Abstract
The key quality requirements of automotive blow molded parts include weight distribution, geometric tolerance and mechanical performance. This work deals with the optimization of an automotive filler panel used in a sports utility vehicle. The part is molded with an insulating material (carpet) on one side, which renders the design of the part complex, due primarily to the non-uniform solidification of the part and the tight tolerance requirements of automotive OEM's. The proposed optimization consists of the manipulation of the die gap programming points and the mould temperature in order to optimize the part thickness distribution and to minimize the part warpage.
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