Moldex3D: Molding Innovation. Larry Ren Channel Manager, WSEU

Transcription

1 Moldex3D: Molding Innovation Larry Ren Channel Manager, WSEU

2 Overview of Moldex3D 2

3 CoreTech System & Moldex3D > The world s leading innovator of professional true 3D CAE software for injection molding simulation to bring product design excellence. > Extended worldwide sales and service network to provide local, immediate and professional support: 9 global offices More than 160 global resellers with 250+ sales points R&D Department: 4 Groups - 11 Groups Over 250 employees Global support network 3

4 Moldex3D Reference Customers Automobile High Tech/Electronics Material/Equipment 4

5 Moldex3D Product Evolution R3.x Shell Gas Shell FPCW Complete 3D Solid Simulations R6.x R5.x R4.x Solid RIM Solid Fiber Solid FPCW Mold Insert R7.0 Enhanced Flow Parallel-SMP Tetra Mesh Two-Color Molding Insert Molding FEA Integration R7.1 Solid MCM Solid I2 Hybrid Mesh Cooling Optimization SolidWorks Embedded R8.0 Enhanced FastCool Parallel- Cluster Windows x64 BLM Design Verification Automatic 3D Meshing R8.1 edesign Designer RHCM IC Packaging Optical Molding Optics R9.0 Viscoelastic Transient Cool License Manager Conformal Cooling NX, Creo Embedded R9.1 Solid Warp+ Remote Computing BLM+ explorer Injection Compression HyperWorks Partner Alliance ICM R10.0 Gas / Water Injection Stress Remote Computing on Linux edesignsync Microcellular Foaming Underfill R11.0 Advanced Hot Runner Co-Injection DOE MuCell Underfill Viewer Cloud Computing Compression Molding R12.0 Compression Molding Bi-Injection PIM / MIM Annealing Process 2-Way Core-Shift Thermoplastic + Thermoset Hybrid Run edesignsync Post-Process Designer BLM Project Solid Mesh

6 6 Versatile Pre-processing Options

7 Moldex3D s Unique 3D Meshing Kernel Runner Wizard Gate Wizard Parametric runner Direct runner surface Symmetry 7

8 Moldex3D s Unique 3D Meshing Kernel Advanced Hot Runner Cooling Wizard Parametric cooling 8 Conformal Cooling

9 Moldex3D s Unique 3D Meshing Kernel AutoHybrid BLM (Boundary Layer Mesh) 9 3D Moldbase

10 Integrated Command and Improved Workflow R12 > One click to generate solid mesh > Efficiently minimize user operations Part Runner Gate Cooling System Solid mesh (BLM) Hybrid runner Gate refinement Moldbase solid 10

11 High Performance Computing (HPC) Module HPC > All edesign and Solid solvers support parallel computing with an effective utilization of multi-core CPU and PC cluster > Remote computing using client-server architecture is supported 10x speedup with 16 cores (4x4) 1 core 2,519 3,418 7,640 Remote computing 2 cores 1,156 1,812 3,912 CPU Socket (elements: 713,558 3D-Flow) 4 cores 8 cores 1, , Phone Cover (elements: 1,006,448 3D-Flow) Car Fan (elements: 1,422,416 3D-Flow) sec sec sec sec sec sec sec sec sec sec 0 1,000 2,000 3,000 4,000 5,000 6,000 7,000 8,000 9,000 11

12 Moldex3D Product Portfolio > Moldex3D provides a series of simulation packages to efficiently evaluate molding behaviors and improve product quality: edesign Basic edesign Professional (edesign+shell) Advanced (edesign+solid+shell) IC Packaging > Solution Add-on modules provide the broadest range of solutions for different industries 12

13 edesign Basic Package > edesign Basic Provides a full range of flow simulation capabilities Predict filling performance, decide ultimate gate location, eliminate weld lines and air traps Included modules Plastic Designer Flow Parallel computing Project 13

14 edesign Package Included modules > edesign Equipped with auto-meshing feature and intelligent modeling wizards for streamline CAD-to-CAE simulation process Delivers reliable analysis results and quickly verifies part and mold designs Easy to use without additional training, efficiently minimize user operation Designer Project Parallel computing Flow MCM Pack Cool Warp 14

