Optimization of the injection molding process MOLDFLOW SIMULATIONS

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2 Optimization of the injection molding process MOLDFLOW SIMULATIONS Mark Klarenbeek November 17 th 2016 LinkedIn

3 Agenda Pezy Group Accelerating innovation Introduction injection molding simulation software Necessity of injection molding simulation Examples 3

4 Accelerating innovation Brands, products, equipment 100+ specialists

5 Accelerating innovation 100 Specialists 20+ Years of customer relations 100+ Specialists

6 Accelerating innovation 400+ Clients 20+ Years of costumer relations 100+ Specialists

7 Accelerating innovation 300+ Patents 400+ Clients 20+ Years of costumer relations 100+ Specialists

8 Accelerating innovation Groningen Amsterdam Houten Eindhoven Singapore International network of partners and suppliers 5 offices 300+ Patents 400+ Clients 20+ Years of costumer relations 100+ Specialists

9 From design to small series production Offering expertise in all aspects End-to-end project management Business or product idea Innovation & Design Engineering & Prototyping Industrialization & Small series production Sales & Service Sourcing and supply base support

10 Agenda Pezy Group Accelerating innovation Introduction injection molding simulation software Necessity of injection molding simulation Examples 10

11 Injection molding simulation History FillCalc C-MOLD AC Technology Cadmould I-DEAS for Plastics 11

12 Injection molding simulation Overview FIX FEM MODEL Finite Element Model BOUNDARY CONDITION IMPORT CAD MODEL Filling Pressure Temperature Air traps Fiber Orientation Shear rates Frozen layers Shrinkage Warpage Etc. START ANALYSIS RESULTS & INTER- PRETATION 12

13 Injection molding simulation Overview DEMO 13

14 Injection molding simulation Overview FIX FEM MODEL Finite Element Model BOUNDARY CONDITION IMPORT CAD MODEL Filling Pressure Temperature Air traps Fiber Orientation Shear rates Frozen layers Shrinkage Warpage Etc. START ANALYSIS RESULTS & INTER- PRETATION 15

15 Finite element modelling Moldflow Dual Domain TM Technology GATE 16

16 Finite element modelling Moldflow Dual Domain TM Technology 17

17 Finite element modelling Moldflow Dual Domain TM Technology 18

18 Agenda Pezy Group Accelerating innovation Introduction injection molding simulation software Necessity of injection molding simulation Examples 19

19 Why simulation? Industrial design Product design Mold design Mold making Production 20

20 Why simulation? Industrial design Product design Mold design Mold making Production 21

21 Simulation for industrial / product design Can I fill this part? Where is the best gate position? What happens if I change the material? Position weld lines? Location air traps? Is there a risk of sink marks? Are the wall thicknesses okay? Deformation of the product (warpage) and / or tolerance issues? Ideal gate position 22

22 Simulation for mold design Position & dimensions of cooling channels? Conformal cooling? Highly conductive mold inserts? Cycle time? Hot or cold runner? Runner balancing? Deformation of the product (warpage) and / or tolerance issues? 23

23 Simulation for production Injection time and injection profile? Switch over point? Packing time and packing profile? Process window? Stable process? Decrease cycle time? Deformation of the product (warpage) and / or tolerance issues? 24

24 Agenda Pezy Group Accelerating innovation Introduction injection molding simulation software Necessity of injection molding simulation Examples 25

25 Example 1 Filling GATE 26

26 Filling Weld line 27

27 Filling Weld line 28

28 Filling 29

29 Filling 30

30 Filling 31

31 Filling 32

32 Filling 33

33 Filling Good filling pattern through living hinge: Straight 34

34 Filling 35

35 Filling 36

36 Filling 37

37 Filling 38

38 Filling 39

39 Filling 40

40 Filling 41

41 Filling 42

42 Filling 43

43 Filling 44

44 Filling 45

45 Filling 46

46 Filling 47

47 Filling Good filling pattern through living hinge: Straight Weld line End of filling - Product 100% filled 48

48 Volumetric shrinkage Sink marks 49

49 Volumetric shrinkage and Sink marks 50

50 Plastic System Part design Mold design Plastic System is complex Simulation helps Processing conditions Material But Simulation is always based on assumptions and simplifications 51

51 Plastic System Mathematical models vs. reality Models are limited Simplifications by user Consious or not User errors No training Interpretation errors Finite Element Model Element size Type of model Numerical tolerances Convergence criteria Changing material behaviour Reliability IM machine... Part design Part design Part design Part design Part design Part design Processing Processing conditions Processing conditions Processing conditions Processing conditions Processing conditions conditions Mold design Mold design Mold design Mold design Mold design Mold design Material Material Material Material Material Material 52

52 Plastic System IF the user understands the assumptions and simplifications THEN the user has a perfect tool to unravel the Plastic System AND the user can virtually optimize the system in a reliable manner Part design Processing conditions Mold design Material 53

53 Example 2 Part design Mold design Processing conditions Material 54

54 Example 2 55

55 Example 2 Runner balancing Ø 5.0 mm Ø 5.0 mm AMA filling simulation 3 different parts Initially Ø = 5.0 mm Goal: Balanced flow Ø 5.0 mm 56

56 Example 2 Runner balancing Ø 5.0 mm Ø 5.0 mm Ø 5.0 mm Filling pattern not balanced 57

57 Example 2 Runner balancing Ø 4.3 mm Ø 5.0 mm Optimized runner design Runner diameters adapted Runner lengths adapted (Less runner scrap) Ø 5.0 mm 58

58 Example 2 Runner balancing Filled Filled Ø 4.3 mm Ø 5.0 mm Filled Ø 5.0 mm Filled Filling pattern balanced 59

59 Example 3 Part design Mold design Processing conditions Material 61

60 Example 3 Gate location Automotive headlight frame Warpage is critical PA GF30 Gate 62

61 Example 3 Gate location Initial gate location Gate 63

62 Example 3 Gate location Deflection in Z-direction for initial gate Too high, out of spec Gate 64

63 Example 3 Gate location Glass fiber orientation for initial gate Not uniform Gate 65

64 Example 3 Gate location Original gate Central gate 2 x 3 gates Edge gate 66

65 Example 3 Gate location Original gate Central gate Smallest deformation 2 x 3 gates Edge gate 67

66 Example 4 Part design Mold design Processing conditions Material 68

67 Injection pressure (MPa) Example 4 Injection pressure versus time Injection time (s) 69

68 Questions? 70

69 More? Contact Pezy Group if you like to know more about Moldflow: Software Consultancy Advice & Second Opinion Training Material data Network Check out presentation of my Pezy Group colleague Eddy Leeuwangh Creo Parametric 3.0 Tips & Tricks Congresroom 040 Noord 16h05 16h40 71

70 Mark Klarenbeek November 17 th 2016 LinkedIn