Optimal Determination of Reinforcement Ratios for Injection Molded Engineering Components: A Numerical Simulation

In this work, the influence of the glass fiber on the behavior of the injection molding process of a PA6-based AR15/M4 grip was investigated in a numerical way. The process was realistically modeled using Autodesk Moldflow Insight at different percentages of glass fiber (0%, 15%, 30%, 45%). Simulation results were evaluated such as the temperature distribution, flow time, pressure drop, pumping power, volumetric shrinkage and warpage displacement. Findings indicate that with 15% glass fibers, the material had the shortest fill period (0.62 s), minimal pressure drop (0.0061 MPa) and the lowest power consumption (0.000433 kW), indicating maximum flow efficiency. On the other hand, a 30% GF setup had the largest volumetric shrinkage (17.76% at most) and warpage (Y: 1.213 mm), even though it had better thermal conductivity. The 45% GF material produced the least amount of shrinkage and distortion but necessitated a greater energy consumption compared to 30% GF. Overall, the 15% GF grade provided the highest average of process efficiency and dimensional accuracy, therefore, it is the most appropriate grade for precision molded firearm components.