Abstract: To resolve the problem of excessive deformation generating in the injection-molded lower casing of temperature controller of an air conditioner, the lower casing was analyzed by a multi-response Taguchi method and then simulated by a Moldflow software. The results indicated that the optimum combination of processing parameters included a mold temperature of 60 ℃, a melt temperature of 230 ℃, a packing pressure of 60 MPa and a holding time of 20 s. The maximum warping deformation was significantly suppressed to decrease by 0.036 mm when the lower casing was injection molded with these optimum process parameters.

Key words: injection mold, processing parameter, warping deformation, Taguchi method, range analysis method