Injection molding is widely used for mass production of polymer products. One important issue is how to determine the process conditions to produce parts of the best quality. The objective of this paper is to show how C-Mold combined with an efficient optimization system can automatically predict the optimum process to minimize sink marks. C-Mold and Genetic optimization algorithm have been integrated to solve the problem. Sensitivity analysis on part sink marks with respect to process parameters (such as filling time, hold time, cooling time, packing pressure, mold temperature and melt temperature) are also presented in this paper. Simulation results show that holding time, hold pressure and gate size have the greatest effect on part sink marks. A number of examples have been tested and the results show that sink marks can be significantly reduced after optimization.
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