Abstract: An automotive rear lamp housing was selected as the research model in this study. First, the warpage of lamp housing based on the optimum injection parameters was obtained using finite element (FE) software Moldflow. After that, CAE numerical simulation was conducted for the plastic part with reverse deformation design, and the results were compared with that based on original design. After three iterations, the dimension deviation of the simulated warpage from the original model decreased from previous 0.8595 to 0.10875 mm. In the engineering test the feasibility of this approach was confirmed.

Key words: injection molding, dimension precision, warpage deformation, iteration method, reverse deformation method