Graduation Project in Wuhan University of Technology（Dissertation）

Structural Design and Molding Process Optimization Analysis of Lightweight Automotive Decorations

College (Department) International Education Institute

Specialtyamp;Class Vehicle Engineering 1303

Student Name Chen wenxin

Tutor Guo Wei

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Abstract

With the development of the automotive industry, people have higher requirements on automotive decorations, and pay more attention to the design of automotive decorations. The plastic parts have been popularized in the industrial sectors such as aviation, aerospace, electronics, machinery, ships and automobiles because of their advantages of light weight, good flexibility, chemical resistance, electrical insulation and excellent molding performance. At present, most of the automotive decorations are made of plastic materials.Because that different properties of materials and different manufacturing process will directly affect the of the using performance of the product and vehicle quality, so the study of the influences of automotive decorations’ structural design, molding process and injection molding process parameters on the performance of decorative products, and then improve the quality of decorative products and reduce the cost of development is one of the major problems to be solved by all the major manufacturers. It is also an important subject with scientific worth and practice Meaning.

According to the design principle of automotive decorations, the three-dimensional geometric model of automobile glove box cover is established under UG software environment. The finite element analysis model is established in Hypermesh, and the modal analysis and stiffness analysis were carried out in ANSYS software.

Based on the simulation of finite element simulation of microporous foaming injection molding, the mold flow analysis model of the automobile glove box cover was established in Moldflow software. The influences of parameters of the process parameters (gas parameters, injection parameters and cooling parameters) on the filling time, Warping deformation and bubble radius were studied.

Key Words：Automotive decorations; plastic; microporous foam injection molding; finite element; Moldflow; process parameters

Catalog

Abstract I

Chapter 1 Preface 1

1.1 Introduction 1

1.2 The development of Lightweight of Automobile 2

1.3 The development of Automotive Decorations 3

1.4 Research Status of Microporous Foaming Injection Molding Technology at Home and Abroad 4

1.5 The Purpose and Significance of Topic Selection 6

1.6 Main research contents 6

Chapter 2 Analysis of the structure of the glove box cover 8

2.1 Introduction 8

2.2 Foundation of the structure of the glove box cover 8

2.2.1 The simplification of the model 8

2.2.2 Model Import and Geometric Cleaning 9

2.2.3 Extract the midsurface and choose grid 9

2.2.4 Material definition 11

2.3 Modal analysis 11

2.3.1 Boundary conditions of modal analysis 11

2.3.2 Result of modal analysis 12

2.4 Stiffness analysis 14

2.4.1 Load definition of Stiffness analysis 14

2.4.1 Result of Stiffness analysis 15

2.5 Chapter summary 16

Chapter 3 Simulation of Microporous Foam Injection Molding Process Based on Moldflow 17

3.1 Introduction 17

3.2 Introduction of Moldflow 17

3.3 Filling simulation analysis based on Moldflow 18

3.4 General process of filling simulation analysis based on Moldflow 18

3.4.1 Pre - treatment of mold flow analysis 18

3.4.2 Selection of materials for finite element analysis of glove box cover 22

3.4.3 Result of finite element analysis of Microporous foaming injection molding 25

3.5 chapter summary 29

Chapter 4 Effect of Microporous Foaming Injection Molding Parameters on Forming Quality of Automobile Decorations 30

4.1 Introduction 30

4.2Process parameters affecting forming quality inMicrocellular foam injection molding process 30