Moldex 3D Research Articles

PERANCANGAN DAN MODIFIKASI MOLD INSERT UNTUK MENINGKATKAN KAPASITAS PRODUKSI LIGHT GUIDE

The use of plastic is often found in human life. Therefore, many manufacturing companies are competing to increase the production and quality of their plastic products. One way to increase production is to redesign a Mold base so that the Mold has a larger production capacity than before. The increase in product demand from consumers, which was initially 65,000 pcs/month to 95,000 pcs/month, is also the background for conducting this research. The purpose of this study is to redesign the soft tool using the old Mold base. The design uses Siemens UG NX 5 software. The Mold used is a two-plate Mold. The manufacture of the core cavity uses NAK 80 steel and plastic raw material in the form of Polycarbonate (PC). At the end of the study, a simulation was carried out using the Moldex 3D Flow Mold software to see the cycle time of the old and new Mold injection processes. From the results of this study, production capacity increased from 67,804 pcs/month to 118,536 pcs/month resulting in twice as many products as the old Mold design, with an increase in cycle time of 14.37% longer than the old Mold design also ensuring the quality of the product is maintained.

Analysis and Validation of Varied Simulation Parameters in the Context of Thermoplastic Foams and Special Injection Molding Processes.

The simulation solutions of different plastic injection molding processes are as multifaceted as the field of injection molding itself. In this study, the simulation of a special injection molding process, which generates partially foamed integral components, was parameterized and performed. This partial and physical foaming is realized by a defined volume expansion of the mold cavity. Using the injection molding simulation software Moldex 3D, this so-called Pull and Foam process was digitally reconstructed and simulated. Since the Pull and Foam process is a special injection molding technique for producing foamed components, the validity of the simulation results was analyzed and evaluated. With the use of Moldex 3D, varied settings such as different bubble growth models and mesh topologies were set, parameterized, and then analyzed, to provide differentiated numerical calculation solutions. Actual manufactured components represent the experimental part of this study and are produced for reference. Different evaluation methods were used to quantify morphological quantities such as porosities, local densities, and cell distributions. These methods are based on two-dimensional and three-dimensional imaging techniques such as optical microscopy and X-ray microtomography (µ-CT). Thus, this structural characterization of the manufactured samples serves as the validation basis for the calculated results of the simulations. According to the illustrated results, the adequate selection of bubble growth models and especially mesh topologies must be considered for valid simulation of specific core-back techniques, such as the Pull and Foam injection molding process.

Modelling and Simulation of MuCell®: The Effect of Key Processing Parameters on Cell Size and Weight Reduction.

Microcellular injection moulding is an important injection moulding technique to create foaming plastic parts. However, there are no consistent conclusions on the impact of processing parameters on the cell morphology of microcellular injection moulded parts. This paper investigates the influence of the main processing parameters, such as melt temperature, mould temperature, injection pressure, flow rate, shot volume and gas dosage amount, on the average cell size and weight reduction of a talc-reinforced polypropylene square part (165 mm × 165 mm × 3.2 mm), using the commercial software Moldex 3D. The effect of each parameter is investigated considering a range of values and the simulation results were compared with published experimental results. The differences between numerical and experimental trends are discussed.

A Review on Microcellular Injection Moulding.

Microcellular injection moulding (MuCell®) is a polymer processing technology that uses a supercritical fluid inert gas, CO2 or N2, to produce light-weight products. Due to environmental pressures and the requirement of light-weight parts with good mechanical properties, this technology recently gained significant attention. However, poor surface appearance and limited mechanical properties still prevent the wide applications of this technique. This paper reviews the microcellular injection moulding process, main characteristics of the process, bubble nucleation and growth, and major recent developments in the field. Strategies to improve both the surface quality and mechanical properties are discussed in detail as well as the relationships between processing parameters, morphology, and surface and mechanical properties. Modelling approaches to simulate microcellular injection moulding and the mathematical models behind Moldex 3D and Moldflow, the two most commonly used software tools by industry and academia, are reviewed, and the main limitations are highlighted. Finally, future research perspectives to further develop this technology are also discussed.

