Adinda Rahmah Shalihah, Aditya Bagja Subarkah, Farras Novyansyah, Irfan Fadillah, Ammar Fathi Muhadzab, Hafizh Maulana Alfath, Ulima Adristi Azis, Hikari Qurrata’ain Nurhadi

EVALUATION OF INJECTION MOLDING PROCESS PARAMETERS ON THE QUALITY OF BRAKE FLUID RESERVOIR CAP PRODUCTS USING MOLDFLOW SIMULATION

Introduction

Evaluation of injection molding process parameters on the quality of brake fluid reservoir cap products using moldflow simulation. Optimize motorcycle brake fluid reservoir cap quality via injection molding simulation. Analyze melt/mold temperatures to reduce weld lines, sink marks, and warpage.

Abstract

This study aims to analyze the effect of melt temperature and mold surface temperature variations on the quality of the motorcycle brake fluid reservoir cap using Autodesk Fusion simulation. Three parameter variations were applied: 260°C/80°C, 220°C/50°C, and 180°C/20°C, while other process parameters were kept constant. The evaluation focused on fill confidence, weld lines, sink marks, and warpage. The results show that all conditions achieved 100% fill confidence with a filling time of 0.53 seconds. However, higher temperatures reduced weld lines but increased sink marks and warpage. Conversely, lower temperatures minimized deformation but increased the number of visual defects. The medium temperature condition provided the best balance between visual quality and dimensional stability. Therefore, the 220°C/50°C condition is recommended as optimal

Review

The study, "EVALUATION OF INJECTION MOLDING PROCESS PARAMETERS ON THE QUALITY OF BRAKE FLUID RESERVOIR CAP PRODUCTS USING MOLDFLOW SIMULATION," addresses a practically significant challenge in manufacturing: optimizing injection molding parameters for a critical automotive component. By utilizing Autodesk Fusion simulation, the authors aim to provide valuable insights into how varying melt and mold surface temperatures impact the quality of motorcycle brake fluid reservoir caps. This research is highly relevant, offering a simulation-based approach to minimize defects and enhance the reliability of such safety-critical products. The methodology systematically explored three distinct combinations of melt temperature and mold surface temperature (260°C/80°C, 220°C/50°C, and 180°C/20°C), while other process parameters were held constant. The evaluation focused on key quality indicators including fill confidence, weld lines, sink marks, and warpage. The findings reveal that all conditions achieved 100% fill confidence with a rapid filling time of 0.53 seconds. However, significant trade-offs were observed for other defects: higher temperatures effectively reduced weld lines but led to increased sink marks and warpage, whereas lower temperatures minimized deformation but resulted in more visual defects. Crucially, the intermediate condition of 220°C/50°C was identified as the optimal balance, offering the best compromise between visual quality and dimensional stability. This work effectively demonstrates the power of simulation in predicting and optimizing injection molding processes, offering immediate practical guidance for manufacturers of the specific component. The clear identification of an optimal processing window is a direct and valuable outcome. While the study provides a robust analysis of melt and mold temperatures, its conclusions would be further strengthened by future experimental validation of these simulation results. Additionally, expanding the scope to investigate other critical process parameters, such as injection speed, holding pressure, or cooling time, or exploring different material grades, could offer even broader insights into optimizing complex injection molding operations. Overall, this paper presents a concise and impactful contribution to process engineering.

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