This document summarizes Plast-Pro Solutions' Moldflow CAE and design services. It outlines their resources including dedicated Moldflow analysis engineers and commercial Moldflow licenses. It describes Moldflow capabilities like gate optimization and various analysis types. The Moldflow analysis process and developed methodologies are explained. Design services including CAD support are also listed. Finally, two case studies are summarized showing how Moldflow analysis helped solve issues and improve parts.

1. PLAST-PRO SOLUTIONS
Solutions for Quality Plastic Products
PRO-activePRO-venPRO-fessionalPRO-ductive
moldflow@shriramplast.com
Moldflow CAE & Design Services
Presentation

2. Introduction and Setup
Moldflow Legal license details
Moldflow CAE capabilities
Moldflow Analysis Process
Methodologies Developed
 Design services and resource support
Case Studies

3. We Plast-Pro solutions are very focused service provider in plastic Product
designing & process validation with 15+ years of experience in manufacturing and
simulation engineering for automotive, appliances & commodity field.
SETUP
Resources:- We have dedicated 3 Moldflow analysis engineers,1 meshing engineer
& 3 CAD design engineers.
Software:- Autodesk Moldflow Insight 2016/2017 Commercial Moldflow license.
Work Stations:- 4 HP (16GB RAM, 4 Core) workstation,
2 DELL Precision (64 GB RAM, 8 core) Workstation
Data Transfer:- Private FTP & mail server
Introduction

4. Moldflow License Details

5. Plastic Flow Simulation
Gate location optimization
Cavity fill / Runner balancing
Valve gate sequence optimization
Mold cooling Analysis & Optimization
Post Molding Warpage simulation.
Gas Assist Injection Simulation.
2k Injection Molding analysis
Insert & Overmolding simulation
Gas Coring
Moldflow CAE Capabilities

6. RFQ
• Analysis request sheet
•CAD Model
•Discussion
•Finalization to receive PO
INPUT
•Filled Moldflow input sheet
•Final Part CAD data
•Plastic Material Details / UDB
• Mold Design 3D data
PRE
PROCESSING
•Model cleanup
•Mesh preparation
•Mesh quality checkup
•Define boundary conditions
ANALYSIS
•Gate location optimization
•Molding parameters optimization
•Complete analysis sequence
•Specific analysis sequence
POST
PROCESSING
•Analysis results interpretations.
•Proposal report s for discussion
•Product design improvement
suggestions
•Detailed reports with MFR files
CORRELATION
STUDY
•Trial attain to verify parameters
•Correlation study with actual results
•Re- analysis with actual parameters
•Detailed correlation report .
Moldflow Analysis Process
(OPTIONAL)

7. Methodologies Developed
Filling & Packing Analysis
Guidelines
• Mesh Model selection &
approach according to
objective
• Pressure , temperature, time
criterions w.r.t. material family.
• Boundry conditions devloped
to minimze the Gap between
actual and simulation.
Runner Balancing
Methodology For Multi
cavity Molds
• Specific approach developed
for Runner balancing to get
maximum close results at
practical.
• All Runner balancing validation
through actual 3D core cavity
meshing and analysis to get
95% confidence.
Mold Cooling Analysis
Methodologies
• PRE – Mold design cooling
analysis methodology to give
inputs for efficient cooling
channel design before start of
Mold design activity.
• POST-Mold design cooling
analysis approach to highlight
the issues in part cooling and
respective suggestions to
reduce cycle time quality
issues in parts.

8. Providing CATIA designers onsite from 1 to 3 years experience.
 Product designing from concept to tooling.
 Tooling feasibility study support .
 Reverse engineering.
 Plastic mold designing support.
Design services and support

9. Design services and support
Basic Tasks :
2D to 3D file conversion
CAD build as per specified presentations
A surface analysis for given texture
Reverse Engineering
Part Thickness Analysis Report
Advanced Tasks :
Concepts and proposal design
Tooling Feasibility Report
Tooling Feasibility with Proposals on problems
Master Sections Building
RPS and Fixation Proposals
Design for Manufacturing studies
Product re-engineering
Conversion of different material parts into plastic parts
Product detailing
Assembly design
DMU Analysis

10. Moldflow Case Study
Part - Battery cover parts
Material – ABS
Mold – Family Mold of 4 parts
Target-
Balance filling above 90%
Minimum filling Pressure
Part surface without visual marks
Challenges:
Big v/s Small part volume ratio is 1:100
Maximum wall thickness is 2.6mm
Minimum wall thickness of 1.1mm
Simulation 80% Actual 80%
Observation:
Default mesh model and analysis not
helped to get desired results correlation.
Specific approach required to optimize.

11. Part – Transparent Cover
Material – PMMA
Mold – Single gate cold runner
Target-
Solve Problem of sink, flow marks.
Reduce required clamp force.
Reduce scrap rate in trials.
Challenges:
Mold developed without analysis.
Cold sprue with gate , No hot runner
Very less scope to play for gate location
Existing with Issues Improved after analysis
Observation:
Balance filling is very important. Able to
solve sink, Flow mark issues. Clamping
reduced from 650T to 500T.
Moldflow Case Study

12. Our current customers :

13. Thank You