15 Professional Package > Professional Include edesign and Shell technologies Include edesign auto-features and enhance simulation efficiency for complex geometry and conventional large and thin shell-like parts Included modules Designer Shell Mesh Project Parallel computing Flow MCM Pack Cool Warp 15

16 Advanced Package > Advanced Include edesign, Solid and Shell technologies for the highest complexity process simulation Combine the three core features and extend exclusive Boundary Layer Mesh technology Deliver more comprehensive capabilities for advanced analysis Included modules BLM Mesh (Solid) Shell Mesh Project Parallel computing Designer MCM Flow Pack Cool Warp 16

17 Solution Add-on > Solution Add-on - more choices for industries Provide more advanced modules with flexible functionality extensions Bring a broad range of professional solutions for special injection molding processes Included modules edesignsync Fiber Stress FEA/Digimat Interface Compression Molding Expert Viscoelasticity Optics Advanced Hot Runner 17 * Red is new in R12

18 Solution Add-on > Solution Add-on - more choices for industries Evaluate and optimize product performance Help designers to innovate and develop new concept with insightful information Included modules ICM PIM GAIM WAIM Underfill Co-Injection Encapsulation MuCell Bi-Injection 18 * Red is new in R12

19 Standard Modules 19

20 Flow Analysis 20

21 Standard Module - Flow Flow > 3D precise molding predictions and visualizations of weld lines, air traps, venting, short shot, core shift, etc. > Efficiently determines the optimal gate number and locations for flow balance and quality parts > Capable of analyzing the entire cold/hot runner, various gate types and sequential valve gates 21

22 Standard Module Flow: Particle Tracking R12 22

23 Standard Module Flow: Particle Tracking (cont d) R12 Option to release particles at weld line region Visualize weld line movement caused by the push of melt front. 23

24 Standard Module Flow: Micro Molding > Challenge Fabrication of molded parts are not easy for micro-featured parts and micro parts. > Auxiliary technologies have been used Variotherm process: Before mold clamping or after mold clamping. Vacuum assisted molding process. 24

25 Standard Module Flow: Micro Molding IR 25 Plate height: 0.5mm Probe diameter: 0.108mm, height 0.178mm Cavity elements: 700,306 Material: PP

26 Standard Module Flow: Micro Molding Without IR With IR 26

27 Standard Module Flow: Micro Molding Without IR Flow Direction With IR 27

28 Pack Analysis 28

29 Standard Module - Pack Pack > Precise determination of gate freeze time, efficient packing time and packing pressure for sink mark and volumetric shrinkage evaluation > Helps minimize shrinkage variation for warpage control 29

30 PVT Variation History Output R12 > Key Feature Supported in Shell, edesign and Solid projects Visualize melt PVT variation during filling and packing stages in the molding process > Benefit Understand polymer property change during filling and packing stages sensor 11 filling sensor 1 sensor 6 cooling packing 30

31 Cool Analysis 31

32 Standard Module - Cool Cool 1 bar 0.1 bar 1 bar 0.1 bar > 3D cooling simulation with advanced analysis capabilities for mold and cooling circuit designs of complex parts for cycle time reduction with minimized mold temperature difference > Exclusive Transient Cool analysis for variotherm process of various heating systems > Evaluates conformal cooling inserts analysis with 3D coolant channel flow analysis 32

33 History Animation Making R12 > Support to make the history animation of each molding cycle > Supported under transient cooling analysis RHCM process Heating rod Mold temperature gets higher and higher with molding in each cycle 33

34 Standard Module Cool: Conformal Cooling > The conventional design has no cooling channel inside the hallow interior. With conformal cooling design, warp can be reduced. Conventional Conformal 34

35 Cooling Analysis Cooling Temperature Conventional Cooling Conformal Cooling Cooling Temperature ~ Cooling Temperature ~

36 Cooling Analysis Cooling Time Conventional Cooling Conformal Cooling Cooling Time Cooling Time 36

37 Improved Warpage > From the photo of actual product, we can also see the warpage improvement is significant in z direction. Conventional Cooling Conformal Cooling 37

