Optimization of Polymer Thin-walled Cylinder Injection Molding Process under Extreme Conditions Based on Co-simulation

JI Jianhua; LI Zhongjie; MA Yitao; XIE Feipeng; XIE Pengcheng

doi:10.3969/j.issn.1674-6457.2025.11.012

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Journal of Netshape Forming Engineering ›› 2025, Vol. 17 ›› Issue (11) : 136-144. DOI: 10.3969/j.issn.1674-6457.2025.11.012

Intelligent Processing of Advanced Materials

Optimization of Polymer Thin-walled Cylinder Injection Molding Process under Extreme Conditions Based on Co-simulation

JI Jianhua^1a, LI Zhongjie^1a, MA Yitao^1a, XIE Feipeng², XIE Pengcheng^1a,1b,*

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Abstract

To address the degradation of structural properties in polymer thin-walled cylindrical components caused by injection molding quality under high-temperature and high-pressure service conditions, the work aims to investigate the effect of injection molding processes on structural performance and determine the optimal molding process for these components. Moldex3D, Digimat-MAP, and Abaqus numerical simulation software were employed to conduct coupled simulation analyses of molding processes and structural properties. Firstly, injection molding simulations were conducted to obtain thermal residual stress distributions. These residual stress fields were then mapped onto the structural mesh as initial conditions for dynamic structural simulations. Orthogonal experiments were carried out to study the effect of five key process parameters including injection speed, melt temperature, mold temperature, holding pressure, and holding time, on residual stresses. Mold temperature, holding pressure, and holding time were identified as the primary factors affecting residual stresses in thin-walled cylindrical components. Following process optimization, the maximum thermal residual stress in the cylinder decreased by 98.37%, with significantly improved stress distribution uniformity. Dynamic structural simulation results indicated that residual stresses affected the stress distribution during the initial stage of pressure loading, constituting the primary cause of structural failure initiation under extreme service conditions. A multi-physics coupled simulation method and a process optimization strategy are established, which improves the prediction accuracy of the forming process and structural performance of polymer thin-walled cylindrical structures. Optimal injection molding process parameters for thin-walled cylinders are determined, substantially reducing residual stress levels and improving the mechanical response behavior of thin-walled cylinders under extreme service conditions.

Key words

thin-walled cylinder / injection molding / residual stress / co-simulation / finite element

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JI Jianhua, LI Zhongjie, MA Yitao, XIE Feipeng, XIE Pengcheng. Optimization of Polymer Thin-walled Cylinder Injection Molding Process under Extreme Conditions Based on Co-simulation[J]. Journal of Netshape Forming Engineering. 2025, 17(11): 136-144 https://doi.org/10.3969/j.issn.1674-6457.2025.11.012

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