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Moldflow Plastics Advisers

Moldflow Plastics Advisers. Changing the way plastics parts and molds are designed. Problem. Plastics part design done in isolation Plastics parts not designed for manufacturabilty Most analysis packages Not developed for part designers Difficult for designers to learn and use

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Moldflow Plastics Advisers

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  1. MoldflowPlastics Advisers Changing the way plastics parts and molds are designed

  2. Problem • Plastics part design done in isolation • Plastics parts not designed for manufacturabilty • Most analysis packages • Not developed for part designers • Difficult for designers to learn and use • Tend to be feature-based, not solution-based • Do not optimize design process • Simulation-driven design not achieved

  3. Solution: The Plastics Advisers • Moldflow Part Adviser • For Part Designers • Moldflow Mold Adviser • For Mold Designers

  4. PART DESIGNER MOLDER Part Design Parameters MOLD DESIGNER MATERIAL SUPPLIER Manufacturing Constraints Consider Communicate Iterate High Impact Simulation

  5. Moldflow Plastics Advisers Answer basic plastics manufacturing questions: • Will the part fill? • Where are the weld lines & air traps? • Which material and gate location? • Is the runner system balanced? • How to size geometry for optimal manufacturability?

  6. Unique Desktop Simulation • Specifically focused on the design market • CAD integrated • Solids-based • Extreme ease-of-use • Robust solution process • Practical design advice • Design optimization

  7. Industry Best CAD Integration Moldflow has taken an aggressive stance in lining up CAD vendors to resell it’s Part Adviser ... We believe that CAD vendors, Moldflow and the users will all benefit. -- Dave Weisberg, Engineering Automation Report

  8. 3D Solids Based • No model translation! • No meshing! • No midplaning! • No model clean-up!

  9. Virtual Plastics Manufacturing Experience Extreme Ease of Use • Intuitive User Interface • Analysis Assistant • Results Adviser • 3D model manipulation • Tool tips & on-line tutorials • Comprehensive help system • Local language support

  10. Robust Solution Process • Breakthrough Technology • Unique Dual Domain finite element analysis solution • US Patent No. 6,096,088 • Non-Newtonian, non-isothermal solver • Simulates true plastics behavior • Delivers results in a fraction of the time

  11. Unique On-Line Advice • Adviser Assistant for Analysis Setup • Dynamic Adviser - Context sensitive and model based results help • Comprehensive help system

  12. Unique On-Line Design Guide • Provides practical advice considering plastics manufacturing constraints • How to better control plastics behavior using proper design techniques

  13. Molding Parameters • Complete Moldflow materials database • More than 7,500 plastics materials • Molding conditions can be automatically determined • Uses the material supplier’s recommended mold and melt temperature • Automatically identifies an injection time that minimizes the pressure to fill the component and maintain an acceptable flow front temperature

  14. Molding Parameters

  15. Best Gate Location Analysis • Analyzes various locations on the model for its suitability as an injection point • The most suitable areas are rated as best, and the least suitable areas of the model are rated as worst

  16. Best Gate Location Analysis

  17. Process Condition Optimization • Based on part geometry, material, injection location, and user requirements for surface gloss: • Indicates the optimum processing conditions • Indicates the effects of variation from optimum process conditions

  18. Process Condition Optimization

  19. Confidence of Fill • Indicates the probability of a region within the cavity filling with plastic • Derived from pressure and temperature • Simple color-coded display • Green will definitely fill • Yellow may be difficult to fill or may have quality problems • Red will be difficult to fill or will have quality problems • Detailed advice from the Results Adviser

  20. Confidence of Fill

  21. Quality Prediction • Predicts expected quality of the part's surface appearance and mechanical properties • Derived from pressure, temperature, shear rate, shear stress and cooling time results • Simple color-coded display • Green will have high quality • Yellow may have quality problems • Red will have quality problems • Detailed advice from the Results Adviser

  22. Quality Prediction

  23. Cooling Quality • Identifies areas of heat concentration on the model • Derived from surface temperature variance and freeze time variance results • Simple color-coded display • Green no cooling problems • Yellow may have cooling problems • Red will have cooling problem • Detailed advice from the Results Adviser

