Research on Lightweight Injection Molding (CAE) and Numerical Simulation Calculate of New Energy Vehicle

In this paper, the new energy automobile front-end frame of a factory is taken as the research object, the polypropylene plastic is used to replace the traditional sheet metal material, and the hyper mesh is used to load the front-end frame’s six loading loads, which are the locking limit tension and the cushion impact force, respectively, pedestrian impact strength, condenser support strength, radiator support strength, oil cooler support strength, ensure to achieve certain mechanical properties before production. The maximum warpage deformation is 1.023 mm by mold flow analysis with Moldflow. It does not meet the needs of manufacturers, so it is necessary to optimize the process parameters. We use the mold temperature, melt temperature, holding pressure, injection time, and holding time as test factors, and take the amount of warpage as the optimization goal. Then this paper uses the orthogonal test method to design the test plan and establishes 25 groups of 5-level 5-factor orthogonal tests. Moreover, the effect of the deformation on the warpage is analyzed. These are all to obtain the minimum warpage deformation and find the optimal combination of process parameters. Verification by numerical simulation shows that the warpage is reduced to 0.632 mm. By analyzing the range and variance, the combination of process parameters is optimized, and the warpage is effectively reduced. In the premise of satisfying mechanical properties, plastic instead of steel, to achieve a lightweight design. It provides correct theoretical guidance for setting the actual injection molding process parameters.