BASICS OF MOLD FLOW ANALYSIS FOR PLASTICS.pptx

11/30/2024 Disclosure or duplication without consent is prohibited 1
What is Mold Flow

What is Mold Flow?
Mold flow analysis (MFA) software simulates the flow of plastic, which allows you to elevate part and mold
design to create products of impeccable quality. Like other simulation software, MFA gives you a virtual
sneak peek into how your material of choice will fill the mold's cavities and offers a head's up on potential
problem spots. The benefit is obvious, right? Simulating the process digitally means you can make changes
BEFORE A TOOL IS CUT. This one thing is a big cost savings, not to mention a time saver as well

What is Mold Flow?
Utilizing Moldflow software, there are tremendous benefits, including:
1. Optimize part design
2. Reduce time-to-market
3. Save cost and time on mold tryouts
4. Lower development and production costs
5. Provide a framework to establish reputable processes
6. Improve product quality
7. Decrease cycle times

Mold Fill Analysis
The Mold Fill module uses predictive technology to simulate the filling process. Key
analyses include:
1. Optimize the number, size, and location of gates
2. Balance the runner system design
3. Reduce material stress levels
4. Predict weld line locations
5. Validate pressure and temperature distribution within the mold
6. Optimize processing conditions – including melt temperature, injection rate, and cavity pressure

Mold Pack Analysis
Building on the results of a Mold Fill analysis, the Mold Pack module optimizes the packing phase to ensure
a uniform packing condition. As an indication of part warpage, volumetric shrinkage is evaluated and the
pack pressure profile is optimized. The result is minimized warpage with an improved surface appearance.

Mold Cool Analysis
The Cool Analysis module assesses an existing cooling layout to determine potential molding problems. Steel
types, cooling channel sizes, bubblers, baffles, coolant temperatures, and flow rates are all evaluated. Using
this analysis, the Mold Cool module recommends practical tooling design changes to ensure uniform cooling.
Mold Cool takes into account:
1. Number, location, depth, and pitch of cooling channels
2. Cooling circuit layouts
3. Coolant temperatures and flow rates
4. Cycle times

Warp Analysis
Using the results from the Fill and Cool analyses, the Warp Analysis module enables prediction of plastic part
shrinkage and warpage. Warp Analysis diagnoses the cause(s) of warping and recommends the appropriate
solution, such as gate location changes, design parameter changes, and reduction of wall thickness variations.

MPI 3D
MPI 3D addresses a class of problems previously unsolvable using traditional finite element analysis
techniques. In thick-walled parts, molten plastic can flow in all directions. Using a proven methodology based
on a solid tetrahedral, finite element volume mesh, MPI 3D enables true, three-dimensional simulations on
thick-walled parts.

Inputs for Moldflow

What are the inputs for Mold flows?
 Following are the basic requirements for a Moldflow Analysis:
 Clean IGES of part, exported from a solid model.
 Single part per file. - No assemblies.
 No radii smaller than 0.5 mm. ( Remove all small features before exporting)
 No text, symbols or logos. (Part should be free from radius and text)
 Material details
 Before exporting the part file to IGES, export it into step file and later on export the step file to IGES.
(Surface missing problem will be solved)
 Process Parameters (for existing Molds)
 Mold design (feed system & cooling channels)- for existing mold
 Machine Parameters

Molding Defects which may be detected by Mold flow

Sink Mark

Air Streaks

Air Entrapment

Weld Lines

Voids

Jetting

Burn Marks

Deformation

Dark Spots

Examples

Fill Time – Differences for Feed System Design 1
Filling is not uniform for all cavities.
Cavity A & Cavity B will fill in 2.272 sec
Cavity C & Cavity D will fill in 3.029 sec

Feed System Design 2 (After Runner Balancing)
Zoom View of Gate Position
Sprue:
Start Dia: 3 mm
End Dia: 5.7 mm
Length: 80 mm
Gate:
Start Dia: 0.8 mm
End Dia: Calculate it by angle
Runner (b):
Dia: 3.29 mm
1
3
5
Runner (a):
Dia: 2.19 mm
2
Runner (b):
Dia: 3.40 mm
4,
4a
The mold is having cold feed system of four cavities

Fill Time for Feed System 2
Fill Analysis Results
Fill time is about 1.911 sec.
Red colored region will fill last.

Fill Time – Differences for Feed System Design 2
Fill Analysis Results
Filling for all cavities are uniform. Fill time is 1.911 sec

BASICS OF MOLD FLOW ANALYSIS FOR PLASTICS.pptx

More Related Content

Similar to BASICS OF MOLD FLOW ANALYSIS FOR PLASTICS.pptx

Recently uploaded

BASICS OF MOLD FLOW ANALYSIS FOR PLASTICS.pptx