1. Ritz Chang1, Eric Hsueh 2 , Hank Liao1, Stephen Chung1 , Venny Yang1
and Srikar Vallury1
Moldex3D for Effective Design Validation, Optimization of
Plastic Parts and Molds, and Cooperation with
HyperStudy and Radioss/OptiStruct
1CoreTech System (Moldex3D), 2 Flotrend Corporation

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> Moldex3D Overview
> Moldex3D Expert – DOE Analysis
> Integration of Moldex3D and HyperStudy
> Integration of Moldex3D with OptiStruct and RADIOSS
Outline

3. Moldex3D Overview

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> The world’s leading innovator of professional true 3D CAE
software for injection molding simulation
> World’s largest professional team (250 employees, 80%
technical professionals ) dedicated to plastics injection
molding simulation
> Provide leading software solution and attentive technical
support to work with global customers for optimizing the
process from design through manufacturing
> Assist users to significantly reduce product development
time, achieve design excellence, and shorten time to
market
Moldex3D - MOLDING INNOVATION

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> Moldex3D employs the leading theories of polymer
physics, fluid dynamics and material mechanics to
simulate injection molding process and product quality
> Digitally validate and optimize the product and mold
design upfront for producing quality parts efficiently and
effectively
> Identify the root causes of quality blemishes scientifically,
replace the time-consuming trial-and-error approach
What’s Moldex3D for?
Iteration

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> Aesthetics and Dimensional Concerns
– Weld line, air trap, flow mark
– Flow balance and part weight
– Shrinkage and warpage control
– Fiber orientation
> Being More Competitive
– Cycle time reduction by removing
hot & cold spots
– Mold structure optimization
– Reduce mold trial & tooling cost
> Reaching Lean Production
– Injection conditions optimization
– Clamping force reduction
– Machine selection
How Moldex3D Can Help?
6

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> Adopted by 1,800+ renowned companies and industries to prove its
capabilities of bringing quality solutions:
Moldex3D Reference Customers
Automobile High Tech/Electronics Material/Equipment

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APA Available Modules – What’s New
RADIOSS
FEA Interface
Moldex3D
Molding Analysis

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Integration of Moldex3D with
HyperWorks
3.Output Response 1
(Total Displacement)
7.Optimal process condition with
minimal displacement/stress
4. Export fem file with
Moldex3D FEA Interface
6.Output Response 2
(Max Stress)
2.DOE setup in HyperStudy;
Perform a series of injection
molding analysis
5.Set up boundary conditions for
structural analysis
HyperMesh
HyperMorph
OptiStruct
1.Multiple Choice on
Pre-processing tools

10. Moldex3D Expert
DOE Analysis

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What is Moldex3D Expert
> Moldex3D Expert Module equips with Design of Experiment
(DOE) method to assist designers to determine appropriate
injection molding condition
> Optimization application
– Dimension of runner, gate position, and optimal process
condition etc.
– Providing 15 Taguchi orthogonal arrays up to L54

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Advantage – Diversity of Design Factors
Various control factors
1. Manufacture parameters (Process)
2. Material
3. Designs of runner and gate (Mesh)
4. Part Design (Mesh)
Various quality factors
1. Experimentally measurable factors:
Deformation, sink mark, etc.
2. Non-experimentally measurable factor:
Volume shrinkage, internal pressure, etc

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Advantage – Various Statistic Results
Quality Response of each factor
S/N Response of each factor
Quality Response of each run
Sensitivity analysis

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Case study – Geometric Accuracy for Fisheye Lens
63.5 mm
17.5mm
2.8 mm
Fisheye lens Cooling channel
Runner
Cavity

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Case Study – Step up of DOE
> Step 1 : select DOE module in expert run
> Step 2 : specify a quality factor
> Step 3 : specify control factors and corresponding levels
> Step 4 : assign Taguchi orthogonal array
Parameters of ODE
Level 1 Level 2 Level 3
A Filling time 1 s 2 s 4 s
B Melt temperature 225 235 245
C Packing pressure 60 80 100
D Mold temperature 110 120 130
1 2 3 4
Filling time, melt temperature, packing pressure, and
mold temperature are chosen as control factors
Quality factor:
smaller line shrinkage along
the center axis

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Case Study – Analysis Result
> From the results of S/N ratio, the following information
can be obtained.
– Best combination : A3 B1 C3 D2
– Most sensitive factor: Packing pressure
– The effect of filling time and mold temperature are minor.
Filling time Melt temperature
Packing pressure
Mold temperature

17. Integration of Moldex3D and
HyperStudy

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Moldex3D-HyperStudy Integration
> Step1: Create a preliminary run in
Moldex3D
> Step2: Prepare Batch and Scrip file
> Step3: Set up a Study for Moldex3D
Molding Analysis on HyperStudy
> Step4: Set up a DOE analysis in
HyperStudy
> Step5: Validate the optimized result
in Moldex3D, or in other FEA
product (FEA Interface)
Step1, 2
Step3
Step4
Step5

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Prepare Batch and Script File
> A preliminary run for target project
> Batch: *.bat generated using any note pad tools
> Script: *.msp generated using Moldex3D Script Wizard
Run Moldex3D
Moldex3D Script file
Project file path for analysis
Script file path
Batch file

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DOE Study: Select Design Variables
Choose Filling Time, Injection pressure
and Packing Time as design variables.

