Computer determination of weld lines in injection molding based on filling simulation with surface model

Weld line is aesthetically unpleasant and affects the mechanical strength of injection molded parts. Because of the ever-increasing requirements for parts performance, lots of researchers have performed various studies related to the weld lines optimization. However, research about the computer determination of weld lines in injection molding remains scarce. In this paper, a weld line computer determination method based on filling simulation with surface model is proposed, from which the positions and lengths of the weld lines can be predicted. According to the characteristics of the surface model, all weld lines are classified into two different types. Initial welding node searching and revision algorithms for the two different types of weld lines are first developed. Starting from initial welding nodes, weld lines are then extended by a pre-extension algorithm and an extension algorithm. In the weld line extension algorithm, 135 degrees is set as a welding angle threshold for forming weld lines. Finally, the effects of cavity thickness, process parameters, and mesh densities have been investigated. Moreover, Moldflow simulation results and real parts in production have been conducted to verify the proposed determination method, which demonstrate that the proposed method is correct and effective in actual production.