Optimization of Injection Process Parameters and Mold Design for Card-cover Based on the Response Surface Methodology
The complex structure and multiple reinforcing ribs of the automotive power card-cover could prevent the flow of materials during injection molding process,which led to problems,such as,melting lines,warping deformation and so on.And it affected the surface quality and structural strength of the product.Therefore,the theoretical algorithm and finite element simulation were combined to research the injection molding process optimization and mold design of card-cover.The results show that firstly the point gate and its location are determined according to the product characteristics,and then the double gates structure is determined by Moldflow analyzed results.Secondly,taking the weld line as optimization objective,the experimental schemes of response surface method are established and the Moldflow analysis is carried out.Then,the least square method,variance analysis,regression analysis,etc.are adopted to ensure the best process parameters,the optimal process combination with the welding line as the optimization objective is determined as the melt temperature of plastic products(A)260℃,mold temperature(B)65℃,injection time(C)1.5 s,holding pressure(D)70 MPa and holding time(E)10 s.The maximum length of the fuse line is about 5.8 mm,which is reduced by 81.6%compared with the initial analysis scheme(31.5 mm).Finally,UG software is used to design the injection mold of the card-cover,the product is filled completely and the surface quality is good by production verification,which provides guidance for the production.
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