Numerical Simulation and Process Optimization of Injection‐Molded Silicone Rubber Cable Joints for High‐Voltage Applications

ABSTRACT The injection molding process critically affects the mechanical reliability of 110 kV silicone rubber cable intermediate joints. In this study, a 3D geometric model based on the actual joint cross‐section was established and applied to insert injection molding simulations. An orthogonal experimental design combined with range analysis and analysis of variance (ANOVA) was used to quantify the effects of key process parameters on flow behavior, viscosity, and volume shrinkage. The results show that melt temperature predominantly controls the flow front temperature and maximum viscosity, with contribution ratios of 87.89% and 75.72%, respectively, while mold surface temperature is the primary factor governing both maximum and average volume shrinkage rates, contributing up to 98.63%. At a significance level of 0.01, packing time is identified as the only parameter with a statistically significant effect on average volume shrinkage, and interaction analysis indicates that only the flow front temperature is sensitive to the interaction between melt and mold surface temperatures. A comprehensive evaluation using the entropy weight method yields an optimal parameter combination: mold surface temperature 470 K, melt temperature 285 K, packing pressure 80%, packing time 12 s, and curing time 30 s. These findings provide quantitative guidance for high‐quality molding of high‐voltage silicone rubber joints.