Research on the optimization of the automotive A-pillar guard injection molding process based on RSM

Taking the protective panel of an automotive A-pillar as the research subject, this paper employs the Response Surface Methodology (RSM), in conjunction with Moldflow mold flow analysis technology, to conduct a multi-objective optimization of injection molding process parameters. Utilizing the Box-Behnken experimental design, a second-order response surface model is constructed for die temperature, melt temperature, cooling time, warpage deformation, and volumetric shrinkage rate, while analyzing the primary effects and interactions among these parameters. The optimized combination of process parameters is as follows: die temperature of 50.05 °C, melt temperature of 259.7 °C, and cooling time of 20.75 s. Upon simulation verification, the optimized warpage deformation decreases to 2.045 mm, with a volumetric shrinkage rate of 3.78%. The study demonstrates that the response surface methodology can effectively enhance the stability of the injection molding process and improve product quality, offering theoretical support for the optimization of complex automotive components.