Abstract: In order to predict and reduce the warpage risk, Moldflow software was adopted to analyze and predict the warpage deformation of an injection-molded part before the die design and manufacturing. Taking the warping deformation of automobile glove box cover as a quality evaluation objective, three main factors for warpage deformation, including orientation effect, uneven cooling and uneven shrinkage, are optimized one by one. In the case of die structure, the adjustment of gate position and cooling system could make the warpage deformation decrease significantly. As for the optimization of processing conditions, we conducted an orthogonal experiment with four process parameters, which included the melt temperature, die temperature, holding pressure and holding time. The influence of each process parameter and the optimum process plan were obtained by range analysis. After further optimizing the holding curve of the scheme, the influence level for each process parameter was obtained. The warpage deformation could be further reduced to form the final scheme. The practice production proved that the CAE numerical simulation could provide a good guidance for the design of die and reduce the number of die repair and the probability of die scrap significantly.

Key words: car glove box cover, warpage deformation, orthogonal experiment, optimization