38 Standard Module Cool: Conformal Cooling R12 Support to make the animation for 3D cooling channel simulation result > Benefit More easily comprehend coolant flow behavior in cooling system 38

39 39 Standard Module Cool: Conformal Cooling

40 Warp Analysis 40

41 Standard Module - Warp Warp > Predicts part deformations due to density variation and thermal stress > Includes the anisotropic shrinkage effects if fiber orientation is calculated with the Fiber module > Avoids quality blemishes such as sink marks, volumetric shrinkage and warpage for quality excellence 41

42 42 Standard Module - Warp

43 Multi-Component Molding 43

44 Standard Module - Multi-Component Molding (MCM) MCM > Explicit analysis capabilities for insert molding, overmolding, and multi-shot sequential molding process evaluation > Insightful observation for the thermal and mechanical interactions between different materials so as to avoid warpage and delamination 44

45 MCM: 1 st Shot Affecting 2 nd Shot Part insert temperature from first shot Part Part insert Time = 0.073sec Time = 2.293sec Time = 9.29sec Time = EOC Uniform and normal part insert temperature (30 o C) Time = 0.073sec Time = 2.293sec Time = 9.29sec Time = EOC 45

46 Standard Module - Multi-Component Molding (MCM) > Key Feature Injection molding application support both thermoplastic and thermoset materials Enable to select a thermoplastic material or a thermoset material for part under injection molding application > Benefit Easily analyze a MCM model with both thermoplastic and thermoset R12 Thermoset: LSR Thermalplastic: TPE 46

47 Solution Add-ons 47

48 Advanced Hot Runner 48

49 Advanced Hot Runner Module Advanced Hot Runner > Detailed visualization of melt temperature and moldbase temperature distribution in a hot runner system > Full investigation of hot runner components, including heating coils, manifolds, bushing, nozzles, etc > Sensor-coupled hot runner heating simulation to improve thermal uniformity and prevent degradation of plastic material 49

50 Advanced Hot Runner Module (cont d) > Key Features Hot runner melt temperature control by heating coil settings > Dense heating coil design > Coarse heating coil design 50

51 Fiber 51

52 Fiber Module Short Fiber Long Fiber Fiber > Precise 3D fiber orientation simulation of both short and long fibers by considering fiber length, diameter, concentration, etc. High orientation intensity Low orientation intensity, high isotropic shell core Traditional fiber orientation prediction shell core Moldex3D exclusive long fiber prediction shows a typical orientation retardation and a thicker core 52

53 Long fiber in mold filling of centergated disk for 40%wt-glass/PP > Region B > Region C 53 Experimental data Traditional Moldex3D

54 Moldex3D fiber setting Hybrid: Fastest, but over-predict the fiber orientation in shearing regions ORE: Slowest, but prediction improved IBOF: Medium calculation time and results comparable to ORE Folgar-Tucker: Traditional model, good for short fiber prediction ARD: New model for long fiber prediction, but requires 5 parameters to determine iard: New model for long fiber prediction, requires only 2 parameters to determine. Can be applied to short fiber too. Ci: Fiber-Fiber Interaction Cm: Anisotropic effect alpha: Core width and depth 54

55 Fiber Length Distribution Prediction R12 > Option to activate fiber length distribution prediction > Consider fiber breakage phenomena in filling stage > Fiber length distribution do not affect part mechanical properties in this version > Benefit Observe fiber breakage phenomena around gate region Observe fiber length distribution of part after injection Short fiber, Initial fiber length: 3.5x10-1 mm Long fiber, Initial fiber length: 8.5mm 55

56 MuCell 56

57 57 Microcellular Foam (MuCell ) Process

58 Why Microcellular Molding Process? > Advantages of Microcellular Plastics Weight reduction Material cost Quicker cycle time Low pressure molding process Reduce clamping force Stress-free Less shrinkage/warpage Mechanical Properties Environment friendly CO 2 N 2 58

59 Industries Using Microcellular Injection Molding Business Equipment Automotive Industrial & Electrical 59

60 Microcellular Foam (MuCell ) Module > Control the use of gas to create a foamed part > Consider nucleation rate and bubble growth behavior > Consider SCF concentration variation in molding process Gas Diffusion 60

