimization of injection molding process for motor gear cover with metal inlay based on Moldflow
The motor gear cover of automobile wiper system is generally made by injection molding,and 3 pieces of metal inlays in it play a role in conducting current.During the injection molding process,it is necessary to ensure that there is a certain distance between the metal inlays to ensure the normal operation of the motor.In order to verify whether the design scheme meets the design requirements,the mold flow analysis software Moldflow was used to analyze the injection molding process of the gear cover,accurately grasping the deformation situation of the metal inlay.The simulation calculation result of initial scheme shows that the deformation of inlay 31 for grounding is too large and cannot meet design requirement,which leads to the risk of short circuit from overlapping between two inlays.Aiming at the problem of excessive deformation of inlay 31,the possible reasons were analyzed,and the injection molding process parameters and insert positioning scheme were optimized.Under the premise of meeting the design requirements,the optimal mold temperature and melt temperature were obtained by orthogonal test.The results show that the deformation of inlay 31 is reduced by 27.3% when the mold temperature is 80℃ and melt temperature is 265℃.Through-hole positioning method is changed in positioning of inlay 31,which increase the positioning reliability of inlay 31.After the implementa-tion of two optimization scheme,the maximum deformation is reduced from 0.55 mm to 0.05 mm,which is reduced by 90.9% and can meet design index requirement.
motor gear coverinlaymold flow analysisdeformationprocess parameter
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