While polyurethane foam (PU foam) has huge market demand and wide application, there are some technical challenges in processing and production. For instance, the location of the foam within the part is not easy to access. Often the part defects such as large voids due to incomplete filling and foaming can only be identified after the mold is made and part is produced. Other factors such as venting locations and conditions also have significant influence on the part quality.
To attain comprehensive and accurate PU foaming prediction, Moldex3D ’s approaches are to combine the model development closely with experiments to better understand the foaming phenomena, to enhance material model and parameters, and to validate the models once they are developed.
In the document “Combination of PU FOAMAT System with CAE Simulation for Accurate PU Foaming Prediction”, Moldex3D’s researcher explains our experimental investigation into PU material properties that are required for an accurate PU simulation. We employed FOAMAT 285, a universal foam qualification system to measure physical parameters during foam formation such as foam rise height, reaction temperature, rise pressure, curing and viscosity. The measured foam physical parameters are then fitted using suitable material models, and used in PU chemical foaming simulation for optimal process conditions during foam formation. Lastly, with Moldex3D’s new simulation feature of polyurethane foaming, we can fully understand the dynamic behavior of the foam polyurethane material in both filling and foaming stage.
To read the complete paper, please click here.
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