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Direct-Search-Based Automatic Minimization of

Weldlines in Injection Molded Parts

Abstract -- An automated design methodology was developed to minimize weldlines by optimizing the part and mold design based on a direct-search approach. Weldlines are quantitatively evaluated based on their length and location and the melt front movement with the aid of commercial injection molding simulation software which provides an integrated analysis. A combined implementation of the Complex method and injection molding simulation was developed to reduce and relocate the weldline or to improve the weldline strength. Two parts, Gillette's deodorant base and Cavallero's capacitor can, were chosen for the weldline minimization. Reduction and relocation of weldlines for the razor cap prevented the cracking problem in the original design. For the capacitor can, the original 15.5-mm weldline was minimized to zero by optimizing the gate location. The results of simulation based on the automated design methodlogy agree well with the experimental findings.

Figure 1:   

Comparison of Simulated Melt Front Movement for the Original Design and the Optimized Design of the deodorant base

Figure 2:   

Comparison of Experimental Melt Front Movement for the Original Design and the Optimized Design of the deodorant base

Figure 3:   

Comparison of Simulated Melt Front Movement for the Original Design and the Optimized Design of the capacitor can

Figure 4:  

Comparison of Experimental Melt Front Movement for the Original Design and the Optimized Design of the capacitor can