Optimization of injection molding process parameters using sequential simplex algorithm

In this study warpage and shrinkage as defects in injection molding of plastic parts have been undertaken. MoldFlow software package has been used to simulate the molding experiments numerically. Plastic part used is an automotive ventiduct grid. The process optimization to minimize the above defects is carried out by sequential simplex method. Process design parameters are mold temperature, melt temperature, pressure switch-over, pack/holding pressure, packing time, and coolant inlet temperature. The output parameters aside from warpage and shrinkage consist of part weight, residual stresses, cycle time, and maximum bulk temperature. Results are correlated and interpreted with recommendations to be considered in such processes.