Injection Molding and Warpage of Thin-Walled Parts Based on Simulated Deformation

Injection molding of the typical thin-walled parts, named back cap door of cars, has been systematically investigated. We have focused on the relationship between the injection molding process and warpage, by designing the casting and cooling systems and tailoring the processing parameters based on the simulated analysis of MOLDFLOE software. The optimized processing parameters have been achieved by the compared investigation of the warpage with different gates, the freezing and casting time, the shear to the mold, and the maximum flow pressure. Based on the analysis of the warpage under different mold and flux temperatures, it is found that the former one has little influence, while the latter one exhibits a profound effect on the warpage of the manufactured parts. Finally, some manners have been proposed to reduce the warpage of the thin-walled parts.