汽车电控单元保护壳翘曲变形特性及成型优化
孙宝林1，陈誉12，张艳芹1，吴柳杰3，朱天龙1
1.南京工程学院机械工程学院，南京 211167； 2.燕山大学机械工程学院，河北秦皇岛 066000； 3.宁波赛福汽车制动有限公司，浙江宁波 315000
Warping Deformation Characteristics and Molding Optimization of Automotive Electronic Control Unit Protective Shell
Sun Baolin1, Chen Yu12, Zhang Yanqin1, Wu Liujie3, Zhu Tianlong1
1.School of Mechanical Engineering,Nanjing Institute of Technology,Nanjing 211167,China; 2.School of Mechanical Engineering,YanshanUniversity,Qinhuangdao 066000,China; 3.Ningbo Safe Breaks Systems Co., Ltd.,Ningbo 315000,China
摘要：针对汽车电子控制单元(ECU)保护壳在注塑过程中出现的短射、翘曲变形问题，首先通过优化模具的浇注系统解决了初始试模方案的短射问题，随后优化模具冷却系统，单独建立由冷却不均引起的较大翘曲变形处的冷却管路 ，并适当提高其冷却液温度 ，以减小塑件薄壁内外侧温度差。冷却系统优化后由冷却不均引起的翘曲变形量从初始方案的 0.263 2 mm 减少到 0.161 7 mm，较优化前降低了 38.6%。最后利用 Moldflow 模流分析仿真软件，以熔体温度 、模具温度 、保压压力 、保压时间及冷却时间为影响因素 ，采用 Taguchi 正交试验法进行成型参数优化，并结合极差分析探究成型参数对翘曲变形特性的影响规律 ，获得最佳成型参数，减小塑件翘曲变形量。结果表明，保压压力对翘曲变形影响最为显著，在最佳成型参数组合下，即熔体温度 275 ℃ 、模具温度 100 ℃ 、保压压力 90 MPa、保压时间 10 s 、冷却时间 35 s，ECU 保护壳最大翘曲变形量从初始方案的 1.331 mm 减少到 0.955 4 mm，较优化前降低了 28.2%。
Abstract：In order to address the issue of short shot and warping deformation of the protective shell of automotive electronic control unit (ECU) in the injection molding process, the gating system of the mould was optimized to solve the problem of short shot in the initial trial mold. Subsequently, optimizing the mould cooling system, a separate cooling channel was established for the larger warping deformation caused by uneven cooling, and the temperature of the cooling fluid was appropriately increased to reduce the temperature difference between the inner and outer sides of the thin-walled plastic part. After the optimization of the cooling system, the warping deformation caused by uneven cooling decreased from 0.263 2 mm in the initial design to 0.161 7 mm, reducing the deformation by 38.6% compared with that of before the optimization. Finally, the melt temperature, mould temperature, holding pressure, holding time, and cooling time were selected as the influencing factors, then the Taguchi orthogonal experimental method was applied to optimize the molding parameters by using Moldflow analysis simulation software. Combined with range analysis, effects of these parameters on warping deformation were explored, and the optimal molding parameters were determined. The results indicate that the holding pressure has the most significant effect on warping deformation. Under the optimal molding parameters, namely, 275 ℃ melt temperature, 100 ℃ mould temperature, 90 MPa holding pressure, 10 s holding time, 35 s cooling time, the maximum warping deformation of the ECU shell is reduced from 1.331 mm (in the initial design) to 0.955 4 mm, representing a 28.2% decrease compared with that of before optimization.
关键词：汽车电子控制单元；注塑；短射；翘曲变形；Taguchi正交试验
Keywords：automotive electronic control unit; injection molding; short shot; wraping deformation; Taguchi orthogonalexperiment
基金：教育部社科研究项目(21YJCZH227)，河北省高层次人才资助项目(B2022003022)
本文引用格式：
孙宝林，陈誉，张艳芹，等.汽车电控单元保护壳翘曲变形特性及成型优化[J].工程塑料应用，2023，51(10)：69-75，84.
Sun Baolin，Chen Yu，Zhang Yanqin，et al. Warping deformation characteristics and molding optimization of automotive electronic controlunit protective shell[J]. Engineering Plastics Application，2023，51(10)：69-75，84.
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