Optimization of the injection molding process MOLDFLOW SIMULATIONS Mark Klarenbeek m.klarenbeek@pezygroup.com November 17 th 2016 LinkedIn
Agenda Pezy Group Accelerating innovation Introduction injection molding simulation software Necessity of injection molding simulation Examples 3
Accelerating innovation Brands, products, equipment 100+ specialists
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Accelerating innovation 300+ Patents 400+ Clients 20+ Years of costumer relations 100+ Specialists
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
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
Agenda Pezy Group Accelerating innovation Introduction injection molding simulation software Necessity of injection molding simulation Examples 10
Injection molding simulation History FillCalc C-MOLD AC Technology 1978 2000 2008 Cadmould I-DEAS for Plastics 11
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
Injection molding simulation Overview DEMO 13
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
Finite element modelling Moldflow Dual Domain TM Technology GATE 16
Finite element modelling Moldflow Dual Domain TM Technology 17
Finite element modelling Moldflow Dual Domain TM Technology 18
Agenda Pezy Group Accelerating innovation Introduction injection molding simulation software Necessity of injection molding simulation Examples 19
Why simulation? Industrial design Product design Mold design Mold making Production 20
Why simulation? Industrial design Product design Mold design Mold making Production 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
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
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
Agenda Pezy Group Accelerating innovation Introduction injection molding simulation software Necessity of injection molding simulation Examples 25
Example 1 Filling GATE 26
Filling Weld line 27
Filling Weld line 28
Filling 29
Filling 30
Filling 31
Filling 32
Filling 33
Filling Good filling pattern through living hinge: Straight 34
Filling 35
Filling 36
Filling 37
Filling 38
Filling 39
Filling 40
Filling 41
Filling 42
Filling 43
Filling 44
Filling 45
Filling 46
Filling 47
Filling Good filling pattern through living hinge: Straight Weld line End of filling - Product 100% filled 48
Volumetric shrinkage Sink marks 49
Volumetric shrinkage and Sink marks 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
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
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
Example 2 Part design Mold design Processing conditions Material 54
Example 2 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
Example 2 Runner balancing Ø 5.0 mm Ø 5.0 mm Ø 5.0 mm Filling pattern not balanced 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
Example 2 Runner balancing Filled Filled Ø 4.3 mm Ø 5.0 mm Filled Ø 5.0 mm Filled Filling pattern balanced 59
Example 3 Part design Mold design Processing conditions Material 61
Example 3 Gate location Automotive headlight frame Warpage is critical PA GF30 Gate 62
Example 3 Gate location Initial gate location Gate 63
Example 3 Gate location Deflection in Z-direction for initial gate Too high, out of spec Gate 64
Example 3 Gate location Glass fiber orientation for initial gate Not uniform Gate 65
Example 3 Gate location Original gate Central gate 2 x 3 gates Edge gate 66
Example 3 Gate location Original gate Central gate Smallest deformation 2 x 3 gates Edge gate 67
Example 4 Part design Mold design Processing conditions Material 68
Injection pressure (MPa) Example 4 Injection pressure versus time 75 74 73 72 71 70 69 68 67 66 65 0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 Injection time (s) 69
Questions? 70
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
Mark Klarenbeek m.klarenbeek@pezygroup.com November 17 th 2016 LinkedIn