• crazing;
  • injection molding;
  • simulations;
  • annealing;
  • stress


It is important to study the residual stress distribution and craze formation of transparent overmolded polymeric parts, because the overmolding can cause stress concentration near the interface region and the craze can be generated by the concentrated stress. Thermally induced crazing of an electric appliances product overmolded by using a transparent polymer is discussed in this study. Craze criterion was determined to be 20 MPa at the temperature higher than 60°C by using mechanical characteristic analysis of the polymeric material. Crazes were observed in the product annealed at over 60°C due to thermal residual stresses generated by the temperature difference between the surface and inside of the part upon surface heating. However, they were not observed in the product annealed by infrared radiation (IR) at over 60°C due to simultaneous heating throughout the thickness of the product. The numerical residual stress results were in good agreement with the experimental results, indicating that overmolding process, thermoviscoelastic stress development of the polymeric part, and IR annealing process were considered properly in the three-dimensional numerical analysis. © 2012 Wiley Periodicals, Inc. J Appl Polym Sci, 2012