Correction of mould cavity geometry for warpage compensation
ID Kastelic, Tomaž (Author), ID Starman, Bojan (Author), ID Cafuta, Gašper (Author), ID Halilovič, Miroslav (Author), ID Mole, Nikolaj (Author)

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Warpage is one of the most challenging defects occurring in plastic injection moulded parts. Various approaches to overcome this issue have been proposed in the literature, but they all provide only partial solutions to the problem. This paper proposes a new method for the compensation and minimisation of warpage. The method is based on Mould Cavity (MC) correction. In contrast to other similar methods, here the MC correction is accomplished through a direct comparison of the local deviations of the warped part’s geometry to the desired geometry of the part. Modifying the MC shape accordingly yields parts with a lower shape discrepancy from the desired geometry compared to the nonadjusted shape. The key novelty of the paper is the development of software that iteratively adjusts the MC shape to minimise local deviations. In every iteration, the warped part is compared to the desired geometry in order to compute local deviations between both geometries. Computation is done first by determining the point normal vector of the warped geometry mesh and its piercing point through desired geometry mesh. Second, distance between the base point and the piercing point is calculated. After all local deviations are determined, the MC geometry is adjusted accordingly. Two case studies demonstrate the method’s capabilities. In the first case we present a curved thin-walled plate part. The maximum warpage value of 0.005 mm (0.7% of the initial maximum warpage) was reached after three iterations of MC geometry correction and remained stable afterwards. In the second case the method was tested on the box-shaped part. The maximum warpage dropped from initial 0.711 mm to 0.066 mm after three iterations.

Keywords:computer simulation, injection moulding, warpage compensation, iterative mould cavity, geometry correction
Work type:Article
Typology:1.01 - Original Scientific Article
Organization:FS - Faculty of Mechanical Engineering
Publication status in journal:Published
Article version:Publisher's version of article
Publication date:01.11.2022
Number of pages:Str. 1957–1971
Numbering:Vol. 123
PID:20.500.12556/RUL-142937 This link opens in a new window
ISSN on article:0268-3768
DOI:10.1007/s00170-022-10337-6 This link opens in a new window
COBISS.SI-ID:127300355 This link opens in a new window
Publication date in RUL:05.12.2022
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Record is a part of a journal

Title:International journal of advanced manufacturing technology
Shortened title:Int. j. adv. manuf. technol.
COBISS.SI-ID:25636352 This link opens in a new window

Secondary language

Keywords:računalniška simulacija, injekcijsko brizganje, kompenzacija zvitosti, iteracijska korekcija, geometrija kalupne votline


Funder:ARRS - Agencija za raziskovalno dejavnost Republike Slovenije
Project number:P2-0263
Name:Mehanika v tehniki

Funder:ARRS - Agencija za raziskovalno dejavnost Republike Slovenije
Project number:L2-3172
Name:Razvoj tehničnih smernic za štirislojne zasteklitve

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