Injection Molding Warpage Analysis Essay

The Design and Analysis of Nozzle

Authors: Jin Li Yu, Zai Liang Chen, Xin Zhang, Hui Gao

Abstract: Nozzle is an important component of the spray equipment, the thesis using the theoretical knowledge of fluid to calculate the nozzle’s size to design the nozzle, and also using the stress analysis module of the ANSYS software to analyze the stress to choose the optimal nozzle structure.


Effect of Different Section Shape of Gas Channel on the Gas-Assisted Injection Molding

Authors: Tie Geng, Yan Yun Zhang, Qing Hai Ren

Abstract: The 6 different section shape of gas channel on the Gas-Assisted Injection Molding was researched, which is based on the same processing parameters and the same section area of gas channel.The MPI/3D GAS of Autodesk Moldflow 2010 software was used for numerical simulation.The study will provide the basis for design of gas channel selection in product.


Mold Flow-Based Mold Flow Analysis of Copier Parts and its Solution Optimization

Authors: Jun Kai Yang, Yun Jie Xu

Abstract: Mold flow software is used to conduct mold flow analysis of copier parts, simulate its filling and cooling process, and predict possible defects in the product design process in order to determine the formability of plastic parts and product quality. The optimal mold structure can be obtained by comparing different solutions so as to save production costs and improve product quality and efficiency.


The Application of Hybrid Design Method in Car Body Design

Abstract: Reverse design and forward design have their strong points each other. The advantages of reverse design lie in the treatment of free-form complex modeling, while forward design is good in modeling in simpler feature. The car body often contains complex curved surface and some simple features. Through a single reverse or forward design can’t realize the efficient design. In order to combine advantages of reverse and forward design, using the hybrid design process design can improve the efficiency of the development of car body.


Analysis of Deformation of Reflector for RF-Excited CO2 Laser

Authors: Yan Zhang, Wei Ke An, Yong Zhou, Jing Yin Tan

Abstract: The paper aims to study the deformation and compensation of the reflector for RF-excited diffusion-cooled CO2 laser. Based on ANSYS, the thermal deformation and compensation of the reflector have been calculated, It has been proved that the effect of temperature compensation is obvious, and can correct the thermal deformation of the reflector to the tolerance of the parameter of optical cavity.


This paper presents an approach of how warpage (i.e. part deflection) and injection pressure of an intricate geometry could be minimised by selecting an optimal thermoplastic material and injection gate location (through which the molten plastic flows into the cavity). The numerical analyses for mould filling considered four gate locations along with a PP (polypropylene), PS (polystyrene) and a fibre-filled PP material (each had different shrinkage characteristics, mechanical property and viscosity). Results of the cavity filling simulations indicated that (on average) the largest and smallest warpage was predicted with the PP and PS respectively. The warpage of the fibre-filled PP showed the most gate location dependent behaviour. In addition, the lowest injection pressure was associated with the fibre-filled PP. For reduced pressure, the best and second best solutions for gate location were the top and middle ones. In addition, specific attention was paid to differential fibre orientation, as one of the most important factors responsible for part warpage. In an attempt to maximise the part stiffness, the fibre-filled PP was selected. It became clear that the gate location affected the melt flow evolution and therefore the fibre orientation. Simulation results showed that bidirectional flow and asymmetrical fibre distribution was achieved with the gate positioned at the mid-section of the part. Unidirectional flow and therefore symmetrical fibre distribution could be achieved by placing the gate at the top section of the part. The injection moulding experimental utilised the fibre-filled PP along with the two aforementioned gate locations. It was discovered that warpage was present when the middle gate was applied, but it was successfully eliminated using the top gate location. It can be stated that differential fibre orientation did not cause warpage, but the asymmetrical distribution of fibre orientation did. The information discussed in the paper may be particularly useful in the early mould/part design stages when any modification can still be easily and cost-effectively implemented. An important finding is that the final gate location should only be chosen after the thermoplastic material properties and melt flow direction have been taken into account. The successful reduction of warpage and injection pressure may help to reduce the amount of production waste and energy consumption, ensuring defect-free sustainable manufacturing.

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