基于Moldflow的汽车把手气辅注塑工艺多目标优化

Multi-objective optimization of automotive handles gas-assisted injection molding process based on Moldflow

汽车内饰把手是典型的棒状类零件,常采用气体辅助注射成型(GAIM)技术进行生产,以满足把手强度和轻量化要求。由于GAIM技术的成型参数多,塑件成型质量控制难度大,通过运用Moldflow模流仿真分析并结合Taguchi试验方法,以塑件的气体穿透长度和横截面最小壁厚为质量目标来优化成型工艺参数,选择熔体温度、模具温度、气体压力、气体保压时间和预注射量5个主要因素进行正交试验,采用极差分析研究上述5个工艺参数对气体穿透长度和横截面最小壁厚的影响规律,应用多目标综合平衡法得到优化的工艺参数组合,即熔体温度为250℃、模具温度为50℃、气体压力为10 MPa、气体保压时间为10 s、预注射量为75%。通过实际GAIM验证,塑件气体穿透效果良好,满足穿透长度和横截面最小壁厚的要求,塑件质量减轻25%以上,并具有良好的表面质量和尺寸精度,能够显著缩短成型周期,节约塑料材料,提高生产质量和效率,并满足汽车轻量化要求。

Automotive interior handles are typical rod-shaped parts,which are often produced using gas-assisted injection molding(GAIM)technology to meet the strength and lightweight requirements.Due to the multiple molding parameters of GAIM,it is difficult to control the quality of plastic parts.By using Moldflow simulation analysis and combining with Taguchi test method,the molding process parameters were optimized such as gas penetration length and minimum wall thickness of the cross-section of the plastic parts.Five main factors,including melt temperature,mold temperature,gas pressure,gas holding time,and pre injection volume,were selected for orthogonal experiments,The influence of the five process parameters on gas penetration length and minimum wall thickness of the cross-section was studied using range analysis.The multi-objective comprehensive equilibrium method was applied to obtain the optimized process parameter combination,which includes a melt temperature of 250℃,a mold temperature of 50℃,a gas pressure of 10 MPa,a gas holding time of 10 s,and a pre injection volume of 75%.Through actual GAIM verification,the gas penetration effect of plastic parts is good,meeting the requirements of penetration length and minimum wall thickness of cross-section.The weight of plastic parts is reduced by more than 25%,and it has good surface quality and dimensional accuracy.It can significantly shorten the molding cycle,save plastic materials,improve production quality and efficiency,and meet the requirements of automotive light weighting..