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A weld-line is known as a representative defect in the field of plastic injection moulding, and also as a cause of inferior mechanical propensities and poor appearance. Heating and cooling mould systems, which cost extremely high, are a typical technology to prevent the weld-line. It is important to avoid weld-line defects easily and efficiently during the moulding process. Therefore, low cot design methods that enable to prevent weld-lines are demanded. A weld-line usually is generated at a meeting point of two or more flow fronts of molten resin in a mould, where the flow fronts are solidified and not fully contacted. The authors investigated the effect of the sub-gate which was designed to stir the meeting point and to suppress the weld-line using CAE. Since it is relatively easy to predict weld-line occurrence points by CAE, it is realistic to locate a sub-gate. This study intends to report on the following relevances: ‘Weld-line length and sub-gate geometrical conditions’, ‘Weld-line length and temperature conditions’ and ‘Occurrence trend of weld-lines and flow patterns’.

A study on the optimal mould design method for the prevention of weld-line by injection moulding CAE