Optimization of Mold Heating Structure Parameters Based on Cavity Surface Temperature Uniformity and Thermal Response Rates.

Abstract

Rapid heating cycle molding technology has recently emerged as a novel injection molding technique, with the uniformity of temperature distribution on the mold cavity surface being a critical factor influencing product quality. A numerical simulation method is employed to investigate the rapid heating process of molds and optimize heating power, with the positions of heating rods as variables. The temperature uniformity coefficient is an indicator used to assess the uniformity of temperature distribution within a system or process, while the thermal response rate plays a crucial role in evaluating the heating efficiency of a heating system. The thermal response rate of the cavity and the temperature uniformity coefficient are set as optimization objectives to define parameter ranges for orthogonal experiments. The findings indicate that the optimal range for the lateral distance L₁ is 20-30 mm, for L₂ it is 50-70 mm, and for the vertical distance (h) it is 3-8 mm. The response surface multiple regression equation derived from the orthogonal experiment data demonstrates a model prediction error rate of 1.8% and 2.4%. Additionally, by applying particle swarm optimization to the regression equation, the study identifies an optimal scheme that reduces system energy consumption by 12.5%, achieves a thermal response rate of 0.75 k/s, decreases the temperature uniformity coefficient by 44.6%, and lowers the temperature difference by 52.17%. This optimization ensures efficient heating of the mold cavity, reduces energy consumption, and enhances the uniformity of the surface temperature distribution, ultimately improving the surface quality of the products.