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Reduce the Injection Moulding Cycle time by predicting the manufacturing defects at early stage

BeaconIndiaComments off.

 Introduction:

In Plastics & Mold Industry, Questions we usually ask ourselves when a plastics part & Injection Mold tool for the same is being designed are:

Does my Thumb rule assumptions work?

Whether the gate specified will fill the cavity?

Would there be any Sink Marks?

And this list of questions grows…!

We may not be often very sure when we are about to send an injection Mold for a trial, Just because we are banking on the Thumb rules and we are going to solve the problems may occur using trial & error method as any experts can never predict 100% mould ability.

Solution:

How easy the life would be if we get answers for the above questions by a few clicks..!

Yes, you read it right. Using SolidWorks Plastics we can get the answers just by giving very minimal inputs like plastics material to be used, Injection location, and Run.

Let’s take a deep dive into this…We are done with the part Design; let’s choose a material from the extensive database of Plastics Materials based on the polymer family or the raw material manufacturers’ brand name for the material which also takes care of the Physical, Mechanical and chemical properties of the material selected to simulate the real time conditions.

We have different mesh options as well, where in we can choose between Shell mesh & Solid Mesh, Automatic mesh or manual mesh to have the mesh generated according to the requirements

Solid Mesh

Surface Mesh

Well, now we select the injection location of the part.

Here I have options to let the software automatically decide the gate location or I can choose the injection location which is appropriate.

Considering the diagonal vents on the part. If the flow is perpendicular, then flow fronts may meet and create weld lines, so to avoid or minimize the weld lines, gate location is chosen at this point.

 

 

 

 

 

And there are few fill stage settings like melt temperature, Mold temperature assumptions which is taken care automatically based on the material & gate diameter Inputs.

Let’s run the study and here we go with the results…

Advisor says this part can be successfully filled in 1.5 seconds with an Injection pressure of 100 Mpa. Fair enough, I can still fine tune the analysis in couple of minutes by playing around with the Mold temperature, Gate Diameter, finding an alternate material, All these virtually, So that I can avoid the return of Mold for further rework from Injection Moulding machine to tool room.

Conclusion:

We get the results predicting the fill time, pressure, Temperature, Sink marks, Weld lines, Air Traps and so on. Above that we will also get some advice from the software as we see in the above Image, which is termed as Plastics Advisor, which advices the user on successful filling of the part and also knowledge on why these results are critical.

Not done yet, Post processing is again as easy as clicking a button and I get the results captured and comes out with a nice presentation with flow animation in form of PPT, Doc & HTML.

So in the nutshell, we really need not to bank on thumb rules & assumptions anymore. Within few minutes we can predict the real time scenario of injection moulding of parts and we can modify the designs in no time, re run the analysis and send the part designs with enormous confidence on the manufacturability of the parts.

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