In the realm of injection-molded parts, small length scale deformation defects such as sink marks often pose a major challenge to the aesthetics or functionality of the parts. To address this problem, we present a comprehensive thermoelastomechanical approach that calculates the deformation of injection molded plastic by solving the elastic problem at each time step. In our methodology, two treatments of the molten core are considered: one as a liquid and the other as a rubbery state. Our results suggest that the rubbery state treatment provides higher accuracy in predicting the deformation results, as it maintains the displacement of the localized thermal shrinkage in its vicinity. The validity of our method is supported by empirical measurements on produced parts from the existing literature as well as on samples that we molded independently.
Keywords: injection molding defect; sink mark; volumetric shrinkage.