Everything About Injection Molding Simulation

by Ashish Tools Mould Manufacturer in india The use of Computer Aided Engineering (CAE) for doing injection molding simulation began in circa 1970s. At the time, the CAE technology was used for flow-front predictions only. Such restriction in the function of the CAE was obvious as technology was not at all sophisticated. Now, however, things have changed as the CAE technology can be used for simulation of an injection molding machine as well as procedure.

The process of simulation

An extensive research is carried out upon a specific combination of material, machine and mold. The researchers reviewed filling patterns, part warpage as well as injection pressures. From the study, it was analysed that the best process requires input and output of an injection molding simulation to agree with their real-life counterparts. At present, the process of injection molding benchmarking has gained a lot of momentum. The method of simulation benchmarking helps in the comparison of actual with predicted parameters.

Why simulation of injection molding is so important

• A lot has been demanded from moldmakers in Injection molding nowadays. The demand is because mold designs require getting changed on a continuous basis. And carrying out changes in an existing mold’s design can really cost a fortune. Such change in existing designs is possible if simulation of injection molding is done.

• The process is cost effective when it is compared with building physical prototypes.  The technique is a boon during initial stage of manufacturing molds.

• Simulating an entire injection molding procedure has Higher Return on Investments (ROIs) when compared to simulating other processes of plastic productions.

• The main objective of simulation has been to gain confidence as well as experience in modeling, simulation capability and material selection. The results of such a simulation are used for designing future designs of molds.

Simulation accuracy

Injection molding simulation’s accuracy can be influenced by many elements. A few of the elements are:-
• Location of weld lines
• Predicting filling patterns
• Hesitation marks

Modeling a wall’s thickness is significant for carrying out changes during the end of a design cycle. Every Mold manufacture in India discourages the use CAD model to design a mold’s simulation; the reason being CAD’s inefficiency to design an accurate mold simulation. 

Also, for ensuring the simulation’s accuracy, it is necessary to predict the pressure that is needed to fill a mold. A detailed modeling of the runner is required for predicting such type of pressures. Along with runner, modeling of gating as well as sprue designs has to be done.

In addition, predicting the ejected, finished product’s final warped shape has to be done for guaranteeing the simulation’s overall accuracy. For such type of prediction, it’s necessary that simulation reflects the actual process (especially packing time, cooling time and packing pressure).

How does a simulation’s accuracy arise?
 
• If material data is inappropriate
• If faulty coding of any mathematical expression or associated boundary condition is done
• If the processing conditions used in simulation designing vary greatly from manufacturing process
Simulation provides the best insight to geometries, processes as well as materials that should be used to improve product design. Thus, it’s necessary to simulate a mold as well as its use in an injection molding process.

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Created on Dec 31st 1969 18:00. Viewed 0 times.

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