Injection molding process improvement by structured simulation experiments: a case study

Analysis of injection molding of a food packaging container cover through a finite number of simulation runs is presented. Firstly, simulation of the product was set up on Moldex3DTM software, by a ‘screening’ round of simulation experiments replicating the actual process conditions and matching the process metrics in the injection and packing phases, including the emergence of air traps and the lack of sink marks. In this way, the simulation model was validated. In addition, the degree of influence of each process parameter on the final result was investigated by ANOVA. Based on these insights, Taguchi DoE was implemented on the simulation model aiming at achieving the desired part weight and the minimum clamping force. The best combination of the main process control parameters was obtained highlighting the role of the melt temperature and the Material Flow Index.