NSF/DOE/APC Future of Modeling in Composites Molding Processes Workshop June 9-10, 2004

Sensors, Controls and Automation

Peter KennedyChief Technology Officer

Moldflow Corporation

NSF/DOE/APC Future of Modeling in Composites Molding Processes Workshop June 9-10, 2004

Business of Injection Molding

Part Design Mold Design ProductionMold Build

Multifaceted complex business model & physics

Problems found at process end

Assembly&

Distribution

NSF/DOE/APC Future of Modeling in Composites Molding Processes Workshop June 9-10, 2004

Moldflow Product Families

Design Optimization

Solutions

NSF/DOE/APC Future of Modeling in Composites Molding Processes Workshop June 9-10, 2004

Moldflow Product Families

ManufacturingSolutions

NSF/DOE/APC Future of Modeling in Composites Molding Processes Workshop June 9-10, 2004

Process Optimization and Production Monitoring System

• Systematic process to set up and optimize injection molding machine

• Process monitoring and correction

• Production monitoring of discrete data

• Resource scheduling• SPC & SQC• Web-based reports• ERP integration

NSF/DOE/APC Future of Modeling in Composites Molding Processes Workshop June 9-10, 2004

Systematic Process Set Up and Optimization

• Monitor machine– Pressure sensor

• In-cavity• At barrel• Hydraulic

– Ram Displacement– Machine data

• Set up and Optimize then Monitor– Uses simplified simulation algorithms

NSF/DOE/APC Future of Modeling in Composites Molding Processes Workshop June 9-10, 2004

Opportunities• Apply set up technology to composites

– RTM– Long glass fiber

• Plastication• Gate and mold design

• Develop numerical simulation models for processing and final properties– Use to define control systems for processors

• New Sensors for Composites– e.g. ultrasound, impedance http://www.signaturecontrol.com/)