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

Optimization of the injection molding process

MOLDFLOW® SIMULATIONS

Mark Klarenbeek [email protected] November 17th 2016 LinkedIn

https://www.linkedin.com/in/mark-klarenbeek-0817244?trk=hp-identity-name

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


400+ Clients

20+ Years of costumer

relations

100+ Specialists

300+ Patents

400+ Clients


relations

100+ Specialists


5 offices

300+ Patents

400+ Clients


relations

100+ Specialists

• Groningen

• Houten

• Amsterdam

• Eindhoven • Singapore

• International network of partners and suppliers


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




• Examples

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Cadmould

C-MOLD AC Technology

I-DEAS for Plastics

FillCalc

Injection molding simulation – History

1978 2000 2008

http://www.simpoe.com/home.php

http://www.brandsoftheworld.com/download/brand/40371.html

http://upload.wikimedia.org/wikipedia/en/7/77/Moldflow-logo.png

http://www.brandsoftheworld.com/download/brand/23343.html

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….

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DEMO

BOUNDARY

CONDITION

START

ANALYSIS

RESULTS &

INTER-

PRETATION

FIX FEM

MODEL

Finite

Element

Model

IMPORT

CAD

MODEL


• Filling

• Pressure

• Temperature

• Air traps

• Fiber Orientation

• Shear rates

• Frozen layers

• Shrinkage

• Warpage

• Etc….

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16

Moldflow Dual DomainTM Technology

GATE

Finite element modelling

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18



19

Agenda




• Examples

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Why simulation?

Mold design

Mold making

Industrial design

Product design

Production

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Why simulation?

Mold design

Mold making

Industrial design

Product design

Production

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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

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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?

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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




• Examples

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Example 1 – Filling

GATE

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Filling Weld line

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Filling Weld line

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Filling

30

Filling

31

Filling

32

Filling

33

Filling

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Filling Good filling pattern through

living hinge: Straight

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Filling

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Filling

37

Filling

38

Filling

39

Filling

40

Filling

41

Filling

42

Filling

43

Filling

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Filling

45

Filling

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Filling

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Filling

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End of

filling

-

Product

100%

filled

Weld line Filling Good filling pattern through

living hinge: Straight

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Sink marks

Volumetric shrinkage

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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

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Processing

conditions Material


Processing

conditions Material


Processing

conditions Material


Processing

conditions Material


Processing

conditions Material


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 • ...

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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

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Processing

conditions Material

Example 2

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Example 2

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Example 2 Runner balancing

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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


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Filling pattern not balanced

Ø 5.0 mm

Ø 5.0 mm

Ø 5.0 mm


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Ø 4.3 mm

Ø 5.0 mm

Ø 5.0 mm

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


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Filled

Filled

Filled

Filled

Filling pattern balanced

Ø 4.3 mm

Ø 5.0 mm

Ø 5.0 mm


Processing

conditions Material

Example 3

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Automotive headlight frame • Warpage is critical • PA GF30

Gate

Example 3 Gate location

63

Gate


Initial gate location

64

Gate


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

65

Gate


Glass fiber orientation for initial gate • Not uniform

66

Original gate Central gate

2 x 3 gates Edge gate


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Original gate Central gate

2 x 3 gates Edge gate

Smallest deformation



Processing

conditions Material

Example 4

68

Example 4 Injection pressure versus time

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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)

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Questions…?

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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 [email protected] November 17th 2016 LinkedIn

https://www.linkedin.com/in/mark-klarenbeek-0817244?trk=hp-identity-name

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

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