moldflow at pds - productive design services · 2019-10-31 · moldflow at pds confidential what is...
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Moldflow at PDS
CONFIDENTIAL
Moldflow at PDS
CONFIDENTIAL
What is Moldflow?
Moldflow is a simulation software used to determine the
design of a plastic injected part, optimize mold design and
layout, and validate process used for injection molding
Moldflow products help identify areas that are difficult to fill,
where visual defects may occur, and excessive warp in parts.
Moldflow at PDS
CONFIDENTIAL
4 Step Process1. Prototype - Fill/Pack/Warp
• Prepare supplied prototype data for Moldflow analysis
• Determine fill points for both sequential and open fill patterns
• Validate part dimensions based on ISO thermal analysis
2. Production Fill Points Establish Gating - Fill/Pack/ISO Warp
• Determine fill points for both hard and soft shot
• Optimize process and/or Implement part changes to improve warp
• Use preliminary manifold to validate sequential filling pattern
• Evaluate part dimensions based on ISO thermal warp (hard shot only)
3. Final Gating & Manifold Validation - Fill/Pack/ISO Warp
• Incorporate final tool design including Manifold, approved gate locations and cold runner
(soft and hard shot)
• Use previously optimized process
• Optimize manifold bores using supplier standards or guide lines if needed
• Optimize process and evaluate part dimensions based on an ISO thermal analysis (hard
shot only)
4. Final Gating Manifold & Cooling Design Validation - Cooling/Fill/Pack/Warp
• Prepare final tooling data for Moldflow analysis
• Incorporate supplied cooling lines (hard shot only)
• Use final optimized process, manifold cold runners and gate locations
• Running additional Iterations to achieve acceptable molding conditions
• Evaluate part dimensions (hard shot only)
Moldflow at PDS
CONFIDENTIAL
Moldflow Results
Important Results
Flow:
• Fill Time
• Pressure at V/P Switchover
• Temperature at flow front
• Pressure at Injection Location: XY Plot
• Volumetric shrinkage at ejection
• Time to reach ejection temperature
• Frozen layer fraction
• Air traps
• Clamp force: XY Plot
• Pressure
• Sink marks estimate
• Weld lines
• Cavity Weight
Cool:
• Circuit coolant temperature
• Circuit flow rate
• Circuit Reynolds Number
• Circuit Metal Temperature
• Average temperature, part
• Circuit pressure
• Circuit heat removal efficiency
• Temperature, part
Warp:
• Deflection: All effects
• Deflection: X Component
• Deflection: Y Component
• Deflection: Z Component
Moldflow Simulation
Windage
PDS Moldflow CONFIDENTIAL
Windage Case Study
Windage
• Windage is the process of utilizing the Warp
characteristics from Moldflow to apply reverse
warp to the molded part
• The in mold warp result is corrected for tolerance
considerations
• Areas with high tolerance and excessive warp
can be corrected with this method
Using the Process:
• Windage is applied after all other design
considerations are utilized to reduce warp
• This process is employed in the validation phase if
warp can not be reduced through better gating
• Many large, thin parts require windage to hold
tolerance
Excessive Warp
Moldflow Simulation
Windage
PDS Moldflow CONFIDENTIAL
Windage Case Study
Windage
• Excessive warp was found to be 7.11mm
• Reverse warp is applied to the part design
• The part is rerun in Moldflow with the Windage applied
Moldflow Simulation
Windage
PDS Moldflow CONFIDENTIAL
Windage Case Study
Windage
• The data is reverse engineered to counter act the warp
• Multiple iterations are usually attempted to achieve the best results
• Characteristics change with each situation
Moldflow Simulation
Windage
PDS Moldflow CONFIDENTIAL
Windage Case Study
Windage
• The data is then sent to Moldflow to be verified
• The data can be overlaid with the nominal to ensure part conformity
Moldflow Simulation
Windage
PDS Moldflow CONFIDENTIAL
Windage Case Study
Windage
• Side-by-side comparison of windage result to nominal result show drastic improvement
• The Windage solid brought the maximum deviation down over 6mm, cutting over 85% of calculated warp
Moldflow Simulation
Windage
PDS Moldflow CONFIDENTIAL
Windage Case Study
Windage
Excessive Warp Reverse Engineering
Moldflow Verification New Tool Data
“Reverse Engineering services provide an effective solution to warp reduction. When coupled with Moldflow
Simulation the windage process saves time and money on warp prone parts.”
-Marino Colarossi , President
FEA at PDS
CONFIDENTIAL
FEA at PDS
CONFIDENTIAL
Displacement Studies
• Force Load application
• Enforced displacement
• Linear and non-linear
analysis
FEA at PDS
CONFIDENTIAL
Stress - Strain
&
Material Validation
• Material stress and
ultimate strength
• Plastic Strain and areas
of deformation
• Validation through
situational force
application
• Trial of multiple
materials for each
application
CONFIDENTIAL
Motion Solve StudiesFEA at PDS
• Kinematic motion solve
• Assembly design and
mechanical motion
studies
• Clearance and operation
of moving parts
CONFIDENTIAL
Loading and UnloadingFEA at PDS
• Loading force studies
• Removal Force studies
• Contact surface and
frictional forces
• Direct and angled
removal/insertion loads
• Multiple component
assembly
• Clip holding forces
CONFIDENTIAL
OptimizationFEA at PDS
• Rib design optimization
• Material reduction
• Structural optimization
for specific load cases
CONFIDENTIAL
3D Printing at PDS
CONFIDENTIAL
3D Printing at PDS Material Options
ABS PLA SOFT
• Strong Durable plastic
• Used for functional/
end use printed parts
• Various finishing
techniques
• High Tolerance prints
• Affordable low cost
prints
• Post processing for
visual appeal
• Flexible and durable
• Varying hardness
levels
• Wearables and
functional items