Injection Moulding CAE Optimization Analysis for In-mold Decoration Air Conditioner Covers
For the air conditioner cover plastic parts,the computer aided engineering(CAE)simulation optimization analysis was conducted on the injection moulding of the inner lining body in the in-mold decoration(IMD)process.The required gating system,cooling system,and injection moulding process parameters for the IMD plastic part molding mould design were obtained.The IMD plastic part was composed of a preformed outer wall film of polymethyl methacrylate(PMMA)-epoxy resin(EP)copolymer(PMI)+PMMA(PMI+PMMA)with ink printed patterns,and an inner lining body of a mixture of polycarbonate(PC)and acrylonitrile-butadiene-styrene copolymer(ABS)by the injection molding.The injection molding of IMD was optimized using the"overlapping injection molding analysis"sequence in the Moldflow CAE analysis.In the analysis model,the preformed membrane of IMD plastic part was set as the first shot using PMI+PMMA material inserts,and the inner lining body was formed as the second shot using PC+ABS material.The results show that,under the conditions of controlling the temperature of the molten material in the inner lining body to be 20℃lower than the melting temperature of the preformed membrane and using a single point Φ4 mm hot gate for the optimal gating,the second injection molding optimization of the inner lining body obtains a front temperature difference of 9.5℃corresponding to the optimal gate position,an injection time of 1.533 s,and an injection pressure of 104.52 MPa,which could effectively prevent the remelting of the preformed membranes.In the further flow analysis,the pressure is respectively optimized to 80 MPa/8 s,60 MPa/4 s,40 MPa/4 s,and 20 MPa/2 s.In the further cooling and warping analysis,the cooling system is optimized to use 24 Φ10 mm pipes for cooling.Under the condition of material temperature of 247.5℃,the mould temperature could be controlled at 77.44℃,the forming cycle could be controlled at 43.5 s,and the warping deformation could be controlled below 2.609 mm.The overall forming accuracy of the plastic part could be controlled in the range of MT4 to MT6,effectively meeting the forming requirements of the plastic parts.
Air Conditioner CoverIn-mold DecorationInjection MouldingComputer Aided Engineering Optimization AnalysisProcess ParameterWarping
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维普
