ABSTRACT Aiming to address the low molding precision of injection‐molded glass‐fiber‐reinforced polyamide 66 (GFR‐PA 66) dual gear, this work established a combined modulation method integrating process parameter optimization and cavity profile modification. First, mold flow simulation was conducted to determine the shrinkage characteristics of the gear teeth. Due to the incorporation of glass fiber, uneven shrinkage of the gear teeth is aggravated. A second‐order response surface model (RSM) was established between key process parameters and critical shrinkage modulation targets, and multi‐objective optimization was performed using an improved genetic algorithm. The molding process parameter combination with the lowest shrinkage rate has been identified. Under the optimal molding process parameters, experimental verification was carried out to extract the gear shrinkage model, followed by profile inversion design. After optimized modulation, the shrinkage rates for the top and root of the large gear were reduced to 0.13% and 0.15% respectively, while those for the small gear decreased to 0.33% and 0.37%. The radial runout tolerances for both gears were reduced by 66.9% and 59.1%. The integrated modulation method proposed by this work can provide a theoretical foundation and technical support for the high precision injection molding of composite material gear.
Yang et al. (Mon,) studied this question.
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