Simulation of the gas-assisted injection molding process using a mid-plane model of a contained-channel part

Computer-aided engineering (CAE) simulation and experimental studies have been carried out on the cavity filling and gas packing steps in the gas-assisted injection molding of a contained-channel part. A mid-plane model of the three-dimensional geometry of the mold cavity has been proposed to be analyzed by the finite element method. The shot size, the distribution of the gas bubble and the residual wall thickness were calculated using a commercial simulation software (Moldflow Plastics Insight Version 4.1). The outcomes predicted by simulation were compared with the experimental results indicating the good predictive capability of the proposed model.