Comparative Analysis of Different Injection Molding Process Parameters through Injection Molding Flow Simulation for Various Gate Locations

Abstract

This study deals with part quality concerning gate location on the part for injection molding. Through injection molding filling simulations, basic parameters such as injection pressure, bulk and surface temperature, shear rate, solidification, shrinkage, air entrapment, weld lines and others were analysed. The simulation was conducted on a fan blade model with Polycarbonate material. Polycarbonate is a commonly used polymer in the industry and is famous for its rigidity, strength-to-weight ratio and reliability in critical system. Simulation is done at six possible gate locations labelled A1 through A6. Injection molding filling simulations was performed to evaluate the performance of each gate location. Among the considered gate locations, gate A4 exhibited a considerably high pressure drop, while gate A5 exhibited a comparatively uniform pressure drop across the mould cavity, also gate A5 showed consistent and smooth filling along with uniform cooling implying less chance of defects. Gate A4 and A5 exhibit uniform distribution across the cavity in shear rate analysis. Gate locations A2, A3, A4, and A5 exhibited controlled solidification, indicating consistent part quality. However, Gate A6 exhibited problems with volume shrinkage, which requires process optimization. Gate A6 exhibited a significant reduction in air entrapment as compared to other gate locations.