Moldex3D Italia srlCorso Promessi Sposi 23/D -

23900 Lecco (LC)www.moldex3d.com

2014 Molding Innovation Day

10 Luglio 2014POINT Polo per Innovazione TecnologicaDalmine Bergamo

Moldex3D eDesign rel.13 – (2° parte)

(V.Tsai/T.Sun/S.Canali - Moldex3D)

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3D Cooling Channel Tools

- Newly support of Cooling Channel Designer (CCD), developed by Moldex3D and OPM

- A design tool application integrated in Moldex3D Designer, you can have rapid creation of conformal cooling channel lines based on part geometry

- Other function enhancements

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Designer: Cooling Channel Designer Integration

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More 3D Cooling Channel Simulation Options

> Supports 3D cooling channel simulation in eDesignproject

> Provides Reynolds number prediction > Benefit

– Predicts similar flow patterns in different fluid f low situations

17000 40001 bar 0.1 bar 1 bar 0.1 bar

Reynolds Number

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Multiple Coolant Inlet/Outlet Design Simulation

> Supports the cooling channel analysis of complex co oling design, including multi-inlet and multi-outlet desi gn

> Benefit

– For any complex cooling system design, coolant stre amline and flow filed can be analyzed and visualized in cool ing channels

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Fiber

- Further consideration of screw-induced fiber length, fiber breakage, and fiber concentration simulation

- Other function enhancements

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Fiber: Fiber Length Prediction

> Provides the option to consider fiber breakage beha vior induced by screw

> Moldx3D R13 can also predict the fiber length withi n the melt in the screw stroke area, and the length resul t agrees with the experimental data

Characterization of Fiber Length Distribution in Short and Long-Glass-Fiber Reinforced Polypropylene during Injection Molding Process, KASETSART JOURNAL: NATURAL SCIENCE, Vol. 42, pp. 392 - 397 (2008)

Initially, average fiber length of granules is 7 mm, but the average fiber length is around 0.7 mm at melting zone in screw

PP with 40 wt% of long-glass-fibers

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Enhanced Fiber Length Simulation

Consider fiber breakage in screw

Range from 0.5 - 1.0 mm

Don’t consider fiber breakage in screw

Range from 5.0 – 9.3 mm

Initial fiber length: 10 mm

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Fiber: Fiber Concentration Distribution

> Predicts the fiber concentration distribution in th e molded part

> Considers shear-induced fiber migration behavior in filling stage– Due to the maximum shear rate, fiber disperses alon g the mold wall,

known as low fiber concentration; on the other hand , fiber concentrates highly in the central area for the min imum shear rate

> Not yet considers the impact of the concentration d istribution to the geometry model

Fiber concentration in the thickness direction Shear rate distribution in the thickness direction

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More Options in Fiber Orientation Display

> Supports dense or sparse display of fiber orientati on display in skin

> Benefit– Clearly visualizes the fiber orientation

– Easier to understand fiber orientation

Dense distribution Sparse distribution

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Shrinkage and Warpage Prediction Tools

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Warp: Differential shrinkage effect and differentia l temperature effect

> Provides the contribution of differential shrinkage effect and differential temperature effect in the warpage a nalysis

> Benefit– Visualizes the factor to product deformation, plasti c

shrinkage or mold temperature difference

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Differential Shrinkage Effect

X Displacement (Total)

X Displacement (Differential shrinkage)

X Displacement (Differential temp)X Axis

> Represents the in-plane shrinkage due to PVT distri bution– A proper mold compensation or better packing path d esign

may be the solution if plastic differential shrinka ge effect dominates the part deformation

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Differential Temperature Effect

Warpage: Total effect in Y direction

Warpage: Differential thermal effect in Y direction

With shrinkage and warpage behavior

Only warpage behavior

High coolant temperature

Low coolant temperature

> Represents the out-of-plane warpage due to the differential temperature through thickness– The control of coolant temperature difference betwe en core

side and cavity side can help overcome the part def ormation due to differential temperature effect

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Mold Compensation Function

213mm

> Predicts part deformation distribution under mold compensation situation

> Allows to define mold compensation values in X-Y-Z directions

> Visualizes part variation after mold compensation i n real time

> Benefit– As a reference for mold compensation design to sati sfy part

size requirement

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Hot Runner Simulation Tools

- Standard Cool solver capability enhancement, supporting automatic detection of insulation air gap layer between hot runner metal and mold

- Easier to prepare mesh at air gap region, visualize temperature distribution for better heating rod/coil design verification

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Pack: Valve Gate Switch Control

> Allows to switch valve gate off during the packing stage

> Benefit– Close to real valve gate control

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Multiple Controls in Valve Gate Setting

> Allows to define multiple control points to open/cl ose valve gate– Two controls, Time and flow front, are available.

> Supports repetitive switching for valve gate> Benefit

– Controls complex valve gate movements

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AHR: Heating Rod/Coil Design Verification

> A fast analysis tool to verify the heating rod/coil design

> Simulates the temperature distribution inside hot r unner system by steady state approach

> Benefit

– Based on a new method, the temperature calculation efficiency in hot runner system speeds up 100 times

– Verify if the heating rod and coil designs function the heating properly in the hot runner system during th e design stage

200W heating coil with uniform pitch

200W heating coil with variable pitch

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MuCell®

- Newly support of core-back feature for foaming simulation enhancement, you can get a better understanding on gas volume fraction variation for cell distribution

- Providing cell size and cell density data output to Digimat

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Mucell Core-Back Process

> During the injection procedure, the cavity is initi ally fully-filled, and then foaming happens during the drawback moveme nt on the core side of mold.

