This paper uses a multi-objective optimization method to optimize the injection-molding defects of automotive pedals. Compared with the traditional automotive pedal material, aluminum alloy, the polymer pedal containing glass fibers not only reduces the aluminum pedal by at least half, but also improves the strength and hardness of the fibers by adjusting the orientation of the fibers in all directions. Injection factors include: filling time, filling pressure, melt temperature, cooling time, injection time, etc. For the optimization process influencing factors, herein, we focus on warpage analyzed via flow simulation, and setting warpage parameters and cycle time as discussed by setting different cooling distributions, pressures and temperature schemes. The multi-objective optimization design was mainly used to describe the relationship between cycle time and warpage, and the Pareto boundary was used for cycle time and warpage to identify the deviation function and radial-basis-function network. We worked with a small DOE for building the surface to run SAO programming-which improved the accuracy of the response surface by adding sampling points-terminating the time when the warpage value met the solution requirements, to find out the global optimal solution of the warpage value under different cooling times. Finally, the results highlighted four influencing parameters that match the experimental image of the actual production.
Keywords: Pareto boundary; brake pedal; conformal cooling channel; cycle time; sequential approximate optimization; warpage.