基于Moldflow的PC/ABS汽车后视镜翘曲变形优化分析

为了预测和降低翘曲风险,在模具设计及制造前,先利用Moldflow模流分析软件对产品的翘曲变形进行分析及预测。针对翘曲变形产生的三个主要因素(取向效应、冷却不均、收缩不均)逐一进行优化。通过调整模具浇口位置、优化冷却系统、调整注塑时的保压参数,使产品的翘曲变形量逐渐减小,最终达到质量要求。结果表明,采用PC/ABS共混物注塑制备汽车后视镜外壳的最优方案是:扇形侧浇口;凹模2条水路、抽芯1条水路、凸模3条水路的优化冷却;保压压力85 MPa,保压时间分10,5 s两段。最优方案条件下,翘曲变形量降低约35.0%,并依据最终方案进行了模具设计。

Optimal analysis based on Moldflow for warpage deformation of automotive rearview mirror shell prepared with PC/ABS blend

Moldflow software was used to analyze and predict the warpage deformation of the product before the die design and manufacturing.Three main factors (orientation effect,non-uniform cooling and non-uniform shrinkage) of warpage deformation were optimized one by one.The warpage deformation of the optimized product gradually decreases and meets the product quality requirements by modifying the position of the gate,optimizing the cooling system and adjusting the holding pressure parameters during injection.The results show that the optimal scheme for automotive rearview mirror shell prepared with PC/ABS blend are listed as follows:fan side gate;optimized cooling of 6 waterways including concave die of 2 waterways,core pulling of 1 waterway,punch of 3 waterways;holding pressure is 85 MPa,pressure holding time are 10 s and 5 s.Under the optimal scheme,the total warpage deformation is reduced by 35.0%.The die design was carried out on the basis of the final plan.