Fröccsöntés szimuláció

A fröccsöntés szimuláció lehetőséget kínál a szerszámok és a technológia optimalizálására a termék koncepcionális tervezésétől kezdve a szerszámtervezésen át egészen a tömeggyártási folyamatparaméterek finomhangolásáig. A Moldex3D szoftver lehetővé teszi, hogy költséghatékonyan vizsgáljunk különböző eseteket valódi szerszámok és gépek nélkül, segítséget nyújtva a potenciális problémák előrejelzésében és megoldásában, így biztosítva a gyors és hatékony munkavégzést

Product development support

Injection molding simulation provides significant support during product development, ensuring that the concept is directed towards economically manufacturable solutions from the early stages of the project. This approach saves time and costs associated with later design changes.

By applying simulation, we can quickly and cost-effectively answer key questions that arise during product design:

Can the product be filled?
What is the expected cycle time?
Where should the gate location be?
Where are the cooling and cycle time critical hot-spots?

Mold tool development support

Simulation in tool design allows us to determine the fundamental properties of the tool and test various solutions without manufacturing the actual parts.

Through simulation, we can check important parameters that influence the tool, such as:

Checking runner system, cavity balance
Checking gate type, location and cross section
Checking cooling system, efficiency and effect (warpage)
Checking venting

Product troubleshooting / Process optimization

Simulation can help identify the causes of visible defects in products and improve or optimize the existing process.

By using simulation, we can detect and correct manufacturing errors like:

Short shot
Burn mark
Flash
Warpage
Weld lines
Sink mark
etc…

Additionally, it aids in fine-tuning process parameters:

Filling, packing parameters (time, pressure)
Cooling parameters (temperatures, flow rates)

to reduce cycle time and ensure the highest quality and manufacturing efficiency of the final product.

Analysis type

Fill

During the filling analysis, the virtual filling of the specified mold cavity takes place, from which we can obtain a wealth of useful information about the product, the tool, or the injection molding process. By examining the filling pattern of the melt front and the state of individual elements at specific moments, we can define:

with this information, we can refine our product, tool, or process.

Pack

The examination of the packing phase covers the technological interval during which the holding pressure created by the injection molding machine is applied through the injection point. This lasts from the set switch-over point (filling or pressure-controlled) until the gate freezes or the nozzle closes. The entire phase aims to reduce shrinkage and warpage, thereby improving product quality. A critical parameter during the process is determining the appropriate holding pressure time, as both too short and too long holding pressure phases can lead to uneven shrinkage, resulting in warpage.

Cooling

During the cooling analysis, we have the opportunity to examine the entire thermal balance of the injection molding process and its fluctuations, even simulating steady-state operation using transient analysis. This is a very important part of the process, as it usually constitutes the largest portion of the total cycle time, and its uniformity directly affects the quality of the product (warpage). With the help of simulation, we can easily test numerous cooling concepts to find the one that provides the desired results in terms of both efficiency and uniformity. In the case of a final cooling concept, it can assist us in determining the appropriate parameters (temperature, flow rate), thus ensuring that the Reynolds number and the efficiency of the cooling circuit are truly optimal.

Wrap

Warpage is the greatest enemy of the dimensional accuracy and shape fidelity of a product. Since warpage can be caused by multiple factors, which may also depend on each other, it is not easy to determine its exact cause. With warpage simulation, we are able to examine these effects simultaneously or separately, thus gaining an overall picture of the warpage. During the search for a solution, we can also examine individual components one by one. Depending on the nature of the project, we can then work on solving the problem or use the deformed and compensated product files generated by the software to make corrections.