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Multi-Cycle Analysis Enables Virtual Process and Mold Development
4/11/2012 |
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Using a completely 3D-approach and the integration of a highly developed thermal solver, the virtual process and mold development software SIGMASOFT® allows the calculation of multiple consecutive production cycles, considering the thermal interactions throughout all the components in the mold. The accuracy of the entire simulation is thus dramatically increased.
Schaumburg, IL, April 1st 2012 - SIGMA Plastic Services, Inc., Schaumburg, IL, will present SIGMASOFT® - The Virtual Process and Mold Development software designed for injection molding processes at the NPE 2012, North/South Hall, Booth 65027. One of the highlights of the presentation will be SIGMASOFT®'s unique functionality of "multi-cycle analysis", a new benchmark in injection molding simulation.
"In conventional injection molding software, a fixed mold temperature is defined and the whole simulation is carried out under the assumption that this value remains constant over time", explains Dr. Marco Thornagel, Executive Director of SIGMA® Engineering. "In reality, however, you have a very complex thermal process taking place within the mold: the steel is cooled with a tempering system, the mold is heated when the hot polymer melt enters the cavity and there is a loss of thermal energy towards the surrounding environment. All this is governed by the heat transfer properties of the materials present throughout the system: polymer melt, runner system, inserts, mold, insulation materials. Only when these complex interactions are considered will the real production conditions be reproduced in the simulation. Our customers really appreciate that we already have 25 years of experience in how to make this kind of simulation, with a user friendly meshing algorithm".
The 3D-approach of SIGMASOFT® allows all the components in a mold, including all the thermal and physical properties of each one of them, to be exactly reproduced. Therefore, the heat transfer process can be accurately calculated between each one of these components.
To accurately simulate the production conditions, the heat transfer process taking place in reality has to be exactly reproduced in the simulation. This includes the heat-up during the start-up of the machine, when the mold is heated from room temperature to its production conditions (typically between 60 and 120ºC) by the tempering system. It also includes the warming up produced by the hot polymer melt over several consecutive pre-production cycles, as it happens in the reality.
SIGMASOFT® is able to exactly reproduce the heat-up stage, as well as simulate the thermal evolution of the mold over multiple consecutive production cycles. This accurate calculation predicts the real temperature in each location of the mold during production, producing a condition that more closely reflects reality for the polymer as it freezes inside the cavity. This allows, for example, to predict how long the polymer remains in a fluid condition so that post-pressure can be applied, or where will the thermally induced deformation compromise the part quality.
Another of the advantages of multi-cycle simulation is the possibility to calculate how many production cycles are required for the mold to achieve cyclic equilibrium - and thus consistent quality conditions. Therefore, the number of parts required to produce before the production begins can be predicted. The system can be optimized to minimize the number of pre-production parts that are required. Another possibility is to compare the efficiency of different tempering systems, to understand how to achieve equilibrium more quickly or how to consume less energy.
Caption
Figure 1 - The multi-cycle analysis of SIGMASOFT® allows simulating the heat transfer in the mold from start-up over multiple production cycles, and thus exactly reproduces the real production conditions in the cavity. Left: Temperature distribution in a half of the mold cavity after one cycle. Right: Temperature distribution after 15 cycles.
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Related Exhibition:
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NPE 2012
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The International Plastics Showcase
4/1/2012 - 4/5/2012
Venue: Orange County Convention Center, Orlando FL, United States
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