Optimisation of Mould Design for Injection Moulding – Numerical Approach

Computer simulation of injection moulding process is a powerful tool for optimisation of moulded part geometry, mould design and processing parameters. One of the most frequent faults of the injection moulded parts is their warpage, which is a result of uneven cooling conditions in the mould cavity as well as after part ejection from the mould and cooling down to the environmental temperature. With computer simulation of the injection moulding process it is possible to predict potential areas of moulded part warpage and to apply the remedies to compensate/minimize the value of the moulded part warpage. The paper presents application of simulation software Moldex 3D in the process of optimising mould design for injection moulding of thermoplastic casing.

Solving of Thermoplastic-Carbon Bonding Issue Using Numerical Simulations

The aim of this study was to elaborate on the methods of constructing combined components of a car mirror. The components were made of materials with different thermal expansion coefficient. The basis for the research were numerical simulations prepared in Moldex 3D software. The external cover of a mirror would be made of carbon composite based on epoxy resin (hereafter referred to as carbon), and the internal insert would be made of ABS. The adhesive bonding applied did not provide appropriate properties and led to breaks during usage. After carrying out moldflows it was found that the areas of breaks were determined by the places where fronts of flowing material met during the injection. The cause of breaking was diametrically different thermal expansion of both materials. This induced significant stresses in the adhesive layer. Finally, the effective solution was to change the geometry of the mirror insert made of thermoplastic ABS.

Alternative materials in moulding elements of hybrid moulds: structural integrity and tribological aspects

Hybrid moulds are an increasingly considered alternative for prototype series or short production runs. This type of tools resorts on the use of Rapid Prototyping and Tooling (RPT) to produce the moulding elements (blocks or other inserts). This study was developed using a hybrid injection mould with exchangeable moulding elements that were produced by additive manufacturing (AM), namely vacuum epoxy casting, stereolithography and ProMetal. A full steel tool was also used as a reference. The processing conditions for the polypropylene moulded parts using the hybrid mould were monitored for pressure, temperature and ejection force. The hybrid mould performance was assessed in terms of pressure and temperature evolution during the injection cycle and the AM moulding elements for physical integrity. The data from the polypropylene moulded parts and the moulding inserts are compared with structural and rheological simulations using ANSYS Workbench and MOLDEX 3D. The results show that the hybrid mould performance and the structural integrity of the moulding elements depend on the properties of the materials used. The moulding shrinkage, when resin cores are used, is also affected by the core deformation caused by the injection pressure.

Study on micromoulding of a high viewing angle LED lens

ABSTRACTLenses are used to mount on the light-emitting diode (LED) chip to obtain the desired light distribution patterns. In this study, a lens for large viewing angle and high uniformity LED has been developed with optical grade poly methyl methacrylate (PMMA) material. TracePro software was used to design the lens while Moldex 3D software was implemented to design the mould and the mould filling phenomena. Together with micromoulding technology and Taguchi experimental method with control parameters were mould temperature (MoT), melt temperature (MT), and injection speed, a lens with optical uniformity of 87.18% and viewing angle of 128° has been developed. The experimental results showed that MoT and MT were the main factors affecting the optical quality, each with contributions greater than 50 and 30%, respectively. Though this lens is relatively small in dimension, a draft angle is needed for successful removal of the moulded PMMA lens from the mould.

Comparison of cooling simulations of injection moulding tools created with cutting machining and additive manufacturing

Nowadays injection moulded products are gaining ground worldwide. The production time of the technology is relatively short, and it can produce thousands of products. The manufacturing speed depends on the injection moulding cycle, which is one of the most time-consuming parts of the cooling time [1]. As a consequence, the primary aim of the manufacturers is to minimize the cooling time within the injection moulding cycle. The aim of the research is to investigate whether the cycle time of an injection moulding can be reduced by using an additive manufacturing instead of traditional machining. MoldEx 3D program was used for the simulation. According to the simulation results, the cooling time has decreased more than 9% for a simple geometry product. The cycle time of complex structures can be decreased significantly with using more efficient cooling system. The dimensional accuracy also improved due to the decrease in warp

The simulation of volume shrinkage for double-injection molding with PC and ABS

The objective of this paper was to study and analyze the plastic injection molding parameters to reduce the volume shrinkage of double injection molded part. The specimen was molded with Acrylonitrile-butadiene-styrene (ABS) after Polycarbonate was molded as a half part. The weld line occurred at the haft of the molded part. The simulation with Moldex 3D R13 and the design of experiment with Taguchi method was used to perform the experiments and analyze the data to get the optimum of volume shrinkage. The results showed that melt temperature and packing pressure was significant to the volume shrinkage. When using low melt temperature and high packing pressure, the shrinkage was low and related to the thermal expansion of the material. It would be one of the parameters to the design of double injection molding.