  24. Cooling Quality

  25. Sink Marks Estimate • Predicts the presence and location of sink marks • Provides a relative degree of severity of depth as influenced by the material, part geometry, position relative to the injection location, and processing conditions

  26. Sink Marks Estimate

  27. Gate Design Tools • Automatic Gate Sizing • Calculates the best gate dimensions and automatically updates the model with revised dimensions • Gate Design Advice • Provides gate-specific design advice • Indicates if there is excessive shear stress, shear rate or temperature rise in the gate region • Indicates if the gate dimensions do not conform to established gate design guidelines

  28. Gate Design Tools Before Gate Sizing After Gate Sizing Reduced Injection Pressure and Reduced Shear Rate

  29. Skin Orientation • Plot showing the orientation of polymer molecules and fibers (if any) on the skin (surface) of the part at the end of filling • Can be used to determine part strength • Uniform orientation leads to better surface quality • Available in both Part & Mold Adviser

  30. Skin Orientation

  31. Feed System Design • Feed system design and mold layout • Single Cavity • Multi-Cavity • Family Mold • Automatic Runner Balance • To ensure that all cavities fill at the same time and that the volume of the runner system is minimized

  32. Feed System Design

  33. Mold Design

  34. Performance Adviser • An add-on module for Mold Adviser • Two key functions • Packing Analysis • Extends plastic filling analysis to calculate volumetric shrinkage and identify optimal packing conditions • Warpage Analysis • Indicates cause and potential for part warpage as well as deflected shape

  35. Packing Analysis • Packing Profile • Selected from • Specified Packing Pressure vs Time • % of Filling Pressure vs Time • Results include • Volumetric Shrinkage • % Frozen Layer • Average Temperature • Cooling Time • Grow From (multi-gated/multi-cavity/family molds) • Peak Clamp Force during Packing • Total Part Weight • End of Packing Time • Maximum Wall Shear Stress

  36. Volumetric Shrinkage

  37. Warpage Analysis • Indicates if part is likely to warp beyond acceptable tolerances • Provides advice on cause of warpage • Provides advice on how to correct warpage • Allow the user to reduce warpage by • changing processing conditions • changing material • changing part design

  38. Part Deflection

  39. Warpage Indicator • Warpage indicator • all effects • due to Cooling • due to Shrinkage • due to Orientation • for Fiber filled materials • Simple color-coded display • Green less than 80% of nominal maximum deflection • Yellow between 80% and 120% of nominal maximum deflection • Red more than 120% of nominal maximum deflection

  40. Warpage Indicator

  41. Cooling Circuit Adviser • An add-on module for Mold Adviser • Design & Evaluate cooling circuits to achieve uniform cooling and minimize cycle time • Automated wizard to create cooling circuit layout • Option to read centerline cooling layout from CAD IGES file

  42. Cooling Circuit Design

  43. Cooling Analysis Results • Part Surface Temperature • Average Temperature • Circuit Reynolds number • Circuit Coolant Temperature • Circuit Flow Rate • Circuit Pressure • Cooling Time

  44. Surface Temperature

  45. Cooling Circuit Temperature

  46. Cost Adviser • Cost estimating tool directly embedded from MPA release 7.0 on • Estimate the four components of part cost: • Material Cost • Mold Manufacturing Cost • Machine Operating Cost • Post-molding Cost

  47. Cost Adviser

  48. Internet Ready Reports • Automatic creation and formatting of HTML reports • Easily viewed with any web browser • Highly customizable • Filling animations and model rotations can be included

  49. The Plastics Advisers • Moldflow Part Adviser • For Part Designers • Moldflow Mold Adviser • For Mold Designers

  50. Summary • Moldflow Strategy • Process Wide Plastics Solutions • Moldflow Plastics Advisers • Moldflow Part Adviser & Moldflow Mold Adviser • Design-for-Manufacturability products for part designers • Unique Solution-based Approach • Solves Specific Design-for-Manufacturability Problems • Optimizes Design Process • True Simulation Driven Design

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