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ABSTRACT
A computing method for simulating the energy consumption in an injection molding process using the Moldflow MPI analysis software is proposed. Considering such factors as product structure, processing parameters, and mold structure, it was shown by orthogonal testing that the melt temperature, product diameter, product wall thickness, and gate diameter are the four largest factors impacting on the injection energy consumption. Based on the MATLAB curve fitting toolbox, the relationship between the four main factors and the injection energy consumption was established, and a calculation model for the injection energy consumption was proposed.The accuracy of the model was above 95%. Finally, by using an experimental system of injection energy consumption to research the relationship between energy consumption and actual injection power, and by verifying the calculation accuracy of injection energy consumption of the established model, the results show that the established model can be an excellent predictor of the actual electric energy required and the accuracy of it was above 85% compared with measured experimental data.