Utilizing Simulation Software to Develop Injection Molding Process Windows with High-Impact Polystyrene

While design groups have utilized the abilities of injection molding simulation software, its use is often underutilized by process engineers. To expand the application of simulation software to manufacturing groups, this work focuses on developing a methodology to construct injection molding process windows through the predictions of simulation software. The methodology was developed by testing combinations of controllable process variables in the filling and packing stage of the injection molding process with high-impact polystyrene. Using this method, the process window can be tailored to a manufacturer’s desired product performance measures as well as target a specific defect they are facing. The process windows developed were experimentally validated displaying a successful combination of controllable process variables in the filling and packing stages which resulted in an acceptable part. Additionally, the process window was able to predict the dimensional shrinkage of a part within 1% of the experimentally produced part. This analysis establishes confidence in the software’s ability to aid manufacturing groups to successfully run their operations.