optimization of the injection molding process … injection molding... · optimization of the...

Optimization of the injection molding process

MOLDFLOW® SIMULATIONS

Mark Klarenbeek m.klarenbeek@pezygroup.com November 17th 2016 LinkedIn

3

Agenda

• Pezy Group – Accelerating innovation

• Introduction injection molding simulation software

• Necessity of injection molding simulation

• Examples

Accelerating innovation Brands, products, equipment

100+ specialists

Accelerating innovation

100 Specialists

20+ Years of customer

relations

100+ Specialists

Accelerating innovation

400+ Clients

20+ Years of costumer

relations

100+ Specialists

300+ Patents

400+ Clients

20+ Years of costumer

relations

100+ Specialists

Accelerating innovation

5 offices

300+ Patents

400+ Clients

20+ Years of costumer

relations

100+ Specialists

• Groningen

• Houten

• Amsterdam

• Eindhoven • Singapore

• International network of partners and suppliers

Accelerating innovation

Business or product idea

Innovation

& Design

Engineering

& Prototyping

Industrialization

& Small series

production

Sales & Service

From design to small series production Offering expertise in all aspects

End-to-end project management

Sourcing and supply base support

10

Agenda

• Pezy Group – Accelerating innovation

• Introduction injection molding simulation software

• Necessity of injection molding simulation

• Examples

11

Cadmould

C-MOLD AC Technology

I-DEAS for Plastics

FillCalc

Injection molding simulation – History

1978 2000 2008

BOUNDARY

CONDITION

START

ANALYSIS

RESULTS &

INTER-

PRETATION

FIX FEM

MODEL

Finite

Element

Model

IMPORT

CAD

MODEL

Injection molding simulation – Overview

• Filling

• Pressure

• Temperature

• Air traps

• Fiber Orientation

• Shear rates

• Frozen layers

• Shrinkage

• Warpage

• Etc….

12

Injection molding simulation – Overview

13

DEMO

BOUNDARY

CONDITION

START

ANALYSIS

RESULTS &

INTER-

PRETATION

FIX FEM

MODEL

Finite

Element

Model

IMPORT

CAD

MODEL

Injection molding simulation – Overview

• Filling

• Pressure

• Temperature

• Air traps

• Fiber Orientation

• Shear rates

• Frozen layers

• Shrinkage

• Warpage

• Etc….

15

16

Moldflow Dual DomainTM Technology

GATE

Finite element modelling

17

Finite element modelling

Moldflow Dual DomainTM Technology

18

Finite element modelling

Moldflow Dual DomainTM Technology

19

Agenda

• Pezy Group – Accelerating innovation

• Introduction injection molding simulation software

• Necessity of injection molding simulation

• Examples

20

Why simulation?

Mold design

Mold making

Industrial design

Product design

Production

21

Why simulation?

Mold design

Mold making

Industrial design

Product design

Production

22

Ideal

gate position

• 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?

Simulation for industrial / product design

23

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?

24

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?

25

Agenda

• Pezy Group – Accelerating innovation

• Introduction injection molding simulation software

• Necessity of injection molding simulation

• Examples

26

Example 1 – Filling

GATE

27

Filling Weld line

28

Filling Weld line

29

Filling

30

Filling

31

Filling

32

Filling

33

Filling

34

Filling Good filling pattern through

living hinge: Straight

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

48

End of

filling

-

Product

100%

filled

Weld line Filling Good filling pattern through

living hinge: Straight

49

Sink marks

Volumetric shrinkage

50

Volumetric shrinkage and Sink marks

Part design Mold design

Processing

conditions Material

“Plastic System”

• “Plastic System” is complex

• Simulation helps

• But… Simulation is always based on assumptions and simplifications

51

Part design Mold design

Processing

conditions Material

Part design Mold design

Processing

conditions Material

Part design Mold design

Processing

conditions Material

Part design Mold design

Processing

conditions Material

Part design Mold design

Processing

conditions Material

Part design Mold design

Processing

conditions Material

• 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 • ...

52

“Plastic System”

Part design Mold design

Processing

conditions Material

• 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

53

“Plastic System”

Part design Mold design

Processing

conditions Material

Example 2

54

Example 2

55

Example 2 Runner balancing

56

AMA filling simulation • 3 different parts • Initially Ø = 5.0 mm • Goal: Balanced flow

Ø 5.0 mm

Ø 5.0 mm

Ø 5.0 mm

Example 2 Runner balancing

57

Filling pattern not balanced

Ø 5.0 mm

Ø 5.0 mm

Ø 5.0 mm

Example 2 Runner balancing

58

Ø 4.3 mm

Ø 5.0 mm

Ø 5.0 mm

Optimized runner design • Runner diameters adapted • Runner lengths adapted • (Less runner scrap)

Example 2 Runner balancing

59

Filled

Filled

Filled

Filled

Filling pattern balanced

Ø 4.3 mm

Ø 5.0 mm

Ø 5.0 mm

Part design Mold design

Processing

conditions Material

Example 3

61

62

Automotive headlight frame • Warpage is critical • PA GF30

Gate

Example 3 Gate location

63

Gate

Example 3 Gate location

Initial gate location

64

Gate

Example 3 Gate location

Deflection in Z-direction for initial gate • Too high, out of spec

65

Gate

Example 3 Gate location

Glass fiber orientation for initial gate • Not uniform

66

Original gate Central gate

2 x 3 gates Edge gate

Example 3 Gate location

67

Original gate Central gate

2 x 3 gates Edge gate

Smallest deformation

Example 3 Gate location

Part design Mold design

Processing

conditions Material

Example 4

68

Example 4 Injection pressure versus time

69

65

66

67

68

69

70

71

72

73

74

75

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) In

jec

tio

n p

res

su

re (

MP

a)

70

Questions…?

71

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

Mark Klarenbeek m.klarenbeek@pezygroup.com November 17th 2016 LinkedIn