Cae

Plastic Flow Analysis using CAD/CAE

Univac Precision India pvt ltd Prepared by P.Vijay prasanna

WHAT IS FLOW ANALYSIS ?

Flow analysis is concerned with the behavior of plastics during the mould filling process

WHY DO WE NEED A FLOW ANALYSIS? Since the way in which the plastic flows in to the cavity has a substantial effect on final product performance IT CAN GREATLY REDUCE -

TOOLING LEAD TIMES

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MOULD TRIALS

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COSTLY TOOLING AND

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PRODUCT MODIFICATIONS

Part Designer

Resin Supplier

Part design & Resin supply & Material Compounding Compounding

Process Molder

Optimization

CAE & Shared Design Information

Mold Design

Mold Manufacturing

Mold Maker

An integrated environment

Mold Designer

FLOW ANALYSIS - A USEFUL TOOL

PREDICTING THE IMPACT OF PROCESS CONDITIONS 

 COMPUTING THE OPTIMAL RUNNER SIZE ➽ SIMULATING POST MOLDING DEFECTS

THE MODULES •

MOLDING WINDOW

•

INJETION CANAL GEOMENTRY ,LOCATION

•

FILL ANALYSIS

•

COOLING ANALYSIS

•

PACKING ANALYSIS

• •

SHRINKAGE AND WARPAGE ANALYSIS STRESS ANALYSIS

CAE analysis cycle

Steps in analysis    

Pre-Processing Assign Boundary Conditions Processing Post-Processing

FILLING ANALYSIS 

ESTABLISH THE FILLING PATTERN BY MELT FRONT ADVANCEMENT PLOTS



DETERMINATION OF THE OPTIMUM PROCESSING CONDITIONS



DETERMINATION OF RUNNER AND CAVITY FLOW BALANCE OPTIMIZATION OF INJECTION AND PACKING PROFILES



• •

THE POSITION OF WELD AND MELD LINES AND NATURE OF WELD FINDING OUT THE OPTIMUM WALL THICKNESS OF THE PART

COOLING ANALYSIS 

Cooling time, cooling circuit, connections



Cooling network flow parameters



Effect of mould features such as inserts, Parting planes and Mould external surfaces on Mould cooling

 Effect of part design in Uniformity of cooling of Part and Mould temperature distribution

Effect of Water Flow on Heat Transfer

Analysis of Surface Temperature

One dimensional heat transfer analysis

Two dimensional heat transfers

Coolant temperature : (original cooling lines.)

Computational framework of true 3D molding cooling analysis

in-mold constraint

PACKING ANALYSIS 

To check whether the cavity is fully packed



Prediction of Clamping tonnage required



The volumetric shrinkage of the part



Elimination of the post moulding effects



Position and extent of sink marks

Flow length

• How far the polymer must flow from the polymer injection location.

• Parts with thicker walls have longer flow paths than thin-walled parts as the material will flow more easily in the thicker regions • Parts with larger volumes require more polymer injection locations to fill properly

Important Results from Different Simulation Analysis

Simulation of the filling Simulation of the phase packing phase Filling behaviour Pressure distribution Temperature Distribution

Simulation of the cooling phase

Effectiveness of packingGood estimation of the pressure required cooling time Shrinkage warpage)

(withoutTemperature rise in the coolant liquid

Weld lines

Remaining cooling timeHot spots on the cavity after wall

Air traps

end of pack

Weld Line Locations

Air Trap Locations

The integrated analyses for fiber-reinforced plastic gear via Moldex3D-I2&ansys

The integrated analyses for fiberreinforced plastic gear via Moldex3D