PLAST-PRO SOLUTIONSSolutions for Quality Plastic Products

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Moldflow CAE & Design Services Presentation

Date:- May 2015

Introduction and Setup

Moldflow Legal license details

Moldflow CAE capabilities

Moldflow Analysis Process

Methodologies Developed

Design services and resource support

Case Studies

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.

SETUPResources:- 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

Moldflow License Details

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 simulationGas Coring

Moldflow CAE Capabilities

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)

Methodologies Developed

Filling & Packing Analysis Guidelines

• Mesh Model selection & approach according to objective

• Pressure , temperature, time criterions w.r.t. material family.

• Boundry conditions developed to minimize 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.

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

Moldflow Case Study

Part - Battery cover parts Material – ABSMold – 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 1:100Maximum wall thickness is 2.6mmMinimum 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.

Part – Transparent Cover Material – PMMAMold – 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 runnerVery 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

Our current customers :

Thank You