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PLAST-PRO SOLUTIONSSolutions for Quality Plastic Products
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Moldflow CAE & Design Services Presentation
Date:- May 2015
Introduction and Setup
Moldflow Legal license details
Moldflow CAE capabilities
Moldflow Analysis Process
Methodologies Developed
Design services and resource support
Case Studies
We Plast-Pro solutions are very focused service provider in plastic Product designing & process validation with 15+ years of experience in manufacturing and simulation engineering for automotive, appliances & commodity field.
SETUPResources:- We have dedicated 3 Moldflow analysis engineers,1 meshing engineer
& 3 CAD design engineers.
Software:- Autodesk Moldflow Insight 2016/2017 Commercial Moldflow license.
Work Stations:- 4 HP (16GB RAM, 4 Core) workstation, 2 DELL Precision (64 GB RAM, 8 core) Workstation
Data Transfer:- Private FTP & mail server
Introduction
Moldflow License Details
Plastic Flow Simulation
Gate location optimization
Cavity fill / Runner balancing
Valve gate sequence optimization
Mold cooling Analysis & Optimization
Post Molding Warpage simulation.
Gas Assist Injection Simulation.
2k Injection Molding analysis
Insert & Overmolding simulationGas Coring
Moldflow CAE Capabilities
RFQ
• Analysis request sheet• CAD Model• Discussion• Finalization to receive PO
INPUT
• Filled Moldflow input sheet• Final Part CAD data• Plastic Material Details / UDB• Mold Design 3D data
PRE PROCESSING
• Model cleanup• Mesh preparation • Mesh quality checkup• Define boundary conditions
ANALYSIS
• Gate location optimization• Molding parameters optimization• Complete analysis sequence• Specific analysis sequence
POST PROCESSING
• Analysis results interpretations.• Proposal report s for discussion• Product design improvement
suggestions• Detailed reports with MFR files
CORRELATION STUDY
• Trial attain to verify parameters• Correlation study with actual results• Re- analysis with actual parameters• Detailed correlation report .
Moldflow Analysis Process
(OPTIONAL)
Methodologies Developed
Filling & Packing Analysis Guidelines
• Mesh Model selection & approach according to objective
• Pressure , temperature, time criterions w.r.t. material family.
• Boundry conditions developed to minimize the Gap between actual and simulation.
Runner Balancing Methodology For Multi cavity Molds
• Specific approach developed for Runner balancing to get maximum close results at practical.
• All Runner balancing validation through actual 3D core cavity meshing and analysis to get 95% confidence.
Mold Cooling Analysis Methodologies
• PRE – Mold design cooling analysis methodology to give inputs for efficient cooling channel design before start of Mold design activity.
• POST-Mold design cooling analysis approach to highlight the issues in part cooling and respective suggestions to reduce cycle time quality issues in parts.
Providing CATIA designers onsite from 1 to 3 years experience.
Product designing from concept to tooling.
Tooling feasibility study support .
Reverse engineering.
Plastic mold designing support.
Design services and support
Moldflow Case Study
Part - Battery cover parts Material – ABSMold – Family Mold of 4 parts
Target-Balance filling above 90%Minimum filling Pressure Part surface without visual marks
Challenges:Big v/s Small part volume ratio is 1:100Maximum wall thickness is 2.6mmMinimum wall thickness of 1.1mm
Simulation 80% Actual 80%
Observation:Default mesh model and analysis not helped to get desired results correlation.Specific approach required to optimize.
Part – Transparent Cover Material – PMMAMold – Single gate cold runner
Target-Solve Problem of sink, flow marks.Reduce required clamp force.Reduce scrap rate in trials.
Challenges:Mold developed without analysis.Cold sprue with gate , No hot runnerVery less scope to play for gate location
Existing with Issues Improved after analysis
Observation:Balance filling is very important. Able to solve sink, Flow mark issues. Clamping reduced from 650T to 500T.
Moldflow Case Study
Our current customers :
Thank You