Simulation of an Injection Process Using a CAE Tool: Assessment of Operational Conditions and Mold Design on the Process Efficiency

The present work developed an experimental and simulation study to evaluate the influence of some operational conditions and mold design on the efficiency of an injection process used to produce polystyrene parts. The software SolidWorks Plastic was used to simulate the injection process and assess the performance of the mold considering the absence and the presence of venting. Experimental results obtained by varying the injection pressure, injection temperature as well as the mold temperature were used to validate the simulation data generated considering both mold designs. The findings revealed air entrapment at the end of the mold cavity and low process efficiency when the mold was operated with no venting, regardless the processing conditions. Simulation results indicated a remarkable increase of the process efficiency when vents were included on the parting line of the mold. In addition, the range of processing conditions which led to the highest process efficiency was virtually identified and tested in the real modified mold (with venting system). The findings revealed that the injection cycle time reduced in approximately 35% and the waste generation diminished from 65% to less than 1% when venting was included in the mold design and the optimal operational conditions were used.本研究开展了实验与仿真结合的系统性研究，以探究若干工艺参数及模具设计对用于生产聚苯乙烯（Polystyrene）制品的注塑成型工艺效率的影响。本研究采用SolidWorks Plastic软件开展注塑成型仿真，针对有无排气结构的模具分别评估其工艺性能。通过改变注塑压力、注塑温度及模具温度所获取的实验数据，用于验证两种模具设计对应的仿真结果。研究结果表明，当模具未设置排气结构时，无论工艺参数配置如何，均会在模腔末端出现气体困积现象，且工艺效率低下。仿真结果显示，若在模具分型面增设排气结构，工艺效率将得到显著提升。此外，本研究通过仿真确定了可实现最高工艺效率的工艺参数范围，并在搭载排气系统的改良实体模具中开展了实际验证。结果表明，当采用优化工艺参数并在模具设计中增设排气结构后，注塑循环周期可缩短约35%，废料产生占比从65%降至1%以下。