Thermal-fluid analysis of effective parameters in plastic injection molding for the production of fuse/relay frames for motor housing of a passenger car

Document Type : Original Article

Authors
Fatemeh Rafei 1
Navid Ramezanian 2
sayyed aboozar fanaee 3
1 Department of Chemistry, Faculty of Science, Ferdowsi University of Mashhad, Mashhad.
2 Department of Chemistry, Faculty of Science, Ferdowsi University of Mashhad, Mashhad
3 Department of Mechanical Engineering,, Faculty of Engineering, University of Birjand
10.22077/aec.2025.9761.1031
Abstract
In this work, thermal-fluid analysis and optimization of plastic injection molding of the fuse/relay frame of the motor housing of the Peugeot 206 car have been performed using Moldflow software. Also, the development of multiple decision-making methods and decision support systems to Moldflow software in this work have provided tools for analysis and optimization under conditions of uncertainty of this quality. In order to manufacture parts in a mold with good quality, a cooling system must always be designed to transfer heat evenly to the mold and cool the melt with quality. For this optimization of the system, a cooling temperature range corresponding to the melting temperature has been used. The results of this work show that for a cooling temperature of 150°C, the amount of depression is reduced by at least 49% and the volume shrinkage is reduced by at least 2% compared to other temperatures. The distortion is also increased slightly, so water vapor at a temperature of 150°C will provide the best cooling for the production of the present part. The optimized cooling systems include the designed system (1) with 7 coolant inlets and 7 coolant outlets and 15 baffles, the designed systems (2) and (3) with increased length and including 6 and 15 baffles, respectively. Comparison between the performance of these systems shows that the second cooling system is a selected and efficient cooling system compared to other systems, due to the minimum relative depression of about 6%, the minimum relative distortion of about 5%, and the insignificant change in volumetric shrinkage.
Keywords
Numerical model
Thermal-fluid analysis
Moldflow software
Optimization