The Optimization of Plastic injection molding parameters for production of the lower part of air filter box of Shahin passenger car

Abstract

In this study, the lower part of SP100 air filter box of Shahin passenger car has been studied, which is produced from polypropylene reinforced with 20% talc. Various analysis such as: flow analysis, filling, cooling, sink marks, warpage, weld lines and packing profile were studied. Six different designs with cold and hot runners were considered for this piece. Three different designs of cooling channels were considered in order to compare the effect of different types of cooling channels on the parameters of the plastic injection process. The results show the optimal sprue length and end diameter for the cold runner system were determined to be 245mm and 8mm where for the hot runner were set to 100mm and 3mm, respectively. From this injection molding simulation can be concluded that the design E is the best option which requires a minimum packing time of 30 seconds to eliminate the sink marks, with a maximum part temperature of 108.7°C and maximum coolant temperature of 10.2°C. Considering the least warpage of 1.849 mm and volumetric shrinkage of 13.46% for design E, the suitability and efficiency of the cooling channels in this design is approved.