61 Microcellular Foam (MuCell ) Module (cont d) > Visualization of cell density and cell size distribution after foaming process Melt Front Time Cell Radius Cells Density 61

62 Different Gating Strategy Considering the Thickness > Capture cell density and size based on the cell nucleation and growth simultaneous simulation > Obtain optimal mold design and process condition of microcellular injection molding Recommended to set gate on thin side in microcellular injection molding 62

63 Foam Bubbles Development > Gating into thick section > Gating into thin section Cell Radius 10-5 [m] Cell Radius 10-5 [m] It is easy to foam near gates because of lower pressure caused from larger thickness. Bubbles near gates are very small because of higher pressure. But it is still helpless to fill melt into thinner regions

64 Weight Reduction Weight Reduction: 14.83% Microcellular Injection Molding: 57.51g Conventional Injection Molding: 67.52g 64

65 Tonnage Reduction Tonnage Reduction: 64.8% Microcellular Injection Molding: 3.65 Ton Conventional Injection Molding: Ton 65

66 Dimensional Stability - Volume Shrinkage Volume Shrinkage Microcellular Injection Molding Conventional Injection Molding Improvement Maximum 5.87% 6.07% 3.29% Average 2.54% 3.09% 17.80% 66

67 Dimensional Stability - Y Displacement Microcellular Injection Molding Conventional Injection Molding ~ 0 mm -0.24~ 0.24 mm

68 Connector Case > X-displacement MuCell : 0.1~-0.1 mm CIM: 0.45~-0.45 mm

69 Connector Case > Z-displacement MuCell : 0.098~ mm CIM: 0.415~ mm

70 Powder Injection Molding (PIM) 70

71 Powder Injection Molding Module R12 > Moldex3D R12.0 is supported only in Injection molding stage in the whole Powder injection production workflow 71

72 Phase Separation Phenomena in PIM R12 > Phase separation is also called the Shear-induced Particle Migration Due to the max. shear rate, particles disperse along the mold wall, known as low powder concentration; on the other hand, particles concentrate highly in the central area for the minimum shear rate. 72

73 Powder Concentration Distribution R12 > Blank lines occur potentially in areas with higher concentration distribution shown on surface > Due to max. shear rate, low powder concentration is performed near mold wall; due to min. shear rate, high powder concentration is displayed in the center 73

74 Gas-Assisted/Water-Assisted Injection Molding 74

75 Gas/Water-Assisted Injection Molding Module (GAIM/WAIM) > 3D visualization of dynamic fluid penetration behaviors inside the mold cavity during gas/water assisted injection molding process > Simulation for overflow region and skin thickness distribution for realistic gas/water molding process optimization 75

76 Co-Injection Molding 76

77 Co-Injection Module Volumetric shrinkage Warpage Skin thickness Material distribution 77

78 Co-Injection Module (cont d) R12 > Benefits Visualize core material penetration inside the skin material 78

79 Bi-injection Molding (BIM) 79

80 Bi-injection Molding Analysis R12 > Melt front time animation is available > Gate flow rate history of each gate > Sprue pressure history for each melt entrance Control weld line location by adjust flow rate of each gate 80

81 Bi-injection Molding Analysis R12 > Display weld line along melt front advancement > Predict potential location of weld line 81

82 Injection Compression Molding 82

83 Injection Compression Molding (ICM) Module More uniform pressure distribution > True 3D analysis of the injection compression molding process with compression induced flow > Predicts the required compression force and filling pressure. Provides insightful information such as residual stress, shrinkage, pressure, warpage, etc Smaller shrinkage variation 83

84 Compression Molding Module 84

85 Compression Molding Simulation R12 > Complete compression molding condition settings Include mold compression speed and compression force Include melt temperature and mold wall temperature 85

86 Compression Molding Simulation R12 > Support any charge volume shape setting > Support design of single or multiple charges > Molding with one charge > Molding with two charges 86

