Dong-Gyu Ahn/Dae-Won Kim/Yeol-Ui Yoon
The Journal of Mechanical Science and Technology, vol. 24, no. 1, pp.145-148, 2010

Abstract : The objective of this paper is to examine the influence of injection molding parameters on the core shift to obtain the optimal injection molding conditions of a plastic battery case with thin and deep walls using numerical analyses and experiments. Unlike conventional injection molding analysis, the flexible parts of the mold were represented by 3-D tetrahedron meshes to consider the core shift in the numerical analysis. The design of experiments (DOE) was used to estimate the proper molding conditions that minimize the core shift and a dominant parameter. The results of the DOE showed that the dominant parameter is the injection pressure, and the core shift decreases when the injection pressure decreases. In addition, it was shown that the initial mold temperature and the injection time hardly affect the core shift. The results of the experiments showed that products without warpage are manufactured when the injection pressure is nearly 32 MPa. Comparing the results of the analyses with those of the experiments, optimal injection molding conditions were determined. In addition, it was shown that the core shift should be considered to simulate the injection molding process of a plastic battery case with thin and deep walls.

Keyword : Optimal injection molding condition; Core shift; Thin and deep walls; Battery case; Design of experiments