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Polymers
Volume 18
Issue 11
10.3390/polym18111373
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This is an early access version, the complete PDF, HTML, and XML versions will be available soon.
Article

Research on Bi-Objective Optimization of Injection Molding Process and Mechanical Anisotropy of Glass Fiber-Reinforced Polypropylene Fan Face Shell Based on RSM and NSGA-II

by
Ming Yang
1,
Sailong Yan
1,
Jubao Liu
1,*,
Feng Li
2,
Jianfeng Yao
2 and
Yasheng Li
1
1
Mechanical Science and Engineering College, Northeast Petroleum University, Daqing 163318, China
2
Hongfeng Intelligent Manufacturing (Shenzhen) Co., Ltd., Shenzhen 518117, China
*
Author to whom correspondence should be addressed.
Polymers 2026, 18(11), 1373; https://doi.org/10.3390/polym18111373
Submission received: 21 April 2026 / Revised: 26 May 2026 / Accepted: 27 May 2026 / Published: 31 May 2026
(This article belongs to the Section Polymer Processing and Engineering)
Versions Notes

Abstract

Large glass fiber-reinforced polypropylene (GF-PP) shells are widely used in HVAC and automotive industries, but their injection molding suffers from severe warpage deformation, residual stress concentration, and inaccurate mechanical performance prediction due to neglected molding history. This study proposes an integrated optimization framework for a 30% GF-PP fan face shell. The optimal two-gate molding configuration was determined via Moldflow simulation. A Central Composite Design (CCD) combined with NSGA-II was used to optimize process parameters for minimizing warpage and residual stress. A Moldflow-Ansys co-simulation process was established to characterize fiber orientation-induced mechanical anisotropy, and full-scale mold trials were conducted for validation. The optimized process reduced maximum warpage by 58.03% (from 5.299 mm to 2.224 mm) and residual stress by 13.67% (from 54.93 MPa to 47.42 MPa). The average tensile modulus along the flow direction was 1.85 times that perpendicular to the flow direction. Mold trial results showed a warpage prediction error of only 7.583%. The proposed framework effectively addresses the critical quality issues in large GF-PP injection molding, providing a systematic engineering solution for molding quality control and accurate performance characterization.
Keywords: glass fiber-reinforced polypropylene; injection molding; response surface methodology; NSGA-II; mechanical anisotropy; molding-structure co-simulation glass fiber-reinforced polypropylene; injection molding; response surface methodology; NSGA-II; mechanical anisotropy; molding-structure co-simulation

Share and Cite

MDPI and ACS Style

Yang, M.; Yan, S.; Liu, J.; Li, F.; Yao, J.; Li, Y. Research on Bi-Objective Optimization of Injection Molding Process and Mechanical Anisotropy of Glass Fiber-Reinforced Polypropylene Fan Face Shell Based on RSM and NSGA-II. Polymers 2026, 18, 1373. https://doi.org/10.3390/polym18111373

AMA Style

Yang M, Yan S, Liu J, Li F, Yao J, Li Y. Research on Bi-Objective Optimization of Injection Molding Process and Mechanical Anisotropy of Glass Fiber-Reinforced Polypropylene Fan Face Shell Based on RSM and NSGA-II. Polymers. 2026; 18(11):1373. https://doi.org/10.3390/polym18111373

Chicago/Turabian Style

Yang, Ming, Sailong Yan, Jubao Liu, Feng Li, Jianfeng Yao, and Yasheng Li. 2026. "Research on Bi-Objective Optimization of Injection Molding Process and Mechanical Anisotropy of Glass Fiber-Reinforced Polypropylene Fan Face Shell Based on RSM and NSGA-II" Polymers 18, no. 11: 1373. https://doi.org/10.3390/polym18111373

APA Style

Yang, M., Yan, S., Liu, J., Li, F., Yao, J., & Li, Y. (2026). Research on Bi-Objective Optimization of Injection Molding Process and Mechanical Anisotropy of Glass Fiber-Reinforced Polypropylene Fan Face Shell Based on RSM and NSGA-II. Polymers, 18(11), 1373. https://doi.org/10.3390/polym18111373

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