Service-Life Prediction of Core Inserts Under High-Volume Plastic Injection Molding Conditions

Abstract

High-volume injection molding systems for plastic part production operate under severe thermo-mechanical loading repeated at high production rates. Therefore, premature breakage of hot-work tool steel core inserts directly interrupts production continuity and creates a recurrent maintenance problem. To address this failure mode, this study collected production inputs and failure evidence and established a reliable interpretation by linking computer-aided engineering simulations of the plastic injection molding process, structural FEA of the insert response, and cumulative fatigue assessment using a TMF-creep damage model. This integrated approach provides a comprehensive framework for failure root-cause identification and service-life prediction and improving insert durability in mass-manufacturing environments.