This class will review new functionality in Moldflow Insight software and discuss current research directions in the development of Moldflow Insight software. Capabilities covered will include multi-shot overmolding and mold cooling; composite overmolding; the effect of fiber orientation on viscosity; the effect of material degradation on viscosity; microcellular foaming; improved fiber orientation and fiber breakage calculations; and user routines for viscosity, core-shift and more. There will also be an update of research collaborations in the area of injection molding simulation research.
Injection Molding Analysts, Mold Designers & Plastic Part Designers
Dr. Franco Costa is a senior research leader for Simulation Moldflow at Autodesk, Inc. With over 23 years of experience with Simulation Moldflow software, he has contributed to the technologies of 3D flow simulations, thermal analysis, crystallization analysis, structural analysis, final net-part shape prediction, and multiphysics for the plastic injection molding simulation industry. Franco has moved through roles as a research engineer, Development Team leader, and manager, and he now leads key strategic research projects for the Autodesk Simulation Technology Group as well as acting as an internal reviewer and technology architect. Franco has presented at academic conferences in the field of polymer processing. He also acts as a referee on international journals and often presents overviews of Simulation Moldflow research-technology directions at Simulation Moldflow user meetings. Franco is based in the Autodesk Research and Development Center in Melbourne, Australia.
This class will describe the benefits of using PowerShape software and Moldflow Insight to model and simulate a conformal cooling tool. With 3D printing on the rise, conformal cooling is becoming a more widely available option to create cooling channels in metal in order to more evenly cool a plastic component during the molding process. Utilizing the modeling power of PowerShape to build a mold with channels following the geometry of the plastic part-and then validating the channels using Moldflow-can save time and money by eliminating the need to 'build it and hope it works."
The success of a new product launch relies heavily on the ability of molding thermoplastic parts within specified tolerances and successfully assembling them into a functional product. Building a mold with the correct mold-shrinkage values is crucial for a given plastic material. Currently, a toolmaker guesses the shrinkage value from the range published by a material supplier before cutting steel. Thus, choosing one value at the mid-point of the range results in a part with vastly different shrinkage values in the flow, cross-flow, and transverse directions. Subsequently, many compromises may have to be made in order to qualify the part and approve the tool before routine production. We have been working with Moldflow software to improve and fine-tune the material testing and plastic-part simulation in order to predict accurate shrinkage values to eliminate the guesswork and make more-educated decisions before ordering tools. This session features Moldflow Insight and Moldflow.
Weld lines can have negatively affect the part performance as well as the aesthetics. In this class we will discuss new developments around weld line strength prediction, and show a case study about how to improve a weld line formation after holes by using a differential of local thickness. The area around hole was split in 5 zones or thickness parameters. The maximum of change was 0.5mm. The thickness change was made in Dual domain mesh and after is generate 3D mesh. The weld line was evaluate by how many edge elements was count in “Weld Line” result.<br/><br/>The methodology was used consist in automatic workflow using 3 main programs: ANSA is a pre-processor and responsible for change of thickness in DD mesh and export model for Autodesk Moldflow Insight; this one, by command line, is going to do 3D mesh and set up and run a fill analysis; Isight is an optimization program that will control all process and to do a DOE for measuring a sensibility of thickness around the featur.
The metal injection molding (MIM) process is a combined one of the injection molding and powder metallurgy, and it is used to manufacture complex metallic parts. Now Moldflow Insight software can simulate the MIM process and predict different common defects from the MIM process, such as weld lines, air traps, and "black lines" caused by the powder segregation. The Moldflow Research and Development Team has teamed with AAC Technologies (the world's leading comprehensive microcomponent technology provider) to simulate this process. This class will introduce the basic theory, challenges, and actual cases to show the MIM feature in Moldflow Insight software. Finally, an excellent correlation was achieved with validation data provided by AAC. This session features Moldflow Insight.
What do you do when your Autodesk Moldflow results do not match reality? Learn how to troubleshoot correlation issues and fine tune simulation approaches to improve accuracy. Learn how important it can be to integrate the process into the part design. In this presentation we will present two case studies that highlight “the pursuit of accuracy” and representing the actual molding process. The first case study relates to a Polycarbonate application with a hot runner system that had a pressure correlation issue. We will explore the use of the D3 viscosity coefficient and hot runner modeling techniques. The second case study highlights how cooling with a two shot mold application can improve accuracy and be used for part design consideration (integrating the intended manufacturing process with the part design criteria). Both case studies will help provide insight into how to troubleshoot correlation issues and fine tune simulation approaches.
To archive the lightweight and optimization design for Automotive component, the advance material will be used, so the fiber orientation, the residual stress, weld line location and warpage are very important for the design improve, also the Co-Simulation (Moldflow Insight + Helius PFA + ABAQUS) is used to evaluate the strength and remove the weakness in potential. This will greatly reduce the demand for the high cost of physical prototype testing.
This class will detail how Moldflow Insight software was used to evaluate and optimize conformal cooling designs within 3D-printed injection mold tooling. Three sets of 3D-printed tooling were manufactured using an ultraviolet-curable photopolymer via PolyJet printing. One set of tooling was cooled via cooling channels in the steel mold base; the second set was cooled via straight cooling channels in the mold inserts; and the last set was cooled via conformal cooling channels in the mold inserts. Moldflow simulations were performed to investigate the temperature gradients within the inserts, which were correlated with measured temperatures taken during molding trials. Results showed lower, more-uniform surface temperatures for the inserts with conformal channels. Optimal conformal cooling designs were then evaluated via Moldflow simulations, showing that further improvements are possible as the capabilities of 3D-printed technology continues to advance. This session features Moldflow Insight.
Resin transfer molding (RTM) is a relatively established technique for manufacturing continuous fiber composites. As lightweighting initiatives continue in automotive, new techniques for RTM are being established to reduce cycle time. Join the Moldflow and OCTO Teams for a discussion and demonstration of the RTM capabilities within Moldflow software, including forming simulations to acquire fiber orientations for the flow simulation in Moldflow software. This session features Moldflow and TruPlan.
The fiber orientation as a result of the injection molding process have a high impact on the mechanical behavior that the manufactured product will have. Using different material models will help in understanding the latest improvements on the fiber oreination prediction, and considerations that are needed in order to have a better performance. By having the link between rheology and structural simulations, the material properties can be related with the fiber orientation in order to have a mechanical model that can be closer to reality. Autodesk Helius makes this link and helps in bringing the reality to simulation.
In this session, you’ll have the opportunity to take the Moldflow Associate and Moldflow Professional level certifications. You will also have the opportunity to discuss your use of Moldflow software with expert Moldflow software trainers. Exams will be held Monday, November 14, in room San Polo 3405, Level 3, from 8 a.m. to 5 p.m.
This presentation will show an example of validating the results of a Moldflow Plastic Insight warpage simulation. The topics covered will include material characterization, process setup, model accuracy, mold cavity pressure instrumentation, part shrinkage/warpage, and molded part laser scanning. An actual production mold will be used to conduct this validation study. THe mold has been instrumented with cavity pressure sensors. The molded parts have been scanned with a laser and will be compared with the results obtained from the shrinkage/warpage analysis.
Last year we explored different approaches to injection molding simulations with Simulation Moldflow Insight software. This year we will dive into approaches to measuring warpage results. We have given individual users a problem to solve using Simulation Moldflow Insight software. We will present their approaches, and then we will compare and contrast the different approaches. Analyisto e analyisto, it’s a showdown you don’t want to miss. Let’s get ready to rumble! This session features Moldflow Insight.