> In order to achieve good surface quality, the mold is controlled to move back when the skin layer is formed at the p roper thickness and the core is still hot and soft enough for foaming.

> The quality of the molded part depends on the cell structure and is controlled not only by choosing pr oper molding process conditions, but also by the delay time , core-back speed and core-back distance .

http://www.trexel.com/news-events-awards/news-pdfs/Omnexus_010909.pdf

Ref: Takeshi Ishikawa* and Masahiro Ohshima, JSPP 2012, D-101

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Mucell Core-Back Process Simulation

> Predict pressure variation during core-back process .

> Predict cell size and cell density distribution of c ore-back process

Core-back

Core back start

Larger cell size at core region, and smaller cell size at skin region

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More Digimat options output in MuCell ® Analysis

> A new workflow for MuCell ® part structural performance evaluation

> Moldex3D outputs cell size and cell density data fo r Digimat

> Benefit

– Completely considers the cell size and cell density effects in MuCell ® parts

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Flow/Pack/Cool/Warp Solvers

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Flow: Melt Front Result by Ram Position

> Shows the position of melt front with respect to sc rew ram position during filling and packing stage

> Provides screw ram position as an unit option for X axis in XY-Plot setting

> Benefit– Easier to visualize melt front variation and sprue pr essure

variation with ram position

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Support Overflow Attribute

> Supports overflow attribute in each molding process– The overflow region is not a part of cavity, and th erefore it will

not have to be completely filled in filling analysi s

– The warpage analysis will not consider the deformatio n behavior in overflow region

> Program provides the option to switch on/off the ov erflow region by time in GAIM and WAIM molding processes

Adds an overflow tab, which promotes air venting and molecular chain entanglement to eliminate the weld line of injection molding defect.

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Cool: Mold Preheat Analysis

> Simulates the variation of mold temperature affecte d by the heating of the mold temperature controller befo re the cyclic injection molding process

> Understands the mold temperature distribution at mo ld preheat stage

> Benefit– Decreases short shot parts before steady cycles

Room Temp.Room Temp.

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WAIMWater-Assisted Injection Molding

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WAIM: User-Defined Water Flow Rate

> Allows to define the water flow rate profile of wat er entrance in WAIM project

> Benefit

– Closer to the real setting condition

Ref: S.Sannen, M. De Munck, J. De Keyzer, P. Van Puyvelde, “WATER-ASSISTED INJECTION MOLDING: VALIDATION OF 3D SIMULATIONS

BY EXPERIMENTAL DATA”, ANTEC paper, (2012)

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CMCompression Molding

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CM: Simulation by eDesign mesh

> Improves kernel robustness and capability expanded

> Supports hybrid mesh types, such as tetra and struc tural elements, of compression zone to eliminate the geom etry limitation due to mesh quality

> Benefit– Easier to run the compression molding simulation by

eDesign mesh approach

– Closer to real compression molding situation

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CM: Charge Distribution

> Visualizes the area each charge fills by tracking a pproach

> Shows the volume filled of melt for each charge

> Benefit– As a indicator of compression charge contribution

– It makes the design control of charge size and posit ion easier

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CM: 100% filling stage output

> Solver outputs the result at 100% filling stage automatically

> Benefit

– Understands polymer properties at 100% filling stag e easily

– As a reference to process revision for compression molding

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Stress

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Stress: Mold Deformation Analysis

> Simulates the mold deformation behavior induced by the pressure loading effect in the filling stage and mo ld thermal loading effect in the cooling stage

> Supports user-defined boundary conditions for mold deformation analysis

> Benefit

– Evaluates potential mold defects due to injection m olding process

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FEA Interface

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Coordinate Adjustment for Mapped Meshes

> Provides the coordinate adjustment tool to map one mesh onto the other in FEA Interface– Making the position and orientation of CAE simulati on mesh

coincide with of structural analysis mesh

– Provide “auto move” and “3-points mapping” approaches

> Benefit

– Prevents inconsistent model mapping happened

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FEA Interface: 3D Results to Shell Mesh Mapping

> Maps Moldex3D analysis results to a shell mesh mode l for LS-Dyna structure analysis, the results include: Temperature at EOP and EOC

Volume shrinkage (as initial strain)

Fiber orientation

> Benefit

– Running shell structure analysis in LS-Dyna becomes much easier with seamless integration with Moldex3D via this function

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Multiple Time Step Output of Mold Temperature

> Available output option of mold temperature for mul tiple time steps

> Benefit

– Based on the mold temperature variation history, mo del deformation behavior can be caught more accurately in stress solver

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FEA Supported Versions of Stress Solvers

ANSYS ANSYS 10, 11, 12, 13, 14 and 15

ABAQUS ABAQUS 6.8 ,6.9 ,6.10, 6.11 and 6.12

LS-DYNA LS-DYNA v9.71 R4.2

MSC Marc MSC Marc 2010,2011 and 2012

MSC Nastran MSC Nastran 2010,2011 and 2012

NE Nastran NE Nastran V8.3

NX Nastran UGS NX 7.0

Radioss HyperWorks10.0, 11.0 and 12.0

Moldex3D Italia srl

Corso Promessi Sposi 23/D

23900 Lecco (LC)

www.moldex3d.com

Thank you!谢谢!

Grazie!