Nozzle Pressure- and Screw Position-Based CAE Scientific Process Parameter Setup for Injection Molding Process

This study developed a scientific process parameter setup based on nozzle pressure and screw position, with the process parameter search sequence being injection speed, V/P switchover position, packing pressure, and packing time. Unlike previous studies, this study focuses on the scientific process parameter setup of experiments and simulations, as well as on the implementation of calibration. Experiments and simulations had the same trend of results in the scientific process parameter setup. Although the experiments and simulations had the same trend, the machine response caused parameter errors. After setting the time constant of the simulations, injection speed profiles from the experiments and simulations became closely aligned. The simulation results for the injection speed and V/P switchover position became closer to the experiment results than the results of the uncalibrated simulation. The error between the simulated and experimental injection speed was reduced from 20% to 6% after applying time constant calibration. The V/P switchover point error was also reduced from 11% to 5%, highlighting the effectiveness of the time constant to calibrate the simulation.