Happy New Year 2013! The long-awaited Moldex3D R12 will be released soon. We would like to start with some impressive new simulation analysis functions through the two successive issues in January and February to keep you abreast of the latest “Molding Innovations”.
Stay Agile with Model Creation
Since 2007, Moldex3D Designer has been known to provide eDesign users with revolutionized auto-meshing features and powerful runner/gate wizards. It helps reduce the meshing time from a couple of days down to only a few minutes. Currently, it is widely used by almost every Moldex3D users for design validation and optimization. In R12, we have further extended its meshing capabilities to offer a very intuitive Boundary Layer Mesh (BLM) Generation tool; BLM is widely used by advanced Moldex3D users to perform Solid analysis for investigating the drastic changes of temperature and velocity near the cavity wall during the filling process. Through BLM, complex problems such as viscous heating, runner imbalance and warpage can be easily observed and improved. R12 enables the easy-to-use and powerful pre-processing tool to benefit users who need to prepare BLM for advanced analyses.
In addition, as products have become more complex and multi-functional, mold designers are challenged to find ways to fit runners along with cooling channels, sliders, and pins into limited space; however, typical circular-shaped straight runners usually have to adapt their shapes to avoid above stated components. Moldex3D Designer now provides more options for mold designers to build true 3D runners and gates; whether it is the cross section of runners, gate types, or even the sprue snatch pins. In addition, all geometrical features are now customizable without making additional changes on runner shapes and layouts and can more accurately predict problems such as flow imbalance, viscous heating or even stagnation.
Empower Dynamic Process Capabilities Based on Manufacturing Needs
Different manufacturing needs demand different processes optimization capabilities. Moldex3D R12 addresses these needs with the launch of Compression Molding and Bi-injection modules.
Followed by the injection molding and the injection-compression molding simulation techniques, Moldex3D now introduces the Compression Molding simulation in R12. With the Compression Molding technology, the shape of the charge, the compression zone, the compression surface and the direction can be built easily and defined based on the original cavity mesh. Moldex3D Compression Molding can provide simulations of fiber-filled materials and thermosetting materials; the fiber orientation caused by the squeeze flow can also be predicted. Before molding, valuable information such as the required tonnage to ensure filling, required material amount without short-shot, and the minimum time required to heat the material can all be simulated in advance for better production efficiency and enhanced processability.
The Bi-injection module allows manufacturers to designate a second melt entrance and its respective material and processing condition. Bi-injection molding simulation is realized by calculating the two melt front advancements at the same time. Users can edit the entrance time and flow rate profile to suit their needs. With the features stated above, users no longer need to guess the potential weld line locations and the distribution of the two materials out of thin air. We also provide more in-depth details of setting up two melt entrances in our Tips and Tricks section.
Strengthen Prediction and Optimization Capabilities through Enhancements
Moldex3D Venting analysis now provides trapped air temperature and pressure results to help users maintain mechanical strength; this will be very helpful, especially when venting will affect the quality of the weld line. Using the Venting analysis, the melt qualities at the end of filling can also be predicted based on the pressure of the trapped gas and the temperature. Elevated melt and gas temperature help to improve molecular penetration near the weld line. On the other hand, the burn mark problem induced by the excessive temperature rising from compressing the trapped air can also be prevented.
Except for the orientation of short/long fibers, the fiber breakage is another important issue when using fibrous materials. Based on the stress acting on the fiber during filling, the fiber may bend and even break resulting in a shorter fiber length. The prediction of this commonly observed phenomenon is now available in Moldex3D R12. Part designers can predict and resolve problems such as high shear stress inside the cavity or near the gates which will cause fiber breakage.
The unrivaled simulation capabilities of Moldex3D cover the full injection molding process till the part is ejected. The stress calculation in Moldex3D R12 is now extended to the post-molding annealing process. The thermal residual stress inside the molded parts can be released to prevent further deformation and stress cracking. Moldex3D R12 can simulate the increased displacement and decreased residual stress. This provides a powerful tool to determine processing condition based on the possible annealing method. The process settings for reflowed connectors and high-standard medical devices can benefit a lot from the Annealing Process analysis.
Explore a More Intuitive and Interactive Interface
Moldex3D Online Help now covers the entire simulation process, ranging from the process conditions and computational settings to the material and the result interpretation. The embedded help tool also provides a detailed guide on the process and computation setting in the Process Wizard along with the definition of terms related to materials in the Material Wizard. If you need more assistance for the interpretation of the analysis, simply press F1 while viewing results and the help window will immediately pop out to help you better understand the simulation concepts.
Support user-defined report format
Moldex3D Report Wizard now allows “fully” customizable reports. You can choose the information you want to see, edit the PPT template, and change the angle for viewing models in each result.
Always Stay Ahead with Enhanced Speed
With the algorithm enhancement, Moldex3D R12 now allows up to 80% increase in the speed of filling analysis. The computing time of a model with one million elements will be shortened significantly by decreasing nearly 50%. Along with the exclusive multi-core/multi-CPU/multi-PC parallel computing technique, which helps CAE engineers ease the burden of processing huge simulation models on a single computer by scheduling and assigning the jobs to multiple remote computing farms, Moldex3D enables users to create better plastic parts without having to worry about failing to meet time-to-market.For further information on Moldex3D software, please contact us.
*Note: The computing enhancement on the filling analysis is only applicable for BLM or eDesign Mesh Level 5.
For more sneak peeks of Moldex3D R12, keep an eye out for the upcoming February issue of Molding Innovation.