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Optimizing Injection Molding toward Multiple Quality and Cost Issues

Abstract -- Injection molding part designers are frequently faced with multiple quality and cost issues. These issues are usually in conflict with each other, and thus tradeoff needs to be made to reach a final compromised solution. Since evaluation of part quality and cost via injection molding simulation is very time-consuming, implementation of a conventional multi-criteria optimization procedure to injection molding problems is economically unfavorable. However, many injection molding problems dealing with multiple quality and cost issues can be modeled as constrained problems, with the total cost as objective function and quality quantities as constraints. By introducing a concept of Penalized Total Cost, such constrained problems are further simplified into bounded single-criterion problems. The bounded single-criterion problems are then optimized using a direct search-based optimization procedure. The part chosen for the demonstration is a telephone keypad from Lucent Technologies.

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