Simulation‐based analysis of weld line strength of glass fiber‐reinforced polymer in injection molding

The injection molding market is expected to grow with the increasing demand from various industries, such as automotive and furniture. However, weld lines in the injection molded part reduce the structural strength and affects its appearance. This study evaluates the effect of the weld line on the structure by shifting the position of the weld line outside the area where the load is applied by manipulating the opening time of the injection gates. We examined the effect of weld lines on the strength of a chair through coupled resin flow and structural analyses. The analysis revealed that the position of the weld lines is crucial for structural strength if the knockdown factor (KDF) is low. Additionally, controlling the opening time of the gate and shifting the position of the weld line improved the structure's appearance, number of weld line and avoid the lower meeting angle. However, depending on the material, the effect may be weak. For example, when the weld line location did not change much despite changing the gate timing, little change was observed in the number of weld lines. Hence, the improvement strategy of weld line should be considered for material types and strength. Highlights Injection molding growth driven by automotive, packaging, furniture demand. Weld lines impact structural strength and appearance. Shifting weld line position outside load area improves the structural appearance and strength. Effects of shifting weld line position depended on the material types. Weld line position is crucial for low knockdown factor and affects strength. This study evaluates the effect of the weld line on the structure by shifting the position of the weld line outside the area where the load is applied. Three types of polypropylene materials were adapted and performed simulation analysis. As a result, Although, controlling the opening time of the gate and shifting the position of the weld line improved the structure's appearance, depending on the material, the effect may be weak.