Core Deflection for Pre-mold with Over-mold Injection Molding in Moldex-3D Inteva Products India Automotive Pvt,Ltd

Format:

Book

Conference/Event

Author/Creator:

LONKAR, VISHWAVINUTANA, author.

Contributor:

C, Rupesh Kumar

Kumar, Naveen

Manjunath, Arun

Conference Name:

International Conference on Automotive Materials and Manufacturing AMM 2023 (2023-06-01 : Pune, India)

Language:

English

Physical Description:

1 online resource cm

Place of Publication:

Warrendale, PA SAE International 2023

Summary:

Side door latches in an automotive play a major role in occupants' safety. The latches consist of both retention assembly and actuator assembly. The actuator assembly majorly consists of motor, gear and other components and these are protected through a Plastic Lower case and Housing. The Lower case (over-mold) with the Electrical Component Carrier - ECC (pre-mold) plays an important role in providing electrical power supply to the latch system. Since these parts are manufactured with terminal traces and plastics, upfront mold flow simulations help the product teams to evaluate the short fills, warpage, and other quality aspects in the critical areas of these components.In the part assembly station, the ECC (pre-mold) and the Lower case (over-mold) are connected to the Motor on one side and the Connector on the other. The proper alignment of the pre-mold pins is of great importance and the pre-mold must not be externally visible once the molding is complete. During the prototype build, the pins were offset/dislocated due to pre-mold shift. This in turn caused deformation of the Over-mold resulting in dimensional inconsistency leading to assembly and functional issues.This issue was complex since the part couldn't be modified structurally because of the constraints in packaging as these interfaces with the backplate and the child feature would affect its integrity. Here, overcoming the pre-mold' shift was an important aspect to keep the Lower-case pins within the location limits ensuring a proper part assembly. However, it was challenging to control the pre-mold' shift defect merely based upon the molding manufacturing knowledge. Hence, we had to utilize core-deflection analysis' method in Moldex-3D, an injection molding specialized software, to verify the cause of pre-mold' shift and correct the problem. Virtual simulation technique has helped to resolve the issue and same technic was used in production tool. This paper will provide an insight to both the methodologies used and the tooling changes required to achieve the product assembly requirements

Notes:

Vendor supplied data

Publisher Number:

2023-28-1351

Access Restriction:

Restricted for use by site license