Recently

engineering polymer material is applied widely in aerospace and automotive fields. Engineering plastic products manufactured by injection molding have to endure mechanical

thermal and other complicated service conditions when they work. Under the complicated load conditions

the magnitude of service stress in engineering plastic parts is associated with the structure safety of the engineering devices

especially with people's lives. Taking warpage and residual stress of a hemisphere polycarbonate product as the initial conditions of the mechanical analysis

this paper proposes an efficient service stress optimization strategy with respect to the process parameters and the structure of the product and cooling channel

which integrals injection molding analysis and mechanical analysis. The maximum service stress is finally reduced by using an optimization strategy based on Kriging surrogate model and EI method. The results indicate that the thickness of the product

melt temperature and packing pressure are critical factors to influence the service stress.