87 Compression Molding Simulation R12 > Molding with one charge > Molding with two charges Pressure distribution (125 ~ 184 MPa) Pressure distribution (122 ~ 173 MPa) Fiber orientation Fiber orientation 87

88 Compression Molding Simulation R12 > Molding with one charge Volume shrinkage (-1.24% ~ 1.46%) > Molding with two charges Volume shrinkage (0.57% ~ 4.64%) Max. deformation: 0.36 mm Max. deformation: 1.3 mm 88

89 FEA Interface 89

90 FEA Interface and Digimat Interface FEA Interface > Seamless integration with leading structural analysis software ABAQUS, ANSYS, LS-DYNA, MSC.Marc, MSC.Nastran, NX.Nastran, NE.Nastran, Radioss > Results output items include pressure, reduction of weld line strength, residual stress, fiber orientation, temperature distribution, initial strain, density distribution, etc. > Digimat interface is also available 90

91 Stress Module 91

92 Core Shift with Two-Way FSI Analysis R12 FSI (Fluid-Structure Interaction) Filling analysis : Pressure loading Interaction mesh deformation Structural analysis: Core deflection Part Insert or Mold Insert 92

93 Core Shift Experiment R12 Moldex3D R12 Experiment Reference: Y.C. Cheng and Y. J. Liao, Core Deflection in Plastics Injection Molding: Direct Measurement, Flow Visualization and 3D Simulation, Polymer- Plastics Technology and Engineering, 50: , Showing the same agreement with actual experiment on core deflection, Moldex3D R12 identifies accurately interior core deformation during the filling process. 93

94 Application Real Cases: Earphone jack R12 Core deflection during filling stage In core deflection simulation, the cavity mesh deformation can be further considered with the corresponding melt front behavior Final core shift result at EOF 94

95 Application Real Cases: Syringe R12 Core deflection during filling stage Magnified animation of core shift Core shift easily predict the core deformation 95 Pressure loading history animation

96 Annealing Analysis R12 > Key Features Simulate the product s behavior under the hot oven annealing process. Supported in edesign and Solid project Support for the model with part insert object Support to consider gravity effect Support parallel computing 96

97 Environment Temperature Variation R12 > Define the environment temperature variation with time > Support to consider the molded fiber orientation effect 97

98 Boundary Condition for Thermal Conduction Analysis R12 Initial Temperature = 25 o dt = 0.5 sec. Ambient Temperature = 70 o HTC = Heating Time = 600 sec. 98

99 Relaxation of the Stress and Warpage R12 0 sec. Displacement: ~ e-2 mm Residual Stress: 0.244~ MPa 20 sec. Displacement: ~ 5.873e-2 mm Residual Stress: 0.261~ MPa 99

100 End of Annealing R sec. Displacement: ~ 2.486e-2 mm Residual Stress: 0.236~ MPa 600 sec. Displacement: ~ 2.522e-2 mm Residual Stress: 0.253~ MPa 100

101 Design Of Experiment (DOE) 101

102 Expert Module Expert > A professional tool using DOE (Design of Experiment) for efficient optimization of process conditions, such as filling time, packing time, melt and mold temperature, etc. > A series of analysis jobs will be launched automatically and collected. Graphical summary for part quality evaluation and optimized design will be proposed automatically Best results level 102

103 Expert Module (cont d) > Step1: Quality factor definitions > Step2: Control factor settings > Step3: Select DOE orthogonal array 103

104 Expert Module (cont d) > Quality factor: Minimize warpage displacement > Control factors: Filling time (3 sec-3.2 sec) Melt temperature (230 C-245 C) Packing time (5 sec-5.5 sec) Max. packing pressure profile value (70%-80%) original result optimized result

105 Summary 105

106 Exclusive Features of Moldex3D Pioneering 3D Kernel State-of-the-art FVM method Comprehensive 3D throughout runners, cavity to the mold Versatile Meshing engine Automatic Mesh, man-hours free 3D-based Hybrid Mesh No limit in element count High Performance Computing Super fast by using workstations available in the market or cloud computing No need to reduce the analysis accuracy due to lacking of computing capability 106

107 107 Moldex3D: The Best Choice for Communication & Innovation

108 Thank you for your attention!