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Moldflow Analysis

 

Cool, Fill, Pack & Warp

Go beyond validation to achieve true part optimization with our cool, fill, pack and warp analysis. Verus helps clients produce faultless parts from the beginning by replicating the injection molding process in the design phase of a project.

All analysis and simulations are done in-house by our expert certified Moldflow Analyst. By getting the design right first time, we have the knowledge to reduce production waste and improve client’s profits. We ensure our clients get fast, accurate results and their design optimization is streamlined, responsive and cuts overall costs. We have been doing this for a very long time - with expertise, confidence and speed.

Based on the client's specific molding requirements, we run a cool, fill, pack and warp analysis and deliver our feedback in a detailed report outlining improvements and optimization.

Cool analysis allows the moldflow analyst to accurately simulate any number of cooling designs to achieve uniform part cooling, avoid hot spots and reduce part warpage, critical to the overall moldflow process

Flow analysis includes the filling and packing stages of the injection molding process. These stages produce some of the most important results for evaluating a product design for injection molding manufacturing. A complete flow analysis conducted by Verus Metrology delivers precise results by combining the best software, Autodesk Moldflow Insight, with years of molding expertise and advanced technology. By working with us, clients can enhance their molding outcomes and avoid costly manufacturing challenges upfront.

Warpage results can be used to identify areas of excessive warpage and shrinkage in order to recommend a solution. It is important to ensure the part can be manufactured within tolerance and will not exhibit excessive warp. By referencing product drawings and tolerances, it is possible to take point-to-point measurements from the analysis results to ensure the critical dimensions will be within tolerance after molding.

 


 

Verus’ Fill, Pack and Warp Process

  • Fill time: velocity profiles and shot size (machine-specific)
  • Freeze time: time to freeze the runner, gate and part
  • Pack time & pressure: packing phase profiles (machine-specific)
  • Venting requirements
  • Weld line locations
  • Volumetric shrinkage: shrinkage values for various part geometries
  • Shear rate: shear rates generated during filling and packing
  • Pressure at V/P change over
  • Injection pressure: pressure rates experienced during filling and packing

Reports and results can be tailored to specific requests for part troubleshooting.

At Verus Metrology, we are driven by innovation. This means we are constantly implementing the latest moldflow research and technology to help clients improve their products. Whether it is for saving material or cutting cycle times, our moldflow simulation is an essential tool for breaking new ground.

 


 

Verus’ Integrated Process (VIP)

The Verus Integrated Process, or VIP as we call it, is an innovative integrated service that combines the power of our world-leading bespoke fixture designs, Autodesk Moldflow technology, off-line metrology CMM software and our 3D printing technologies.

Quite often, fixture design, metrology, moldflow and 3D printing are treated as four separate processes with their own specific goals. At the request of our clients, we can incorporate all these technologies and capabilities into the design of our bespoke metrology fixture solutions.

By integrating these services, we offer our customers the best of not one, but four worlds. It is a holistic approach, and it benefits our clients as it allows their as-molded component to be assembled into our fixture designs and programmed off-line; allowing them to see a full metrology ISIR report before a physical molded part has been created, and all in a virtual environment.

 

The Process

It begins with the nominal 3D component model. We import it into our Autodesk Moldflow Insight software and begin the virtual molding process.

After extensive process optimization, the as-molded 3D model is exported from moldflow. We can pick up on any molding problems, such as filling issues, excessive warpage or shrinkage, exactly as the de-molded physical part would be. Validation experiments can also be analyzed, and nominal processing windows established.

These 3D models are then imported into offline Metrology software. It is the same software that drives our CMM's, but it is not connected to a metrology machine. The software can be programmed and run in a virtual environment as if the physical machine and the component were present. A full range of reports can be outputted, including an ISIR report referencing all the drawing GD+T.

With this as-molded 3D model to hand, we can use it to confirm our holding techniques on the fixture design in the 3D assembly and our clients can use it for device assembly and gap analysis. The model can also be used for physical testing of our fixtures and downstream assembly lines, by utilizing our 3D printing technology.

