Optimization of Pressure⁃holding Curve for Injection Molding of Automotive Lifter Switch Panel Oriented to Vague Set

doi:10.19491/j.issn.1001-9278.2021.10.013

Abstract

Abstract:

The problems of warpage and deformation occurring in the injection?molded car lift switch panel were investigated. The warpage deformation of the molded products was obtained through selecting the packing curve model and parameters for the orthogonal experimental design and also simulating and analyzing with the Moldflow software. The optimal process parameter combination of the range analysis and optimization method was obtained from the range analysis of the warpage deformation. The Vague set was employed to optimize the standard deviation of volume shrinkage rate and the maximum volume shrinkage rate through multi?objective optimization. The optimal process parameter combination of Vague set optimization method was obtained. Then， the warpage quantities obtained from different optimization methods were compared. The results indicated that the uneven shrinkage was the main factor causing the warpage of the part. The warpage deformation corresponding to the range analysis and optimization method was 1.5 %， which was lower than the minimum warpage deformation in the orthogonal experiment. The optimization effect was not evident. The warpage deformation corresponding to the Vague set optimization method was reduced by 26.5 % compared to the minimum warpage deformation in the orthogonal experiment. There is no significant difference in the internal pressure distribution of the mold. The Vague set optimization method exhibited a better optimization effect than the range analysis one. This indicates that the Vague set optimization method can greatly reduces the warpage deformation of the mold.

Key words: automotive lifter switch panel, Moldflow, orthogonal experiment, range analysis, vague set, optimization

CLC Number:

TQ320.66⁺2

XUE Maoyuan, MEI Yi, LUO Ningkang, TANG Fangyan, XIAO Zhankai. Optimization of Pressure⁃holding Curve for Injection Molding of Automotive Lifter Switch Panel Oriented to Vague Set[J]. China Plastics, 2021, 35(10): 76-82.

Figures/Tables 13

Fig.1. Structure of the automobile lifter switch panel

Fig.2. Simulation analysis model

Fig.3. Analysis results of the initial scheme

Fig.4. Holding pressure against time

水平	因素
水平	A/s	B/MPa	C/MPa	D/s	E/s
1	6	50	1	5	4
2	7	60	2	10	5
3	8	70	3	15	6
4	9	80	4	20	7
5	10	90	5	25	8

Tab.1. Factor level table

序号	A/℃	B/℃	C/s	D/MPa	E/s	V_max/%	δ/%	翘曲变形量/mm
1	6	50	1	5	4	7.611 5	2.010 4	4.251
2	6	60	2	10	5	7.060 9	2.014 6	4.138
3	6	70	3	15	6	6.460 1	1.969 2	3.947
4	6	80	4	20	7	6.018 5	1.900 8	3.693
5	6	90	5	25	8	5.404 7	1.843 8	3.591
6	7	50	2	15	7	7.287 6	1.763 1	3.725
7	7	60	3	20	8	6.789 8	1.732 1	3.518
8	7	70	4	25	4	6.297 5	1.742 4	3.426
9	7	80	5	5	5	5.885 1	1.982 8	3.904
10	7	90	1	10	6	6.917 6	2.325 6	4.462
11	8	50	3	25	5	7.297 1	1.542 0	3.170
12	8	60	4	5	6	6.791 8	1.780 2	3.572
13	8	70	5	10	7	6.295 5	1.703 1	3.368
14	8	80	1	15	8	6.365 4	2.116 7	4.145
15	8	90	2	20	4	7.024 2	2.204 2	4.311
16	9	50	4	10	8	7.288 0	1.529 8	3.146
17	9	60	5	15	4	6.792 1	1.489 9	2.930
18	9	70	1	20	5	6.295 4	1.900 2	3.762
19	9	80	2	25	6	5.785 5	1.822 9	3.577
20	9	90	3	5	7	5.717 5	2.100 8	4.125
21	10	50	5	20	6	7.288 0	1.354 7	2.783
22	10	60	1	25	7	6.792 2	1.591 8	3.148
23	10	70	2	5	8	6.295 5	1.864 5	3.708
24	10	80	3	10	4	5.786 8	1.809 3	3.560
25	10	90	4	15	5	5.263 0	1.716 6	3.358