Microcellular PP/GF composites: Morphological, mechanical and fracture characterization

The aim of the present work is to analyze the morphology, mechanical properties and fracture behaviour of solid and foamed plates made of glass fiber-reinforced PP. The morphology exhibited a solid skin/foamed core structure, dependent on the foaming ratio. Simulation of the microcellular injection molding process with Moldex 3D® software provided a good approach to the experimental results. The flexural properties and impact resistance showed lower values as the apparent density decreased, but constant specific properties. The fracture characterization was carried out by determining the Crack Tip Opening Displacement (CTOD) at low strain rate, as well as the fracture toughness (KIc) at impact loading. Foamed specimens presented higher values of CTOD than the solid ones and higher as the foaming ratio increases, due to cells acting as crack arrestors by blunting the crack tip. However, the fracture toughness KIc decreased with decreasing the apparent density. Anisotropy due to fiber orientation was also observed. Fibers were aligned in the filling direction in the surface layers, while they were oriented in the transverse direction in the core. According to the amount of fibers oriented in one direction or another, different properties were obtained.

Effect of Injection Flow on Conductive Network in Polypropylene-carbon-filler Composite Bipolar Plates

Bipolar plates have been manufactured by different techniques, such as high performance drilling, compression molding, metal stamping, and injection molding processes. The bipolar plates should be produced via a standard mass production technique in a one-step process, since this can reduce the cost structure of fuel cell stacks, significantly contributed by the bipolar plates. Polypropylene/three-carbon-filler composites were selected for bipolar plate production through an injection molding process for this research work. Although the conductive injection moldable composites can be produced for a bipolar plate application, their electrical conductivity, especially through plane conductivity, has not yet achieved a commercial target. For that reason, a simulation of fiber orientation in an injecting plaque using the finite element simulation program Moldex 3D was carried out with the support of Compuplast Canada Inc. to investigate the effect of an injection flow on fiber orientation in conductive networks. Even the simulation output cannot clearly elucidate the orientation of carbon fibers in the composites containing hybrid fillers as the experimental results showed. Further improvements in the development of conductive networks in injected composite bipolar plates can be achieved, for example, through tailoring of a particular injection mold geometry for the bipolar plate production.

Composite materials molding simulation for purpose of automotive industry

Composite materials loom large increasingly important role in the overall industry. Composite material have a special role in the ever-evolving automotive industry. Every year the composite materials are used in a growing number of elements included in the cars construction. Development requires the search for ever new applications of composite materials in areas where previously were used only metal materials. Requirements for modern solutions, such as reducing the weight of vehicles, the required strength and vibration damping characteristics go hand in hand with the properties of modern composite materials. The designers faced the challenge of the use of modern composite materials in the construction of bodies of power steering systems in vehicles. The initial choice of method for producing composite bodies was the method of molding injection of composite material. Molding injection of polymeric materials is a widely known and used for many years, but the molding injection of composite materials is a relatively new issue, innovative, it is not very common and is characterized by different conditions, parameters and properties in relation to the classical method. Therefore, for the purpose of selecting the appropriate composite material for injection for the body of power steering system computer analysis using Siemens NX 10.0 environment, including Moldex 3d and EasyFill Advanced tool to simulate the injection of materials from the group of possible solutions were carried out. Analyses were carried out on a model of a modernized wheel case of power steering system. During analysis, input parameters, such as temperature, pressure injectors, temperature charts have been analysed. An important part of the analysis was to analyse the propagation of material inside the mold during injection, so that allowed to determine the shape formability and the existence of possible imperfections of shapes and locations air traps. A very important parameter received from computer analysis was to determine the occurrence of the shrinkage of the material, which significantly affects the behaviour of the assumed geometry of the tested component. It also allowed the prediction of existence of shrincage of material during the process of modelling the shape of body. The next step was to analyse the numerical analysis results received from Siemens NX 10 and Moldex 3D EasyFlow Advanced environment. The process of injection were subjected to shape of prototype body of power steering. The material used in process of injection was similar to one of excepted material to be used in process of molding. Nextly, the results were analysed in purpose of geometry, where samples has aberrations in comparison to a given shape of mold. The samples were also analysed in terms of shrinkage. Research and results were described in detail in this paper.