Finally, the as-molded model can be reversed and a model which is now compensated for warpage deflections and shrinkage can be exported and used in the tool design process to cut steel, saving weeks of steel recuts and processing. Typically, when plastic parts come off the line, a lot of troubleshooting and testing takes place. While it is a vital part of the process, it has the potential to slow down production thus causing delays. Furthermore, these delays can be costly as they can have a serious knock-on effect on budgets and timelines.

As VIP catches issues before a part has been created, clients can be confident that when the plastic part comes off the line, it will be as good as it possibly can be. We can eliminate the most common issues that can occur and by doing so, validation and production will run smoother and there will be no expensive delays.

Offline ISIR metrology results to technical drawing GD&T will provide confirmation that the optimized molding process will produce components that will be within manufacturing tolerance.

 

 

Cooling Analysis

A critical phase for determining cycle time, cooling analysis provides the ability to accurately simulate any number of cooling designs to achieve uniform part cooling, avoid hot spots and reduce part warpage.

Used to evaluate and optimize cooling lane design, cooling analysis is critical to the overall moldflow process as cooling design will influence part filling, freeze times, warpage and the overall cycle time. Examining the cooling phase can help determine the coolant conditions needed to maximize the efficiency of the proposed cooling layout.

Boasting several years’ experience in the field of moldflow analysis, our moldflow expert offers cooling simulation tools with result analysis in order to evaluate the technical impact on the product. Working in partnership with our mold tool designer, multiple cooling designs can be analyzed.

 


 

Verus’ Cooling Analysis will assist clients in:

  • Cycle time optimization – based on a specified ejection temperature
  • Cooling design – cooling circuits, inserts, steel types, etc.
  • Reynolds number in each cooling circuit
  • Distribution of average plastic temperature at ejection time
  • Distribution of maximum plastic temperature at ejection time
  • Recommended cooling modifications
  • Flow rate to ensure coolant turbulence
  • Effect on warpage
  • Evaluation of baffles and bubblers
  • Pressure drop along each cooling circuit
  • Appropriate coolant temperature
  • Cavity surface temperature distribution
  • Transient cooling analysis
  • Optimized coolant conditions
  • Conformal vs traditional cooling line comparison
  • Selection of high-conductivity inserts

Reports and results can be tailored to specific requests for part troubleshooting.

 

Twin Shot Molding

Twin shot molding allows for the production of complex moldings from two different polymers during a single machine cycle. This enables the molding to be made with more than one color or different grades of materials to achieve hard and soft surfaces within a single component. Twin shot molding produces complex, innovative plastic injection moldings faster and at a higher quality level than the standard injection molding process.

As well as the cost advantages, Verus’ twin shot molding process allows product designers to create complicated moldings, with a high level of accuracy and repeatability. It also shortens production times and eliminates post assembly, reducing costs and speeding up the delivery of components.

Core shift is a frequent problem with long, slender, and not necessarily thin-walled products, such as vials, test tubes, pen barrels. It is often experienced in molds for thin-walled containers.

Core shift can result in undesirable variations in wall thickness which will affect the final shape and mechanical performance of the part. The core shift simulation provides detailed information about the movement of the mold core and its interaction with the polymer flow process as the plastic is being injected.

 


 

Verus’ Twin Shot Molding Process

The over-molding analysis consists of a 2-step process where a normal Fill+Pack analysis is performed on the first cavity (first component stage), which is then followed by a Fill+Pack analysis on the over-molding cavity (over-molding stage). The consecutive over-molding stage on the second cavity uses a different material from the first analysis, and the first component temperatures are used as the initial temperatures.

  • Core deflection
  • Final core shift
  • Stress in the core
  • Re-melt zones
  • Pre-mold temperature during over-molding
  • Insert over-molding
  • Warpage of the over-molded assembly

Reports and results can be tailored to specific requests for part troubleshooting.

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