Enhancing Gating System Efficiency in Plastic Die Extrusion Through Finite Element Mold Flow Simulation

Abstract

The automotive industry has recently experienced a significant surge in the use of plastic materials. This shift, particularly evident in the move toward replacing heavier metal components with more intricate plastic alternatives, is driven by the industry's focus on developing lighter vehicles. In this study, Mold Flow Analysis (MFA) was utilized to identify the most efficient gate configuration for a plastic cladding component. To minimize warpage and enhance material flow during molding, a CAD-based mold flow simulation was conducted. The analysis compared two gating configurations—an 8-drop and a 6-drop system. Results indicated that the 8-drop setup led to higher levels of warpage, whereas the 6-drop system demonstrated better performance. Consequently, the mold was manufactured using the 6-drop gating design, and production was carried out using this optimized setup. The final part was evaluated using a specialized inspection device to ensure it met the dimensional and quality standards outlined in the technical drawings. Additionally, the component underwent physical validation to confirm its compliance with all design and performance requirements