This paper proposed a gate location optimization scheme to minimize the maximum injection pressure in plastic injection molding. The method utilized a series of higher order response surface approximations (RSA) to model the maximum injection pressure distribution with respect to gate locations, and the global minimum of these response surface models were subsequently sought by a global optimization method based on a multi-start sequential quadratic programming technique. The design points for RSA were evaluated by the finite element method. After a sequence of repetitions of RSA and optimization, the converged minimizer would represent the optimal gate location. A rectangular plate with two segments of different thicknesses was selected to demonstrate the effectiveness of the procedure. The variation of the thicknesses causes the optimal gate location to deviate from the center and induce multiple valleys in the maximum injection pressure distribution, which is ideal for the application of the higher order RSA and a global searching technique.
Reduced Sampling for Construction of Quadratic Response Surface Approximations Using Adaptive Experimental Design