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1InjectionMoldingCAETechnology0IntroductionPlasticproductsfromproductdesigntoproduction,includingmoldingplasticproductsdesign,molddesign,moldmanufacturingandinjectionmoldingprocessparametersandseveralothermainareas.Thetraditionalinjectionmolddesignmainlyrelyonthedesignersexperience,whiletheinjectionmoldingprocessisverycomplex,plasticmeltflowpropertiesofdifferentandeverchangingproductsanddiestructure,processconditionsvary,formingvariousdefects,molddesignoftenrequirerepeatedtrialmode,maintenancemodecanbeputintoproduction,withlittleofasuccessful,identifyproblems,notonlytoreadjusttheprocessparameters,oreventomodifytheplasticproductsandmolds,notonlytimeconsumingandlaborious,butalsoreducesproductdevelopmenttime.TheuseofinjectionmoldingCAEtechnologyinmoldmanufacturingpriortosimulateinjectionmoldingprocessincludingfilling,packingandcoolingandtheearlydetectionofproblems,optimizemolddesignandprocessconditionssettoreducethenumberoftestmodeinordertoimproveproductionefficiency,hasbecomeainjectionmoldingtechnologyisanimportantdirectionofdevelopment.1ThehistoryofInjectionMoldingCAEtechnologyInjectionMoldingCAEtechnologyisbasedonplasticsprocessingrheologyandheattransferofthebasictheory,themeltinthemoldcavityintheflow,heattransferphysics,mathematicalmodel,usingnumericalsolutionmethodofconstructingthetheory,theuseofcomputervisualizationtechnologyimage,visuallysimulatethedynamicsoftheactualshapeofthemeltfillingandcoolingprocess,ananalysistechniques.The20thcentury,60years,theUnitedKingdom,theUnitedStatesandCanadaandothercountriesofthescholars,suchasJRPearsonUnitedKingdom,JFStevensonAmerica,MRKamalCanadaandKKWangAmerica,etc.tocarryoutaseriesof2plasticmeltinthemoldtypecavityflowandcoolingofbasicresearch.Atareasonablesimplification,basedon60yearscompletedaonedimensionalflowandcoolinganalysisprograms,70yearstocompletethetwodimensionalcoolinganalysisprograms,and80yearsfromtheinjectionmoldingCAEtechnologyhasbeguntotheoreticalresearchintothepracticalphase,launchedathreedimensionalflowandcoolinganalysisandthestudyextendedtopacking,fiberorientationandwarpagepredictionofmolecularandotherfields.After90yearscarriedoutintotheflow,packing,coolingandstressanalysis,thewholeprocessofinjectionmoldingprocessesareintegratedresearch.CAEtechnologies,fortheinjectionmolddesignprovidesareliableguaranteethatitsapplicationismolddesigninthehistoryofamajorchange.2TheroleofInjectionMoldingCAEtechnologyUsingtraditionalmethodsofdesignofinjectionmolddesignsuccesswillrelyheavilyontheexperienceofdesigners,butalsoforcomplexpartsgatepositionisreasonableornot,thelocationoftheexhaustslotsettings,todeterminethelocationofweldlinesandsoverydifficult.Dieindeliverywillnormallytakebeforethetestmodeafterrepeatedchanges,untiltheproductshavebeenqualified,whichinevitablyledtotheextensionoftheproductioncycle,andgenerallydifficulttoobtainanoptimaldesignandprocessparameters.TheuseofinjectionmoldingCAEtechnicaldesign,moldisnottrue,becauseofmolddesignconceptstage,canmakeuseofCAEtechnologyininjectionmoldingprocesssimulationflow,makingusuallyonlyinthemoldtryoutphasesinordertofindproblems,suchasshortshots,weldlinesorholesappearinthesurfaceappearanceofpartsandotherissueshavebeenavoided.Whilehelpingthedesignertocompletethebalanceofthesystem,suchasflowchanneldesign,exhaustducts,setting,rationallydeterminetheinjectionmoldingprocessparameters,etc.,sothatusuallymakesthemodificationmustberepeatedtryouttodeterminestructuralparametersofthemolddiedesignandprocessparametersintheconceptualstageabletodetermine,reducethemolddesignandmanufacturingcycleandimprovethemolddesignquality.3Therefore,theroleofinjectionmoldingCAEsoftware,mainlyasfollows1OptimizedesignofplasticproductsPlasticwallthickness,gatenumberandlocationofthedesignofflowchannelsystemforthequalityofplasticproductshaveasignificantimpact.Dependsontheexperienceofthepast,designersusingmanualmethodstoachieve,timeconsumingeffort,buttheuseofCAEtechnologytoquicklydesignthebestproducts.2optimizetheplasticmolddesignCanbecavitysize,gatelocationandnumberofflowchanneldimensionsandcoolingsystemstooptimizethedesign.Onthecomputersimulationtestmold,moldrepairmoldandimprovequalityandreducethenumberofactualtryout.3tooptimizeinjectionprocessparametersSimulationoftheinjectionprocessandfoundpossibleshapedefects,todeterminethebestinjectionpressure,clampingforce,moldtemperature,melttemperature,injectiontimeandcoolingtime.ThisshowsthattheinjectionmoldingCAEtechnologyintermsofimprovingproductivity,reducemolddesignandmanufacturecycleandtoensureproductquality,orreducecosts,reducelaborintensityandsoon,haveverysignificanttechnicaladvantagesandeconomicsignificance.3InjectionMoldingCAEsoftwaretypesandtheirdetailsTodate,amaturebusinessaremoreinjectionmoldingCAEsoftware,MoldflowCorporationMoldflowsoftwareandACTech,Inc.February2000,wasMoldflowMergerandCMoldsoftwareisanexcellentrepresentativeTherearealsoforeignTheTMCONCEPT,CADMold,Fidap,Stirm100,PolyflowandChinasTaiwanregionMoldexpeersoftwareapplicationsarerelativelywideanddomesticintheEighthFiveYearperiodbeganresearchinthisarea,andnowHuazhongUniversityofTechnologyHSCAEsoftwareandZhengzhouUniversity,ZMoldsoftwareinChinaintheleadingposition.MoldflowsoftwareisspecializedininjectionmoldingCAEsoftwareandconsulting4forMoldflowsrangeofproducts,thecompanyissuedsince1976,theworldsfirstsetofinjectionmoldingCAEsoftware,hasbeenaleadinginjectionmoldingCAEsoftwaremarket.To2004,MoldflowInjectionMoldingCAEsoftwareintheglobalmarketshareofover75.MoldFlowsoftwareincludesthreepartsMoldFlowPlasticsAdvisersproductoptimizationconsultant,MPA,MoldFlowPlasticsInsishtinjectionmoldingsimulationanalysis,MPI,andMoldFlowPlasticsXpertinjectionmoldingprocesscontrolspecialists,MPX.Undernormalcircumstances,themostcommonlyusedMPI,ismainlyusedforinjectionmoldingprocesssimulationtogetthebestnumberandlocationofthegate,reasonableflowchannelsystemandcoolingsystem,andcavitysize,gatesize,runnersizeandcoolingsystemstooptimizethesizeandtheinjectionmoldingprocessparametersmayalsobeoptimized.MoldflowSoftwareMoldflowanalysistechniquescanbedividedintothreekinds,namely,Midplane,Fusionand3D.4MoldflowanalysisofMidplaneMidplaneinthesurfaceflowapplicationsbeganinthe20thcentury,the80s.Thegridisathreenodetriangularelement,itsprincipleisthe3Dgeometricmodelofsimplifiedgeometricmodeloftheneutralsurfacetobecreatedinthemodelgridthemiddleofthewallthickness,usingestablishedsimulationanalysisoftheneutralsurface,ietoflowinplanetosimulatethreedimensionalsolidflow.Theanalysisoftechnologicaldevelopmenthasbeenverymatureandstable,andtheadvantagesfortheanalysisofspeedandhighefficiency.Basedontheflowofsurfaceflowsimulationofinjectionmoldingtechnology,softwareapplications,thelongest,widestrange.Butthepracticeshowsthat,basedonthesurfaceflowsimulationsoftwareintheapplicationoftechnologythathassignificantlimitations,specificallyasfollows1Theusermustconstructamidsurfacemodel.Usingmanualdirectlyfromthephysicalmodelstructureinthesurfacemodelisverydifficultandoftentakesalotof
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