In today's competitive business environment the automotive industries aim to increase the usage of the plastic materials in automobile components in order to reduce the weight of the vehicles. Although the plastic materials provide a considerable savings on vehicle weight, these materials have some problems to be solved. One of the difficult problems encountered in the production of plastics is the flow lines on surfaces because of its unpredictable behavior. As a result, the considered problem faced by automobile companies often spend plenty of time and money is an issue to resolve. In this study "the source of plastic flow lines on automotive external aesthetical parts'' is investigated by using material flow analysis tool of Autodesk Simulation Moldflow 2016®. According to conventional methodologies; weld lines, temperature differences, filling times, clamping forces, shrinkages parameters are examined deeply before tooling phase especially to eliminate aesthetical problems. Considering these conventional methodologies, an unordinary situation was observed, such as flow lines on visible surfaces in the front bumper after the tool stage. Therefore, the flow analysis tool is used simulate these flow lines on the material. Flow directions and flow velocity are comprehensively examined step by step during filling analysis. As a result of the analyzes, the geometric factors that affect the balance of flow and brings turbulence are detected. After the root cause analysis for plastic deformation, different design proposals are analyzed to find the best solution. Analyzes are repeated in the same conditions that are considered to be made for all geometric changes. The experiment results are comparatively analyzed and the solution that has the best flow balance is selected.
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