CAE software | product development
Simulation using CAE software delivers many advantages in part design and process set-up for injection moulders but must be used early for maximum gain, writes Mark Holmes
Simulation rewards moulders
Plastic injection moulding is not a simple process. The complex combination of shear dependent materials and a process that involves many time, temperature and pressure variables makes it diffi cult to predict whether or not a mould will work optimally. CAE (computer- aided engineering) software has been developed to provide plastic moulders and part designers with a window into the process, providing an integrated tool that allows the processing of injection moulded parts to be simulated at the design stage to predict exactly how plastic will fl ow in the mould and to identify and eliminate features that might compromise performance or cycle time. According to Mark Fischer, Director PTC Creo
Product Management, there are a number of new technologies driving developments in CAE software today, with cloud computing prime among them. “Cloud computing is now helping the user fi nd the best design for moulding. Variables can include gate location, melt temperature and mould temperature, and it may take lots of runs to fi nd the best solution. Each simulation takes time and cloud computing is a nice solution. The user can set up various conditions and run them remotely. The design job can be continued and then the results analysed when they are completed,” he says. “In addition, IoT (Internet of Things) applications are permitting new connections between the digital and physical worlds, for example in intelligent manufactur- ing systems. New software solutions are also being
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used to reduce the amount of plastics material being used through lightweight design,” Fischer says. With the development of Creo 3.0, PTC has forged a
partnership with Moldex3D to integrate the latter’s mould analysis product into its PTC Creo software (the new addition is marketed as Creo Mold Analysis). Moldex3D is claimed to be able to simulate a wide application range of injection moulding processes to optimise product design and manufacturability, shorten time-to-market, and maximise product return on investment. “Our focus is to help designers and engineers
analyse their design early and often during the design process, explains Fischer. “Having access to Creo Mold Analysis, users are able to determine the feasibility of a design by performing a 3D thickness check to analyse the model’s geometry and fi x basic issues before handing off to a mould design expert. Through our partnership, if the user needs more capabilities in this area the full solution can be acquired directly from Moldex3D. In the future, the integrated solution will be enhanced to encompass a broader set of capabilities. Creo Mold Analysis allows easy identifi cation of potential fi lling problems. It is also possible to fi nd the best solution to reduce the cycle time and cost by running multiple analysis studies.” PTC Creo says that the new software can be fully
integrated with Creo Mold Design, which permits design features such as runner and cooling channels to be
January/February 2016 | INJECTION WORLD 43
Main image: BASF says its proprietary Ultrasim
software, used here to model an automotive seat shell, fi lls the gap
between fi ll simulation and full structural analysis
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