Abstract
In this study, the optimum design of mold feed systems is determined for plug cover housing (PCH), which is a cover-assembly product that protects the wiring of automobile connectors. The design goal is to achieve the filling balance of the resin in the left and right covers while avoiding the occurrence of weld lines in the hinge as much as possible. For the optimization, an orthogonal array experiment and a main effect analysis of the design factors are performed, and the factors that cause the interactions with the two design characteristics are selected as the design variables. We present some design alternatives, i.e., some combinations of the design variables, and analyze the filling-simulation results, expected molding risk, and cost economics to select an optimum design solution among the design alternatives. In the optimal solution, the weld line is generated at a position outside the hinge, and the filling balance is also acceptable, showing that both design goals can be satisfied simultaneously despite conflicting with each other.
