Investigation on the Effect of Reducing the Mold’s Size Gate System on the Quality of PC/ABS Part

Part quality plays a very important role in producing good and accurate parts in injection molding process. Numerous strategies have been investigated to determine injection molding conditions that minimize the appearance of internal and external defects. In this work, we propose a new method for the optimal design for the gating system of the mold. Hence, a new geometry of the gating system in the injection molding process is presented. The existing edge gates cause turbulence of the molten plastic in the cavity, resulting in internal and external defects. Other factors that affect the quality of the part can be the injection parameters or the mold cavity. In this paper, a simple method is presented to study the effects of changing the gating system’s size on the quality of injected PC/ABS parts. The optimal injection parameters are confirmed by a SolidWorks simulation to determine the defects that occur after this change. In this investigation, some defects of the new gate size such as weld lines and residual stresses as well as high injection pressure compared to the current gate will be discussed.