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Journals / Türk Mühendislik Araştırma ve Eğitimi Dergisi / 2026 / Cilt: 5 Sayı: 1

Effect of Material Selection on Warpage and Shrinkage Behavior in an Automotive Fuse Box Housing: A Numerical Flow Analysis

Otomotiv Sigorta Kutusu Muhafazasında Malzeme Seçiminin Çarpılma ve Büzülme Davranışı Üzerindeki Etkisi: Sayısal Akış Analizi

Asiye Esra Çelik(BALIKESIR UNIVERSITY, FACULTY OF ENGINEERING, DEPARTMENT OF MECHANICAL ENGINEERING, MECHANICAL ENGINEERING PR.)0009-0005-3731-9677
Alp Eren Dede(BALIKESIR UNIVERSITY, FACULTY OF ENGINEERING, DEPARTMENT OF MECHANICAL ENGINEERING, MECHANICAL ENGINEERING PR.)0009-0009-5391-8695
Fuat Tan(BALIKESİR ÜNİVERSİTESİ, MÜHENDİSLİK FAKÜLTESİ)0000-0002-4194-5591
Pages
30–45
Publication Date
2026-05-24
DOI
—
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AI Summary & Key Takeaways

AI Insight
⚡ TL;DR(Too Long; Didn't Read)

Besides, the study makes available to engineers valuable information about material choice and processing variables for automotive parts with exquisite details, thus providing a solid platform for minimizing quality defects during manufacture and improving the sustainability of product performance under harsh conditions prevailing in engine compartments.

📌 3 Key Takeaways

🎯
Objective & Hypothesis:This paper presents the study of structural performance enhancement and validation of manufacturing methods of a car fuse box cover, through a series of numerical simulation at different levels.
📊
Key Findings & Data:Four material alternatives: Ultradur B 4300 G6 (PBT-GF30), Ultramid A3HG6 HR (PA66-GF30), Cycoloy CX7240 (PC/ABS), and ME212U (PP-TD20) were analyzed using Moldflow at important stages such as Filling, Packing, and Warpage.
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Conclusion & Impact:Besides, the study makes available to engineers valuable information about material choice and processing variables for automotive parts with exquisite details, thus providing a solid platform for minimizing quality defects during manufacture and improving the sustainability of product performance under harsh conditions prevailing in engine compartments.
🔬Design:Araştırma Makalesi
📍Scope:Comprehensive Sample
⚙️Variables:Enjeksiyon kalıplama · kalıp akış analizi · çarpılma

Abstract

This paper presents the study of structural performance enhancement and validation of manufacturing methods of a car fuse box cover, through a series of numerical simulation at different levels. Four material alternatives: Ultradur B 4300 G6 (PBT-GF30), Ultramid A3HG6 HR (PA66-GF30), Cycoloy CX7240 (PC/ABS), and ME212U (PP-TD20) were analyzed using Moldflow at important stages such as Filling, Packing, and Warpage. Along with the use accurate rheology and thermodynamics data, the methodology also considers Pressure, Volume, Temperature (PVT) and viscosity, shear rate relationships to help make predictions of flow behavior, pressure distribution, and the final deformation of the part. Comparative analysis of the simulation results established Cycoloy CX7240 as the optimum material for this specific application, owing to its outstanding thermal and mechanical properties, superior dimensional stability, and reliable locking mechanism. Besides, the study makes available to engineers valuable information about material choice and processing variables for automotive parts with exquisite details, thus providing a solid platform for minimizing quality defects during manufacture and improving the sustainability of product performance under harsh conditions prevailing in engine compartments.

Özet

Bu makale, farklı seviyelerde gerçekleştirilen bir dizi sayısal simülasyon aracılığıyla, bir otomobil sigorta kutusu kapağının yapısal performansının iyileştirilmesi ve üretim yöntemlerinin doğrulanması üzerine yapılan bir çalışmayı sunmaktadır. Dört malzeme alternatifi: Ultradur B 4300 G6 (PBT-GF30), Ultramid A3HG6 HR (PA66-GF30), Cycoloy CX7240 (PC/ABS) ve ME212U (PP-TD20), Doldurma, Paketleme ve Çarpılma gibi önemli aşamalarda Moldflow kullanılarak analiz edilmiştir. Doğru reoloji ve termodinamik verilerinin yanı sıra, metodoloji ayrıca akış davranışı, basınç dağılımı ve parçanın nihai deformasyonunun tahmin edilmesine yardımcı olmak için Basınç, Hacim, Sıcaklık (PVT) ve viskozite, kayma hızı ilişkilerini de dikkate almaktadır. Simülasyon sonuçları karşılaştırıldığında, üstün termal ve mekanik özellikleri, geometrik doğruluğu ve güvenilir kilitlenme işlemi ile Cycoloy CX7240'ın bu özel uygulama için optimum malzeme olduğunu kanıtlamıştır. Ayrıca, bu çalışma mühendislere otomotiv parçaları için malzeme seçimi ve işleme değişkenleri hakkında değerli bilgiler sunarak, üretim sırasında kalite kusurlarını en aza indirmek ve motor bölmelerinde hakim olan zorlu koşullar altında ürün performansının sürdürülebilirliğini artırmak için sağlam bir temel oluşturmaktadır.

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Cite This Article

Çelik, A. E., Dede, A. E., Tan, F. (2026). Effect of Material Selection on Warpage and Shrinkage Behavior in an Automotive Fuse Box Housing: A Numerical Flow Analysis. Türk Mühendislik Araştırma ve Eğitimi Dergisi, Cilt: 5 Sayı: 1, 30–45. https://ajindex.com/articles/1646979

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