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> Select response factor from *.mer file which create by
Moldex3D
DOE Study: Select Response
Response Factor: Total Displacement
2. Open *.mer file and
select response factor
1. Click “Extracts”
3. Import
Expression

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DOE Study: Specification and Run Task
Choose the DOE model
Define design variable array
Optimized design factors

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Optimized Result
Variables Initial Results DOE Results
Design Variables
Filling Time (sec) 2 2.3
Melt Temperature (˚C) 230 220
Mold Temperature (˚C) 70 65
Packing Pressure Profile( %) 75 80
Response Variable SD for Total Displacement (mm) 0.354 0.262
Warpage Improvement
{[0.354-(Other results)]/0.354}*100%
0% 26%
Initial results DOE results
Upper and lower limit values fixed to initial results

24. Integration of Moldex3D with
OptiStruct and RADIOSS

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Workflow of Moldex3D and HyperWorks
OptiStruct
• Topology Optimization
HyperMesh
• Supports CAD geometry and existing finite element models
• Build and Optimize meshes from a set of quality criteria
HyperStudy
• Manage DOE optimization workflow, and design variables
• Call Moldex3D, write input and record output of analysis
Moldex3D
• Perform a series of injection FRM molding analysis
• Export fem file with Moldex3D FEA Interface to RADIOSS
RADIOSS
• Non-linear Structural analysis

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> Model
– Use: Engine bracket
– Dimension: 62 x 187 x 110 mm
> Material
– PA6_Durethan BG30XH20 (GF 30%)
> Platform
– Moldex3D & HyperWorks 13.0
> Goal
– To find process conditions which minimize warpage for
fiber-reinforced plastics parts
– To find the optimized geometry within allowable stress
Case Study
Moldex3D
RADIOSS

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Topology Optimization with Optistruct
> Original model imported in OptiStruct

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Topology Optimization with Optistruct
> Result of Topology Optimization

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HyperMesh
> Develop Solid mesh with optimized geometry and quality
criteria

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> DOE Class:
– 16-run Fractional Factorial
> Initial Design Variables
– Filling Time: 6.27 sec
– Injection Pressure: 155 MPa
– Packing Time: 20 sec
> Design Variables
– Number of Variables: 3
– Filling Time: 5-10 sec (16 levels)
– Injection Pressure: 50-200 MPa(16 levels)
– Packing Time: 10-30 sec (16 levels)
> Response Variable
– Total Displacement (Moldex3D)
Molding Process Optimization through
Moldex3D and HyperStudy by DOE

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DOE Study: Optimization Output
Initial run
DOE run
Optimized Response

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> DOE analysis is performed by
HyperStudty cooperating with
Moldex3D
> Optimal process condition as
result to reduce part deformation
during injection molding
DOE Optimal Results
Variables Initial Results DOE Results
Design Variables
Filling Time (sec) 6.27 6.9
Injection Pressure (MPa) 155 170
Packing Time(sec) 20 22
Response Value Total Displacement 2.331 2.250 3.4%

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Structural Analysis for Fiber-reinforced
product
> Traditional structural analysis
– Assume isotropic materials.
– Neglects molding effects,
– Results not reflect real situation.
> Moldex3D FEA interface + RADIOSS
– Provide the following material information
to non-linear stress solver:
• Stiffness matrix
• Thermal expansion coefficient
• Density

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Export FEM file to RADIOSS
Through Moldex3D FEA Interface,
Export fem file for RADIOSS Set B.C. in RADIOSS:
Initial Strain + External force + Constraints
NOTE:
Initial strain output from FEA interface has
considered fiber-induced anisotropic
mechanical properties.

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Structural analysis with Radioss
> Validation with Max. displacement result
> The weight decreased by 15% with acceptable deformation
Original Design Modified Design
Max. displacement= 0.166 mm
Max. displacement= 0.190 mm

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Structural analysis with Radioss
> Validation with Max. von Mises stress result
> Evaluate the structure strength
Max. von Mises stress = 14.2 MPa
Max. von Mises stress = 20.7 MPa
Original Design Modified Design

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Conclusion
> OptiStruct helps to rapidly develop lightweight, structurally
efficient designs by creating innovative concepts
> By iteration between Moldex3D and HyperStudy, Optimal
process condition for fiber-reinforced product can be obtained
> Simulation results from Moldex3D for the optimum process
conditions can be analyzed
> Moldex3D FEA Interface provides material information
considering fiber-induced anisotropic properties, while
RADIOSS use this to perform non-linear FEA
> Moldex3D, along with HyperWorks, helps find potential
problems, provide optimized solutions and make competitive
products