Minimization of sink mark depth in injection-molded thermoplastic through design of experiments and genetic algorithm

This paper deals with minimization of sink marks occurring behind the rib in plastic injection molding. In terms of rib structure and injection processing parameters, a theoretical analysis model was created. Meanwhile, finite element flow analysis with design of experiments (DOE) and genetic algorithm (GA) was integrated. Values of sink mark depth depend on design variables and technological parameters. Out of all, the four most influential variables, viz., rib thickness, mold temperature, melt temperature, and coolant temperature, were selected for optimization. The mathematic relation between sink mark depth and variables was established by conducting a set of FE analyses at various combinations of variables based on central composite design (CCD). Furthermore, the influence incidence of each factor and interaction between each variable on sink marks were investigated. The prediction model of sink marks was effectively coupled with GA for optimization of variables to minimize the sink depth. Results of the contrast analysis indicated that the proposed methodology could be used effectively in minimizing sink mark depth and parameter optimization design.