Moldex3D R11 – State-of-the-Art Optimization Technology

of Plastic Injection Molding through DOE Approach

(PresseBox) ( Aachen, )
The new Moldex3D/DOE (design of experiments) module has been developed to enable optimum process parameters to be established rapidly and systematically - by means of DoE and without recourse to complex "trial and error" tests - from existing simulation results. It is a professional tool that helps users evaluate the appropriate settings of runner size, gate location and optimal process conditions for injection molding part designs.

Manual data input by the user is kept to a minimum, state SimpaTec, Reseller of Moldex3D, the world leading CAE product for the plastics injection molding industry. The module then performs independent, parallel iterations on the results using the Taguchi method. When finished, the program spits out statements about quality and response factors, and suggests an optimized process structure (Fig. 2).

For example, an injection molded part (Fig. 1) was found to undergo volumetric shrinkage of not more than 3.31%. In an attempt to reduce this, the mutual influence of several process parameters on each other was calculated, namely: filling time (3.0 to 3.2 s), melt temperature (230 to 245 ˚C), holding pressure time (5.0 to 5.5 s) and maximum pressure in the holding pressure phase (70 to 80%) were iterated in the specified range. Subsequent application of the DoE-optimized molding parameters substantially reduced the level of volumetric shrinkage to a maximum value of 1.48%.

The latest Moldex3D R11 provides other enhancements and new features more, e.g. a specially developed structural-mechanical tool (which is based on linear-elastic principles and incorporates relevant information such as weld lines and fiber orientation into the simulation); geometry changes without the need for external CAD programs; the use of tracer particles to depict mold filling; the simulation of the flow behavior of the coolant within the injection molding simulation in true 3-D by means of CFD analysis and to optimize it to requirements. Furthermore, crystallization can now be visualized during filling, and in the holding pressure and cooling phases. R11 also supports a core shift analysis to simulate deflection of part inserts due to imbalances in filling pressure and so helps the injection molding process to be optimized.
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