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PLAST-PRO SOLUTIONS Solutions for Quality Plastic Products

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Moldflow CAE & Design Services Presentation

Date:- Jan 2017

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Introduction and Setup

Software license details Moldflow CAE capabilities

Moldflow Analysis Process

Methodologies Developed Hyper Mesh capabilities

Design services and resource support

Case Studies

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We Plast-Pro solutions are very focused service provider in plastic Product designing & process validation with 15+ years of experience in manufacturing and simulation engineering for automotive, appliances & commodity field. SETUP Resources:- We have dedicated 6 Moldflow analysis engineers,2 meshing engineer, 2 CAD design engineers,1 business development & 1 HR & Account Dept. Software:- Autodesk Moldflow Insight 2016/2017 Commercial Moldflow license. Altair Hyperworks 14.0 Work Stations:- High Configuration Workstations. Data management:- Centralized with automatic backup system. Data Transfer:- Private FTP & mail server

Introduction

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WS 1 WS 2 WS 3 WS 4

WS 5 Team Lead

Server

HDD 1

HDD 2

Continuous data

synchronization as

backup

Permanent

backup system

DVD RW

IT & Data Backup System:

All WS are secure with antivirus

and media/USB restricted.

Laptop 1 Manager

FTP server

Administrator

Working Backup

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Mr.Narendra Alone

(Manager)

Business Development

Nilesh

Moldflow Analysis And Meshing

Gaurav

(Team Lead)

Moldflow

Mandar Rushikesh Rahul Nikhil Saurabh

Meshing

Jeevan Priyanka

CAD

Sunayana Bhushan

HR And Account Dept.

Kshamita

ORGANISATION STRUCTURE:

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License Details

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Plastic Flow Simulation

Gate location optimization

Cavity fill / Runner balancing

Valve gate sequence optimization

Mold cooling Analysis & Optimization

Post Molding Warpage simulation.

Gas Assist Injection Simulation.

2k Injection Molding analysis

Insert & Overmolding simulation

Gas Coring

Moldflow CAE Capabilities

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RFQ

• Analysis request sheet

•CAD Model

•Discussion

• Finalization to receive PO

INPUT

• Filled Moldflow input sheet

• Final Part CAD data

•Plastic Material Details / UDB

• Mold Design 3D data

PRE PROCESSING

•Model cleanup

•Mesh preparation

•Mesh quality checkup

•Define boundary conditions

ANALYSIS

•Gate location optimization

•Molding parameters optimization

•Complete analysis sequence

• Specific analysis sequence

POST PROCESSING

•Analysis results interpretations.

•Proposal report s for discussion

•Product design improvement suggestions

•Detailed reports with MFR files

CORRELATION STUDY

•Trial attain to verify parameters

•Correlation study with actual results

•Re- analysis with actual parameters

•Detailed correlation report .

Moldflow Analysis Process

(OPTIONAL)

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Methodologies Developed

Filling & Packing Analysis Guidelines

• Mesh Model selection & approach according to objective

• Pressure , temperature, time criterions w.r.t. material family.

• Boundry conditions developed to minimize the Gap between actual and simulation.

Runner Balancing Methodology For Multi cavity Molds

• Specific approach developed for Runner balancing to get maximum close results at practical.

• All Runner balancing validation through actual 3D core cavity meshing and analysis to get 95% confidence.

Mold Cooling Analysis Methodologies

• PRE – Mold design cooling analysis methodology to give inputs for efficient cooling channel design before start of Mold design activity.

• POST-Mold design cooling analysis approach to highlight the issues in part cooling and respective suggestions to reduce cycle time quality issues in parts.

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Hypermesh Capabilities

Shell Meshing – 1) Mid-Surface

2) Outer surface Solid Meshing – 1) Tetra Mesh

2) Hexa Mesh 1D Meshing Assembly for Different solvers Penetration free model building Specific meshing for Moldflow Feature Based Meshing Analysis and Criteria Based Meshing Mesh Morphing

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Providing CATIA designers onsite from 1 to 3 years experience.

Product designing from concept to tooling.

Tooling feasibility study support .

Reverse engineering.

Plastic mold designing support.

Design services and support

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Glass Fiber Parts Mold Cooling Analysis

Moldflow Case Study - Automotive

Sequential Injection for Big

aesthetic parts

Automotive IP & Bumpers

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Moldflow Case Study - Appliances

Part - Battery cover parts

Material – ABS

Mold – Family Mold of 4 parts

Target-

Balance filling above 90%

Minimum filling Pressure

Part surface without visual marks

Challenges:

Big v/s Small part volume ratio is 1:100

Maximum wall thickness is 2.6mm

Minimum wall thickness of 1.1mm

Simulation 80% Actual 80%

Observation:

Default mesh model and analysis not

helped to get desired results correlation.

Specific approach required to optimize.

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Part – Transparent Cover

Material – PMMA

Mold – Single gate cold runner

Target-

Solve Problem of sink, flow marks.

Reduce required clamp force.

Reduce scrap rate in trials.

Challenges:

Mold developed without analysis.

Cold sprue with gate , No hot runner

Very less scope to play for gate location

Existing with Issues Improved after analysis

Observation:

Balance filling is very important. Able to

solve sink, Flow mark issues. Clamping

reduced from 650T to 500T.

Moldflow Case Study - FMCG

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Our current customers :

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Thank You