on 11/06/2018

 

COMPANY CATEGORY
SPECIAL PRIZE WINNER

Project Name: 2K-ICM Simulation Framework to Enable Design Optimization for Surface Aesthetics


Company: SABIC Research & Technology Pvt. Ltd. – Bangalore, INDIA
By Raghavendra Janiwarad, Bhaskar Patham

Summary

Two-shot Injection-Compression molding (2K-ICM) has immense potential to realize single-part solutions for large and complex components with high surface areas. The development of aesthetic defects like sink marks in 2K-ICM is governed by a complex interplay of several factors. The objectives were to demonstrate a simulation framework for 2K-ICM by leveraging Moldex3D to capture the key aspects of the process for a model-ribbed geometry and investigate the geometrical and processing factors underlying the development of sink marks. A fully validated simulation enabled quicker adoption of this technology by minimizing or eliminating the trial-and-error process associated with machine and grade selection, mold design, and optimization of processing parameters.

Challenges

  • Lack of full understanding for 2K-ICM
  • Complicated design and process guidelines for 2K-ICM
  • Sink marks

Solutions

Moldex3D helped to develop a fully validated simulation framework for 2K-ICM. Thermal history of the first shot was interlinked with the second shot in ICM via Multi-Component Molding (MCM) module. The simulation captured several complex phenomena, such as local variations in thermal gradients, the interfacial temperature changes, re-melting of the first shot, the differential cooling and shrinkage between the two shots at the interface, and volumetric shrinkage governed by geometrical design aspects (e.g. rib thickness). These helped to conclude how both processing aspects and part design, specifically ribs molded in the first shot, impacted the development of surface defects in large parts molded by 2K-ICM.

Benefits

  • Competency development in complex 2K-shot molding process by considering the thermal history of the first shot
  • Minimized or eliminated the experimental trial and error approach
  • Optimized part design for better manufacturability
  • Minimized complicated molding process and tooling cost in the design phase
  • Enabled proper machine selection, faster time to market, and evaluation on part design complexity
  • Reduced overall product cycle time
  • Enhanced credibility/confidence in the simulation results and capability to suggest better solutions to customers

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