Tab.2. Orthogonal test result

Fig.5. Range analysis chart

序号	V_max		δ
序号	$t O$	$1 ? f O$	$t P$	$1 - f P$
1	0	0	0.324 6	0.382 5
2	0.234 4	0.267 2	0.320 3	0.377 8
3	0.490 3	0.535 9	0.367 1	0.428 4
4	0.678 3	0.718 1	0.437 5	0.502 5
5	0.939 7	0.950 0	0.496 2	0.562 2
6	0.137 9	0.159 6	0.579 4	0.643 7
7	0.349 9	0.391 4	0.611 3	0.674 0
8	0.559 5	0.604 5	0.600 7	0.664 0
9	0.735 1	0.770 6	0.353 1	0.413 3
10	0.295 5	0.333 4	0.000 0	0.000 0
11	0.133 9	0.155 0	0.807 1	0.848 2
12	0.349 0	0.390 5	0.561 7	0.626 7
13	0.560 4	0.605 3	0.641 2	0.701 9
14	0.530 6	0.576 0	0.215 2	0.259 7
15	0.250 1	0.284 3	0.125 0	0.153 9
16	0.137 7	0.159 4	0.819 7	0.858 6
17	0.348 9	0.390 3	0.860 7	0.892 4
18	0.560 4	0.605 3	0.438 2	0.503 1
19	0.777 5	0.809 1	0.517 8	0.583 6
20	0.806 5	0.834 9	0.231 5	0.278 5
21	0.137 7	0.159 4	1.000 0	1.000 0
22	0.348 9	0.390 3	0.755 8	0.804 5
23	0.560 4	0.605 3	0.474 9	0.540 7
24	0.777 0	0.808 6	0.531 8	0.597 5
25	1.000 0	1.000 0	0.627 3	0.688 9

序号	V_max		δ
序号	$t O$	$1 ? f O$	$t P$	$1 - f P$
1	0	0	0.324 6	0.382 5
2	0.234 4	0.267 2	0.320 3	0.377 8
3	0.490 3	0.535 9	0.367 1	0.428 4
4	0.678 3	0.718 1	0.437 5	0.502 5
5	0.939 7	0.950 0	0.496 2	0.562 2
6	0.137 9	0.159 6	0.579 4	0.643 7
7	0.349 9	0.391 4	0.611 3	0.674 0
8	0.559 5	0.604 5	0.600 7	0.664 0
9	0.735 1	0.770 6	0.353 1	0.413 3
10	0.295 5	0.333 4	0.000 0	0.000 0
11	0.133 9	0.155 0	0.807 1	0.848 2
12	0.349 0	0.390 5	0.561 7	0.626 7
13	0.560 4	0.605 3	0.641 2	0.701 9
14	0.530 6	0.576 0	0.215 2	0.259 7
15	0.250 1	0.284 3	0.125 0	0.153 9
16	0.137 7	0.159 4	0.819 7	0.858 6
17	0.348 9	0.390 3	0.860 7	0.892 4
18	0.560 4	0.605 3	0.438 2	0.503 1
19	0.777 5	0.809 1	0.517 8	0.583 6
20	0.806 5	0.834 9	0.231 5	0.278 5
21	0.137 7	0.159 4	1.000 0	1.000 0
22	0.348 9	0.390 3	0.755 8	0.804 5
23	0.560 4	0.605 3	0.474 9	0.540 7
24	0.777 0	0.808 6	0.531 8	0.597 5
25	1.000 0	1.000 0	0.627 3	0.688 9

Tab.3. Converted Vague set values

序号	V_max相似度	δ相似度	总相似度
1	0	0.327 7	0.092
2	0.234 5	0.323 5	0.142
3	0.478 3	0.368 9	0.209
4	0.660 0	0.437 0	0.268
5	0.931 9	0.493 7	0.343
6	0.140 1	0.574 2	0.192
7	0.345 0	0.605 3	0.245
8	0.544 5	0.594 9	0.286
9	0.716 6	0.355 3	0.257
10	0.293 1	0.000 0	0.064
11	0.136 1	0.799 5	0.254
12	0.344 2	0.557 1	0.232
13	0.545 3	0.634 5	0.298
14	0.516 8	0.220 3	0.175
15	0.249 6	0.129 9	0.091
16	0.140 0	0.812 2	0.258
17	0.344 1	0.854 2	0.315
18	0.545 3	0.437 6	0.243
19	0.759 6	0.514 5	0.311
20	0.789 4	0.236 5	0.240
21	0.140 0	1.000 0	0.311
22	0.344 0	0.747 8	0.285
23	0.545 3	0.473 1	0.252
24	0.759 0	0.528 1	0.315
25	1.000 0	0.620 9	0.394

Tab.4. Similarity and total similarity of optimal ideal value

工艺参数	平均相似度					最大水平
工艺参数	水平1	水平2	水平3	水平4	水平5	最大水平
A	0.210 7	0.209 0	0.210 0	0.273 3	0.311 4	水平5
B	0.221 2	0.243 8	0.257 5	0.265 2	0.226 5	水平4
C	0.171 8	0.197 7	0.252 5	0.287 5	0.304 7	水平5
D	0.214 6	0.215 5	0.256 8	0.231 5	0.295 9	水平5
E	0.219 8	0.257 9	0.225 3	0.256 3	0.254 9	水平2

Tab.5. Average similarity of each variable

Fig.6. Model pressure distribution diagram

Fig.7. Warpage cloud diagram of optimal process combination of different optimization method

优化方法	翘曲变形量/mm	优化效果/%
正交试验	2.783	—
极差分析	2.748	1.25
Vague 集	2.045	26.50

Tab.6. Optimization effect comparison

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