Optimization of Injection Molding Process Parameters for High-Precision Polymer Parts Using Digital Modeling and Grey Relational Analysis

The article presents the results of research aimed at improving the quality of high-precision parts made from polymer composite materials (PCM) produced by injection molding. A methodology for multi-criteria optimization of molding process parameters was tested, based on the integration of experimental design using the Taguchi method, computer-aided engineering analysis (CAE) in the Moldex3D environment, and Grey Relational Analysis (GRA). The methodology was applied to a gear wheel made of reinforced polyetheretherketone (PEEK). An optimal set of process parameters was determined to ensure minimal warpage, residual stresses, and shrinkage. A comparative analysis of the quality of reinforced and non-reinforced castings was conducted, quantitatively proving the advantages of the hybrid technology using an insert manufactured by selective laser melting (SLM).