CAE Injection molding analyses

Analysis of an injection molding cycle

We use pre- and post-procesor Moldflow Synergy for analysis. Synergy contains a very efficient generator of a Midplane mesh, DualDomain and volumetric tetrahedral mesh and a sofisticated editor final element mesh.

CAD data can be imported from all common CAD systems, parts as well as assemblies. Unique database of 10 000+ polymers and grades.

Simulations are done in Autodesk Moldflow Insight Ultimate.

Simulation analysis of the cycle shows:

• Locations of melt flow slow down in the cavity
• Weld lines and their effect on quality
• Shear stress of the melt and risk of degradation
• Air traps and trapped air back pressure, air hooks
• Potential void locations
• Pressure at the cavity entrance, pressure field during the cycle
• Clamping force of the injection machine
• Melt flow front temperature, temperature field of the part during the cycle, temperature field of the mold during the cycle
• Weight of the part
• Orientation and anisotropy of strength of the part made of fiber-filled plastics
• Longitudinal and transverse shrinkage of plastics with CRIMS data measured
• Warpage of the part after ejection from cavity and warpage causes

Simulation of processes

Besides standard injection molding of thermoplastics we simulate

• Metal and plastic insert overmolding
• In-mold labeling, in-mold lamination
• 2K and 3K injection molding
• Rapid mold heating and cooling using water, steam, heating cartridge, induction heating
• Conformal cooling
• Gas-assisted injection molding (GIT)
• Microcellular injection molding with and without core back
• Injection with a chemical blowing agent (CBA)
• Injection-compression molding with packing by mold or core back
• Co-injection molding
• Bi-injection molding
• Powder injection molding
• Compression molding
• Rubber, liquid silicone injection molding
• Resin transfer (RTM) and structural reaction injection molding (SRIM)
• Reaction injection molding