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Abstract The injection molding procedure primarily involves a sequential process that converts plastic pellets into a molded item. Through a repetitive cycle, identical components are created by melting resin pellets or powder and then injecting the resulting polymer melt into a hollow mold cavity using high pressure. Injection molding has posed challenges for numerous manufacturers and researchers aiming to create cost-effective products that meet specified criteria. This research explores the holistic process of designing, analyzing, and manufacturing of an injection mold for an air filter box bottom cover, focusing on cost-effectiveness while addressing common challenges in achieving high-quality parts. For the production of this part, a material called Poly Propylene talc filled PPTF is employed due to its enhanced stiffness, making it appropriate for this application where dimensional stability is crucial. Through moldflow simulation, potential issues like uneven flow, problematic weld lines, and air traps are identified. Based on these findings, the mold design is optimized by strategically placing gates, controlling weld line position, eliminating gas traps, equalizing pressure drops, and reducing stress levels. The optimized parameters are then implemented in manufacturing, leading to improved part quality through reduced defects and better dimensional accuracy. Additionally, the research helps minimize production costs by reducing rejections and rework. This, multifaceted approach not only streamlines the process but also contributes to the efficient and cost-effective production of high-quality air filter box bottom covers.
Krishnappa et al. (Fri,) studied this question.