Abstract
In recent years, there has been a rapid development of computer-aided design (CAD) and computer-aided manufacturing (CAM) techniques for product development. Their application to the design and production of injection molds has the potential to reduce overall production costs substantially, with improved molding quality. It is also possible to obtain a “first time right” mold without any tool tryouts. Thermal analysis is one of the first steps toward developing a CAD system for injection molds. Once the temperatures at different points inside the cavity are known, the cooling channel design can be optimized. Also, stresses and shrinkages inside the cavity can be studied knowing the temperature profiles. In this article, the problem of determining the thermal residual stresses in the injection-molded polystyrene ring has also been studied. Thermal residual stresses are developed due to the nonuniform cooling of the molten plastic inside the mold cavity.
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