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Mold Analysis Gets Faster, Easier, Smarter.doc

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Mold Analysis Gets Faster, Easier, Smarter.doc

MoldAnalysisGetsFaster,Easier,SmarterOnDec.28,MoldflowCorp.beganshippingamajornewreleaseofitsflagshipinjectionmoldsimulationsoftware.MoldflowPlasticsInsight6.0.MPI6.0isengineeredtoworkmuchfaster,beeasiertouse,andprovidemoreusefulinformationthanbefore.Manyofitsenhancementsaredirectedparticularlyatanalyzingthick,solidpartsorthinpartswithlocalizedthicksectionsusingtheMPI/3Dmodule,whichemploys3Dsolidgeometrymeshelements.SomeofthesenewfeatureswilllaterbeextendedtomoretypicalthinsheUplasticgeometriesthatutUizeconventionalmidplaneanalysisorMoldflowsproprietaryDualDomainsurfacemeshtechnique,suppliedintheMPI/Fusionmodule.MPI6.0alsoenhancesspeedandaccuracyinanalyzingconventionalthinshellpartsforexample,inpredictingfiberorientationinreinforcedparts.Therearealsoimprovedcapabilitiesforanalyzingverythinpartsless1mmwhicharebecomingmorecommon.Andthematerialsdatabasehasbeenexpandedwithhundredsofnewmaterialsandthousandsofupdatestomaterialsproperties.Inrecentmonths,Moldflowalsocameoutwithenhancementstoitssimpier,faster,lowercostMoldflowPlasticsAdvisersMPA,andtoothersoUwareproductsforCADintegration.Faster3analysisMuchfaster3Danalysescomefromanewcoupled3DflowsolverinMPI6.0.TheoldersolverofferedusersachoiceofFastorfullNavierStokescalculations,thelatterbeingslowerbutmoreaccurate.Thenewcoupled3DflowsolvergivesonlyfullNavierStokessolutionsupto800fasterthanbeforeandiseven34fasterthemthepreviousFastanalysis.Anumberofother3DflowimprovementsalsoresultFlowfrontadvancementcanbecalculatedinlaiertimestepstogainspeedwithoutsacrificingaccuracy.Shearheatingcalculationsaresaidtobemoreaccurate,especiallyatpointswhereshearchangesrapidlyalongtheflowpath,suchasnearagateandinflowsaroundcomers.Thenew3DWarpsolvercancalculatewarpageof3Dpartsanaverageof7timesfaster.Additionaltimesavingsareavailablefromthenewabilitytouseacoarsethroughthicknessmeshtosimplifywarpmodels.Thiscanmakecalciilationsupto35timesfaster.Apartfromspeedandaccuracyimprovements,MPI6.0providessomepreviouslyunavailableinformation.Moldflowsaysthisisthefirstsoftwareevertosimulatethegettingphenomenonwhenmeltfirstentersacavity,whichtendstobemoreofaprobleminthickerparts.Thissoftwareadvancecouldbehelpfulindesigningautomotivelenses,wherejettingoftheinitialflowthroughthegatecancausevisibledefects.AlsonewistheabilityofMPI/3Dtopredictpartialremeltingoftheinterfacezoneduringovermoldingofoneplasticwithanother.Thisalertstheusertothepossibilityofsmearingthefirstmaterialintothesecond.Thisresultiscurrentlyavailableonlyfor3Danalyses.Inaddition,MPI/3Dnowcanpredictairtraps.Thisfeaturewaspreviouslyavailableforthinshellmodels,but3Danalysiscanrevealairpocketsdeepwithinpartsaswellasonthesurface.MPI/3DcannowsimulategasassistmuchfasterthroughuseofIDbeamelementsinsteadofsolidelementsinrunnersandoverflowwells.Gasassistsimulationisalreadyavailableforthinshellmodels.MPI6.0alsocanaidshopfloortroubleshootingbyimportingdataonactualmoldingmachinecharacteristics,processsettings,andprocessvariationsfromMoldflowPlasticsXpertMPXorShotscopemonitoringsystems.Thisallowsasimulationtoberunwithreallifeconditions.MPI6.0canalsoexporthotrunnertemperaturesettingsandlayoutstoMoldflowsAltaniumMatrixprocesscontroller,whichdisplaysgraphicdiagramsofthehotrunnersystem.MP1/3Dprovidesnewflexibilitytodisplaythetemperaturedistributionthroughoutanycrosssectionofthemold.Thisprofileofsteeltemperaturescanhelpoptimizecoolingchannellayout.{ThinsheUanalysishasamorelimitedcapabilityofthissort.MPI6.0cannowisolatethecausesofwarpagefor3Dpartsasitalreadydoesforthinshellmodels.Itcancalculatedeflectionsduetounbalancedcooling,nonuniformshrinkage,andfiberorientation,inadditiontothetotaldeflection.Inaddition,thinshellsimulationshaveanewabiKtytoisolatewarpageduetocomereffects.Previousabilitytocalculatecoreshifthasbeenenhancedwithnewcalculationsofstressesonthecorestogiveinsightintocorefatiguebeforeactualcrackingoccurs.EasiermoreflexibleInMPI6.0theuserinterfaceforalltypesofanalyseshasbeenreorganizedforgreaterconvenienceandlessscreenclutter.Forexample,modelingandmeshingtools,whichformerlyopenedinwindowsontopofthemodel,nowhavebeenmovedtopanelsontheleftsideofthescreen,soasnottoobscuretheviewofthemodel.Also,themodelingandmeshingtoolshavebeenconsolidatedintoagraphicalToolboxthatavoidstheneedtopickthroughmenus,andtheProjectandStudypanelsaremergedintoanewTaskstab.Alltextuallogwindowshavealsobeenconsolidatedintoone.Andnow,asinglemouseclickhidesallpanelstoleavetheentirescreenfreetodisplaythemodel.Evaluationofmodelsisfasterandeasierwithanewsystemofdirecteddiagnostics.Diagnosticwarningsaboutmeshingproblemsarenowprioritizedbydegreeofseverity,andwhenaproblemisselected,themodelautomaticallyorientsitselftogivethebestvisibilityoftheproblemmeshelements,whicharealsohighlighted.Thesystemnowalsoautomaticallyidentifiesisolated,extremelylargeelementsforcorrection,andtheautofixingfionctionisextendedtocorrectcolapsedareasofthemesh.AnothernewabilityislocalmeshrefinementinMPI/3Dtoincreaseordecreasetbenumberoflayersofelementsinaspecificareaofthemodelasalreadycanbedonewiththinshellmodels.Before,3Danalysisallowedusersonlytoincreaseordecreasethesizeofelementsinthelayers.NowitisalsopossibletogenerateanalysisreportsinMicrosoftWordorPowerPointformatsinadditiontohtml.Faster,simpler,smarterInSeptember,release7.2ofMoldfiowPlasticsAdvisersMPAaddednewcapabilitiestothissimplified,easytoleamproductforpreliminaryanalysisofmoldingfeasibility.OneofthemainnewfeaturesistheAdvancedGeometryAdviser,whichchecksanewlyconstructedmodelandsuggestswaystoimproveitbeforestartingtheanalysis.Itcanidentifythick,solidregionsthatcouldbethinnedtoreducemoldingcycletimeandmaterialcost,thinareasthatwouldretardflow,andcosmeticfeaturessuchasfilletsandtextthatcouldberemovedfromthemodelbecausetheydonothavemucheffectonanalysisresultsbutincreaseanalysistime.FasteranalysisisalsopossibleusinganewNaturallyBalancedanalysismode.Thismodeallowsyoutoselectanaturallybalancedrunnersystemfromalibraryofcommonlyusedlayouts.Youcantheneditthepropertiesofspecificrunners,ifnecessary.Analysisisperformedonasinglehighlightedcavityandresultsareextrapolatedtotheentirelayout.FillingandpackinganalysestherehytakemuchlesstimethanafullanalysisinstandardMultiCavitymode.Inaddition,thenewreleaseletsyouimportcenterlinesofcomplexorcurvedrunnersfromaCADfileinIGESformat.TheCoolingCircuitAdviserincludesanewCoolingSystemWizardthathelpscreatecoolingcircuitsmoreefficientlythanhefore.Withthenewwizard,youcansetchanneldiameters,distanceahoveandhelowthepartingplane,numherofchannels,distancehetweenchannels,anddistancetoextendhosesheyondthemoid.Youcanalsoassignpropertiestomultiplecoolinglinesatonceandspecifythecoolinginletlocation.MPA7.2alsorevealsnotjustthelocationofweldlinesandairtraps,huttherelativeseriousnessofthesedefects.Itdoessohypresentingthedetailsonflowfronttemperature,pressuredrop,injectionpressure,andfilltimewhenthesedefectswereformed.NewCADtoolsTwoothernewupdateslastSeptemherwereMoldflowDesignLinkMDL5.2andCADDoctor2.0.MDLallowsdirectimportofsolidgeometrydatafromleadingCADsystemsintoMPIandMPA.MDL5.2hasupdatedinterfacestothelatestCADreleasesofParasolid,SolidWorks,andCatia.MoldflowCADDoctorchecks,corrects,andhealssolidmodelsimportedfrompopular3DCADsystemsinpreparationforanalysesusingMPIandMPA.Version2.0hasanewinterfacetoMDLtoimportdatafromCatiaV5,Parasolid,Pro/Engineer,SolidWorks,andSTEPformatsvs.justCatiaV4andIGESbefore.MatthewH.NaitoveNewsinnanotestingDSMXploreinGeleen,TheNetherlands,representedintheU.S.hyDieterScientific,presentedanunusuallahoratorydevicefordevelopingexpensiveproductslikenanocomposites.Itisatinyconicaltwinscrewextruderdesignedforbatchoperation,unlikeanormalcontinuousfeedextruder.Itisfedhyasyringelikedevice.Atwopositionvalveeitherdischargesmeltattheendofthescrewsorrecirculatesithacktothefeedendofthescrewsinaclosedloop.DSMXplore,whichoriginallybuiltlabequipmentformaterialssupplierDSM,becameaseparateunittwoyearsago.DSMsoriginallabextruderprocessed5ccbatches,soitneededonlyapinchofexpensivenanomaterialstoruntests.Thelatestgenerationusesinsertstochangetheeffectivebarrellengthandbatchsizefromaminimumof2.5ccupto15cc.DSMhassoldover50oftbelahunits.Pricesrangefromahout80,000to100,000.ElementisSpecialties,asupplierofmontmorillonitenanoclay,hasdevelopedanewinfraredspectroscopytesttoassessplateletdispersionandorientation.BasedonIRabsorptionbythesiliconoxygenbondsintheclay,abroadabsorptionbandindicatesagglomeratedclayAhandthatnarrowsandformsapeakindicatestheclayisexfoliated.Elementissmethodcanalsomeasureplateletorientation,whichiskeytoharrierpropertiesinextrudedormoldedparts.AsampleisrotatedaroundtheYaxisofanIRbeamwhilethebeamissuccessivelypointedinYandZdirections.IftheIRabsorptionhandvariesinintensity,itindicatesnonrandomorientationoftheplatelets.AlternativetestmethodslikeelectronmicroscopesandXraydiffractionanalysisaremuchmorecomplexandprovidelessclearresults,Elementissays.ISI

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