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Flow Analysis |
Cooling Analysis |
Warp Analysis | Advanced
Capabilities On this page:
Core Deflection Analysis
Moldflow’s Core Deflection solver is a methodology now employed
within the software that integrates a mechanical solver along
with their famous flow calculation solver. Core Deflection
Analysis is employed when the mold has a long cantilevered core
that shifts during filling and packing. Without this technology,
finding an optimal location for a hot drop would be impossible.
This saves costly rework on molds when it is done up-front. We
are no longer measuring solely how the molten resin takes the
form of the cavity. Now we are looking at how the cavity changes
in response to the flow of resin, and then re-calculating how
this reaction to the flow of resin affects this very flow in
turn.
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Traditional Flow Analysis (no
core deflection) |
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(Core Assumed to be Rigid) |
The first image shows the
predicted gate location for a balanced filling pattern using
the traditional solver assuming a rigid core.
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| Filling Pattern |
Deflection of Core
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Core Deflection
with same gate location |
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The gate location from the
previous analysis is run this time with core deflection
technology. Allowing the core to shift due to injection
pressure changes the flow pattern and results. |
| Filling Pattern |
Deflection of Core
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| Core Deflection
with new gate location |
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The third image shows the core
deflection and the filling pattern for the proper gate
location. Since the core is allowed to move, it will always
deflect some amount, but the final part after processing
actually yields a balanced wall thickness throughout the
part. The deflection plots shown reflect the positive net
displacement of the core, not along any specific axis. |
| Filling Pattern |
Deflection of Core
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For more information on how core deflection technology can
help you solve your molding problems, please
contact us.
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Clamp Over-Tonnage Analyses
Clamp Over-Tonnage deals with the question, “What happens to
my part when the polymer hydraulic force exceeds the clamp
force of the molding press?” Traditionally, Moldflow and
other software solvers would reduce the injection pressure
to balance the system. This, however, cannot be done in
practice. One method to approximate a solution to this
dilemma was posed by Cascade at the 2003 Moldflow User’s
Group Conference in Pittsburg, Pennsylvania.
With the advent of the core deflection capability, we can
now re-define the term “core” and proceed with an analysis
method that actually incorporates the stretch of the
tie-bars and the forces associated with the filling of the
cavity, including imbalanced filling. To find out more
about how to leverage our advanced services to help your
organization, please contact us.
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Venting Analysis
Venting analysis is a process that determines the amount of
venting required either for a local air entrapment or globally
for an entire mold. The analysis is based on the volume of air
to be evacuated, maximum temperature to be achieved by the
air and time to vent. This scientific method helps to prevent
re-melting of the frozen layer (shiny spots), or other more
severe defects of the molding process like burns or dull
patches due to adiabatic heating of trapped air.
Cascade’s proprietary venting calculator can be used to specify
a total parting line length for venting over a whole mold, or
it can be used for a localized air entrapment to help
determine the best methods for venting in difficult areas.
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Structural Analysis
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Grabber Analysis
A waste container is shown being squeezed by an automated
grabber in the animation to the left. This example
demonstrates our ability to incorporate advanced structural
analysis capabilities. The actual stress-strain curve of the
thermoplastic material is simulated using non-linear material
characteristics. Non-linear geometry is invoked as the grabber
squeezes the container, then releases and returns to its
original shape. Contact with friction takes place between the
container and grabber arms as well as between the container
and ground.
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Injection Molding Machine
The injection of plastic into the mold to produce a part
places various stresses on the tool and subsequent molding
machine. These forces and moments can cause parting lines to
open, tie bars to flex and platens to deflect. The analysis
at the left is a quarter model of a large eight-tie bar
injection molding machine. Upon build up of clamp tonnage, the
animation shows the movement of the injection molding system
during the filling and packing of a symmetric part. Components of
both the tool and machine can be evaluated for fatigue
failure. Tool designs may be modified early in the design
stage to prevent costly tool repairs down the road.
Deflection is exaggerated 200X actual for visualization
purposes. |
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