Mitigation of Sink Voids in Thick-Walled Thermoplastic Components via Integrated Taguchi DOE and CAE Simulations

A gauge plate is a typical thick-walled injection-molded component featuring a complex construction used in high-speed railways, and it is prone to sink voids during the injection process. It is difficult to obtain a void-free injection molded part due to uneven cooling-induced localized thermal gradients, crystallization shrinkage of semicrystalline thermoplastics, fiber orientation-induced anisotropic shrinkage, injection parameter-dependent fountain flow, and inconsistent core compensation. This work employed design of experiment (DOE) and computer-aided engineering (CAE) simulations to analyze the influence of injection parameters on the volumetric shrinkage of the gauge plate and to identify the optimal injection process. A Taguchi orthogonal array L9 was applied, in which four injection molding process parameters were varied at three different levels. The fundamental causes of sink void defects in the gauge plate were then examined via MoldFlow analysis on the basis of the optimized injection parameters. The MoldFlow study indicates a high probability of the presence of sink void defects in the injection-molded gauge plate. To minimize sink void defects, a structural optimization design of the gauge plate was implemented to achieve a more uniform wall thickness, and the advantages of this optimization were demonstrated via comparative analysis. The small batch production of the injection-molded gauge plates demonstrates that the optimized gauge plate shows no sink voids, ensuring consistent quality that adheres to the engineering process and technical specifications.