Improving the quality and dimensional accuracy of thin-walled polymer parts by CAE simulation in Moldex3d
DOI:
https://doi.org/10.31471/1993-9965-2025-2(59)-75-84Keywords:
injection molding, thin-walled polymer parts, dimensional accuracy, CAE simulation, Moldex3D, mold, molding parameters, shrinkage, warpage, technological process optimizationAbstract
Modern manufacturing of complex injection molds is characterized by increased demands for quality, dimensional accuracy, and stability of cast product properties. This necessitates predicting their behavior as early as the design stage. Practice shows that a significant portion of mold designs require refinement due to the complex interaction of thermal, rheological, and shrinkage processes occurring during injection molding. In this context, the application of CAD/CAE systems for numerical analysis of technological processes is a crucial tool for enhancing the validity of design and engineering solutions and reducing mold debugging costs. This article presents the results of a study on the application of the Moldex3D software suite for the analysis and optimization of the injection molding process for thin-walled polymer parts. The primary focus is on investigating the influence of injection molding parameters and mold design features on part formation, quality, and dimensional accuracy. Numerical modeling was used to analyze mold filling, packing, and part cooling processes, considering their impact on warpage, shrinkage, and geometric deviations. Based on the simulation results, characteristic zones of defect concentration, such as warpage and short shots, were identified, and their causes were determined. A series of numerical experiments provided the basis for recommendations on optimizing injection molding parameters and mold design solutions aimed at reducing deformations and ensuring specified dimensional accuracy of the parts. Particular attention was paid to the correct application of the software, specifically the influence of simulation method selection, boundary, and initial conditions on the reliability of quantitative results and their qualitative interpretation. The obtained results can be used in the design and refinement of injection molds for thin-walled polymer parts with high requirements for quality and stability of geometric parameters.
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