Injection Molding Analysis for Bird-Feeder by Optimizing the Shrinkage and Warpage Deformation

Abstract

Injection molding is one of the most appealing advanced manufacturing technologies for producing complex- shaped parts with superior properties. The advantage of injection molding simulation lies in its cost-effectiveness and time effi- ciency, as it helps prevent issues at the design stage rather than addressing them during production. Several defects can occur, such as sink marks, short shots, or warping. Consequently, a poor understanding of how injection parameters influence the formation of these defects continues to limit the widespread use of this process in industry today. The main objective of this paper is to digitally simulate the injection process within a mold cavity of complex shape. To achieve this, properties such as viscosity, specific heat, density, and thermal conductivity were characterized. The position of the injection gate and the design of the part were modified to minimize air traps and warpage. These changes were then implemented in the Moldex3D simulation software to simulate various parameters using the finite element method (FEM), including the filling time, shear rate, viscosity, and volumetric shrinkage. The outcomes in terms of packing, warpage, and filling are satisfactory. This study aims to enhance part quality by simulating several gate locations on the same model and evaluating their impact on fill patterns and part quality. The research makes the following contributions: monitoring each gate's flow rate analysis; finding areas with air traps, warpage, and weld lines; strengthening the plastic part's rigidity,