This class will discuss the requirements and workflow for simulating flow imbalances in injection molding that are caused by shear heating in branched runner systems. Validation case studies will also include the MeltFlipper design, as well as in-cavity flow imbalances that lead to race-track effects. This class will focus on the use of the Autodesk Moldflow Insight software.
Autodesk Moldflow users who are interested in simulating flow imbalances caused by shear heating
John Beaumont is president of Beaumont Technologies and program chair of the Plastics Engineering Technology program at Penn State University, Erie. He has authored several books including Successful Injection Molding and Runner & Gating Design Handbook as well as contributing the design chapters of the Injection Molding Handbook. His earlier industrial credits include positions as engineering manager for Ciba Vision Corp and technical manager for Moldflow’s US operations during the mid-80’s. Shortly after joining Penn State in 1989, he founded and directed the Plastics CAE Center for nearly 20 years. In 2001, John founded Beaumont Technologies which is the pioneer and world leader of in-mold rheological control technologies. John is an SPE Fellow and a past chair of the Injection Molding Division Board of Directors.
Dr. Franco Costa is a Senior Research Leader for the Autodesk® DLS-Simulation group. Over 20 years with Autodesk Moldflow®, he has contributed to the technologies of 3-dimensional flow simulations, thermal analysis, crystallization analysis, structural analysis, final net part shape prediction and multi-physics for the plastic injection molding simulation industry. Starting with Autodesk Moldflow as a doctoral scholar, Franco has moved through roles as a research engineer, development team leader, and manager and now leads key strategic research projects for the Autodesk Simulation technology group. Franco has presented at academic conferences in the field of polymer processing, acts as a referee on international journals, and often presents overviews of Autodesk Moldflow research technology directions at Autodesk Moldflow user meetings. Franco is based in the Autodesk R&D Center in Melbourne, Australia
Sabic is a major manufacturer of long fiber filled polypropylene. These long fiber filled plastics can be used to produce light weight structural components with excellent structural properties. Light weighting products is particularly important in the Automotive and Transportation industry, where weight reduction is a major driver for improving fuel economy and reduces the overall carbon footprint over the product life. To leverage the high strength-to-weight ratio, the design of the products have to account for the manufacturing process. The Autodesk Moldflow 2012 release includes the ability to calculate the orientation of long fibers during the injection molding process, which is the main component in understanding the strength characteristics of the products. The understanding of the strength of the products can then in turn be fed back into the design to optimize the design of a lightweight, yet strong, plastic product.
This class will discuss the tools available in Autodesk® Moldflow® Insight for simulating the dynamic temperature changes experienced in the mold during an injection molding process by using the Cool Finite Element Method (FEM) functionality. Topics covered will include modeling requirements, process setup and workflow, theory, result interpretation, and validation examples. Focus will also be given to new functionality available in the Scandium Technology Preview supporting dual-domain part models, thermoset molding and variable coolant inlet temperature processes, including Rapid Heating and Cooling of the Mold (RHCM), also known as Rapid Temperature Cycling or Variotherm. In addition, examples will be shown to demonstrate how to model complex 3D cooling channels (conformal cooling).
In this class, you will learn how to set up, run, and interpret the results for a Design of Experiment (DOE) analysis. The DOE tool in Moldflow Insight is now very powerful and can help you solve many problems. Setting up a DOE analysis to target specific requirements is the key to getting the most from the analysis. This class will introduce you to tips and tricks to get the most from the DOE analysis.
Accuracy of injection molding simulation is influenced by many factors such as modeling of part geometry, mesh type and density, mathematical solution, and process settings. The focus of this class is the influence of material data on simulation precision and accuracy. This class outlines the background behind the development of Autodesk world-leading material-testing laboratories, the importance of material data to accurate simulations and, through sensitivity studies, the influence of uncertainties in material properties on simulation results.
The Autodesk® Moldflow® product team and the University of Bradford have a long-standing collaboration investigating key injection molding effects such as fiber orientation, residual stresses, warpage, post-injection product performance, heat transfer, and feature replication. This class will focus on academic and industrially relevant components from the initial design phase, through production using both conventional- and micro-injection molding, to final product property assessment in terms of mechanical performance, geometric tolerances, and feature replication.
Do you use CAD models with Autodesk Moldflow products? If yes, then don't miss this class. We will discuss how to leverage Autodesk Inventor® Fusion technology as the front-end modeler and idealization tool for Autodesk Moldflow. We will show how to use Inventor Fusion to import CAD data, then edit and simplify it in preparation for Autodesk Moldflow simulation. We will discuss the techniques to simplify a part model and make design changes, such as modifying the part thickness and adding ribs, using Inventor Fusion. We will also discuss the alternative workflow of starting the simulation process in Autodesk Moldflow Insight, launching Inventor Fusion from Autodesk Moldflow Insight to modify geometry, and then rerunning the solver analysis in Autodesk Moldflow Insight.
This class will show you how Autodesk Moldflow can be integrated as a new discipline in numerical optimizations of mechanical part behavior. We will show the influences of fiber orientation on mechanical behavior due to changes in design variables. We will also show how the workflow changes when Moldflow is incorporated into the optimization process. Finally, we will give examples of the use of the new method of integrative optimization.
This class will demonstrate how the use of experimental test data of several tensile specimens of varying fiber orientation can help determine an adequate failure criteria for a given reinforced thermoplastic. This criteria can then be utilized to better predict failure of complex part designs with widely varying fiber orientations. Data for a 30% glass-reinforced PEEK material will be shown as an example of this approach to orthotropic failure analysis.
Fiat is one of the top car manufacturers in the world and is using the power of simulation extensively in their product development. In this class, we will show how simulation technology can be used to validate design and quantify defects that can show up during manufacturing and final assembly. We will visualize production defects in plastic parts using Autodesk® Moldflow® and Autodesk Showcase®.