An Integrated Approach to Development And Simulation Manufacturing Processes of Optical Products

Abstract The engineering management process and automation method for making pilot set of optical polymer parts used in LED systems are considered. Optical system and lens geometry development are realized in Zemax. 3D model and molding tools with further generating of NC coded data are developed in Cimatron E. Pre simulation of injection molding process is realized in Moldex 3D and thermo-mechanical analysis is provided by OOFELIE. 3D printer Objet is used for parts prototyping on different stages of the process. Data and process management are realized with a help of PDM system SmarTeam.

Experiment and simulation of foaming injection molding of polypropylene/nano-calcium carbonate composites by supercritical carbon dioxide

Microcellular injection molding of neat isotactic polypropylene (iPP) and isotactic polypropylene/nano-calcium carbonate composites (iPP/nano-CaCO3) was performed using supercritical carbon dioxide as the physical blowing agent. The influences of filler content and operating conditions on microstructure morphology of iPP and iPP/nano-CaCO3 microcellular samples were studied systematically. The results showed the bubble size of the microcellular samples could be effectively decreased while the cell density increased for iPP/nano-CaCO3 composites, especially at high CO2 concentration and back pressure, low mold temperature and injection speed, and high filler content. Then Moldex 3D was applied to simulate the microcellular injection molding process, with the application of the measured ScCO2 solubility and diffusion data for iPP and iPP/nano-CaCO3 composites respectively. For neat iPP, the simulated bubble size and density distribution in the center section of tensile bars showed a good agreement with the experimental values. However, for iPP/nano-CaCO3 composites, the correction factor for nucleation activation energy F and the pre-exponential factor of nucleation rate f0 were obtained by nonlinear regression on the experimental bubble size and density distribution. The parameters F and f0 can be used to predict the microcellular injection molding process for iPP/nano-CaCO3 composites by Moldex 3D.

Numerical Simulation of Differential Injection Molding Based on Moldex 3D

Differential injection molding is one of the key technologies for micro-manufacture. The mechanism of melt pump based on the differential injection molding is presented. The differential injection molding system is added into the traditional injection machines. Melt is plasticized by the plastication system, then after being split, pressurized and measured by the differential system, it enters the cavity to realize the function of multiple micro injection molding machines. Moldex 3D software is used to simulate the filling history of the micro-structure via differential injection molding technology. The product's filling volume under different processing parameters is compared, which provides theoretical basis for the optimization of the molding parameters in differential injection molding technology.

Simulation of Micro-Gear Manufactured by Differential Injection Molding Based on Moldex 3D

In this article, the structure of the differential pump is introduced, which is the core part of the differential injection system. The micro-gear with a shaft collar is simulated as it is an important micro-part and has great potential application in mechanical transmission. The Moldex 3D simulation software is used to investigate effects of processing parameters on the micro-gear such as melt temperature, mold temperature, injection time and packing time etc. By comparing the micro-gear's warpage under different processing parameters, it can be concluded that melt temperature has a greater impact on the molding quality than mold temperature. In addition, the effects of injection time and packing time on the micro-gear's molding quality are also investigated.

An Optimum Design and Fabrication of Focus Lens for High Intensity Light-Emitting Diodes

A maximum output intensity of high-power light-emitting diodes (LEDs) with high-efficiency focus lens is demonstrated. A commercial software package of Trace Pro and one-factor method are used to simulate the focus lens. The optimum parameters of focus-lens design are the radius curvature, cavity depth, and lens height are 2.75, 2.45, and 5.7 mm, respectively. For the fabrication of focus lens with injection molding, the optimum parameters are simulated by adapting Taguchi's method of the smaller-the better algorithm in a software package for Moldex 3D. By employing both optimum design and fabrication of the focus lens, a maximum peak intensity for 64.6 cd for a 1 W blue LED module was realized under a constant driving current of 320 mA and the voltage of 3.2 V. In comparison with a commercial focus lens used in high-power LEDs under the same test conditions, the high-power LEDs with proposed focus lens exhibits about 2–3 times improvement in the output intensity. This study may provide a practical guideline for design and fabrication of a high-efficiency focus lens used in high-intensity high-power LED modules.