Strategies for adjusting process parameters in CAE simulation to meet real injection molding condition of screw positions and cavity pressure curves

Numerical simulations of polymer melt flow behavior in mold cavities help optimize process parameters. However, mathematical models, processing conditions, material property settings, and machine aging can cause simulations to differ from experimental results. The accuracy of simulations can indicate injection mold quality, which is used to determine the optimal process parameters. However, the optimal process parameters for simulations are very different from the real situation and cannot be directly applied in practice. Therefore, the simulation setup in the manufacturing process requires additional molding trials, resulting in time and cost consumption. This study used high-precision injection molding machines, material property settings, mold dimensions, and mold temperatures to assess the difference in pressure curves between simulations and real molding. This study also developed a method for adjusting the injection molding process parameters of a simulation to decrease the difference in pressure and screw position curves between the simulation and real molding, thus quantitatively improving the quality prediction capacity of simulations. The results contribute to the research on directly applying the injection molding process parameters of a simulation to real molding to achieve smart manufacturing.