Ritz Chang1, Eric Hsueh 2 , Hank Liao1, Stephen Chung1 , Venny Yang1

and Srikar Vallury1

Moldex3D for Effective Design Validation, Optimization of

Plastic Parts and Molds, and Cooperation with

HyperStudy and Radioss/OptiStruct

1CoreTech System (Moldex3D), 2 Flotrend Corporation

2

> Moldex3D Overview

> Moldex3D Expert – DOE Analysis

> Integration of Moldex3D and HyperStudy

> Integration of Moldex3D with OptiStruct and RADIOSS

Outline

Moldex3D Overview

4

> The world’s leading innovator of professional true 3D CAE software for injection molding simulation

> World’s largest professional team (250 employees, 80% technical professionals ) dedicated to plastics injection molding simulation

> Provide leading software solution and attentive technicalsupport to work with global customers for optimizing the process from design through manufacturing

> Assist users to significantly reduce product development time, achieve design excellence, and shorten time to market

Moldex3D - MOLDING INNOVATION

5

> Moldex3D employs the leading theories of polymer

physics, fluid dynamics and material mechanics to

simulate injection molding process and product quality

> Digitally validate and optimize the product and mold

design upfront for producing quality parts efficiently and

effectively

> Identify the root causes of quality blemishes scientifically,

replace the time-consuming trial-and-error approach

What’s Moldex3D for?

Iteration

6

> Aesthetics and Dimensional Concerns

– Weld line, air trap, flow mark

– Flow balance and part weight

– Shrinkage and warpage control

– Fiber orientation

> Being More Competitive

– Cycle time reduction by removing

hot & cold spots

– Mold structure optimization

– Reduce mold trial & tooling cost

> Reaching Lean Production

– Injection conditions optimization

– Clamping force reduction

– Machine selection

How Moldex3D Can Help?

6

7

> Adopted by 1,800+ renowned companies and industries to prove its

capabilities of bringing quality solutions:

Moldex3D Reference Customers

Automobile High Tech/Electronics Material/Equipment

8

APA Available Modules – What’s New

RADIOSS

FEA Interface

Moldex3D

Molding Analysis

9

Integration of Moldex3D with

HyperWorks

3.Output Response 1

(Total Displacement)

7.Optimal process condition with

minimal displacement/stress

4. Export fem file with

Moldex3D FEA Interface

6.Output Response 2

(Max Stress)

2.DOE setup in HyperStudy;

Perform a series of injection

molding analysis

5.Set up boundary conditions for

structural analysis

HyperMesh

HyperMorph

OptiStruct

1.Multiple Choice on

Pre-processing tools

Moldex3D Expert

DOE Analysis

11

What is Moldex3D Expert

> Moldex3D Expert Module equips with Design of Experiment

(DOE) method to assist designers to determine appropriate

injection molding condition

> Optimization application

– Dimension of runner, gate position, and optimal process

condition etc.

– Providing 15 Taguchi orthogonal arrays up to L54

12

Advantage – Diversity of Design Factors

Various control factors

1. Manufacture parameters (Process)

2. Material

3. Designs of runner and gate (Mesh)

4. Part Design (Mesh)

Various quality factors

1. Experimentally measurable factors:

Deformation, sink mark, etc.

2. Non-experimentally measurable factor:

Volume shrinkage, internal pressure, etc

13

Advantage – Various Statistic Results

Quality Response of each factor

S/N Response of each factor

Quality Response of each run

Sensitivity analysis

14

Case study – Geometric Accuracy for Fisheye Lens

63.5 mm

17.5

mm

2.8 mm

Fisheye lensCooling channel

Runner

Cavity

15

Case Study – Step up of DOE

> Step 1 : select DOE module in expert run

> Step 2 : specify a quality factor

> Step 3 : specify control factors and corresponding levels

> Step 4 : assign Taguchi orthogonal array

Parameters of ODE

Level 1 Level 2 Level 3

A Filling time 1 s 2 s 4 s

B Melt temperature 225 235 245

C Packing pressure 60 80 100

D Mold temperature 110 120 130

1 2 3 4

Filling time, melt temperature, packing pressure, and

mold temperature are chosen as control factors

Quality factor:

smaller line shrinkage along

the center axis

16

Case Study – Analysis Result

> From the results of S/N ratio, the following information

can be obtained.

– Best combination : A3 B1 C3 D2

– Most sensitive factor: Packing pressure

– The effect of filling time and mold temperature are minor.

Filling time Melt temperature

Packing pressure

Mold temperature

Integration of Moldex3D and

HyperStudy

18

Moldex3D-HyperStudy Integration

> Step1: Create a preliminary run in

Moldex3D

> Step2: Prepare Batch and Scrip file

> Step3: Set up a Study for Moldex3D

Molding Analysis on HyperStudy

> Step4: Set up a DOE analysis in

HyperStudy

> Step5: Validate the optimized result

in Moldex3D, or in other FEA

product (FEA Interface)

Step1, 2

Step3

Step4

Step5

19

Prepare Batch and Script File

> A preliminary run for target project

> Batch: *.bat generated using any note pad tools

> Script: *.msp generated using Moldex3D Script Wizard

Run Moldex3D

Moldex3D Script file

Project file path for analysis

Script file path

Batch file

20

DOE Study: Select Design Variables

Choose Filling Time, Injection pressure

and Packing Time as design variables.

21

> Select response factor from *.mer file which create by

Moldex3D

DOE Study: Select Response

Response Factor: Total Displacement

2. Open *.mer file and

select response factor

1. Click “Extracts”

3. Import

Expression

22

DOE Study: Specification and Run Task

Choose the DOE model

Define design variable array

Optimized design factors

23

Optimized Result

Variables Initial Results DOE Results

Design Variables

Filling Time (sec) 2 2.3

Melt Temperature (˚C) 230 220

Mold Temperature (˚C) 70 65

Packing Pressure Profile( %) 75 80

Response Variable SD for Total Displacement (mm) 0.354 0.262

Warpage Improvement

{[0.354-(Other results)]/0.354}*100%0% 26%

Initial results DOE results

Upper and lower limit values fixed to initial results

Integration of Moldex3D with

OptiStruct and RADIOSS

25

Workflow of Moldex3D and HyperWorks

OptiStruct

• Topology Optimization

HyperMesh

• Supports CAD geometry and existing finite element models

• Build and Optimize meshes from a set of quality criteria

HyperStudy

• Manage DOE optimization workflow, and design variables

• Call Moldex3D, write input and record output of analysis

Moldex3D

• Perform a series of injection FRM molding analysis

• Export fem file with Moldex3D FEA Interface to RADIOSS

RADIOSS

• Non-linear Structural analysis

26

> Model

– Use: Engine bracket

– Dimension: 62 x 187 x 110 mm

> Material

– PA6_Durethan BG30XH20 (GF 30%)

> Platform

– Moldex3D & HyperWorks 13.0

> Goal

– To find process conditions which minimize warpage for

fiber-reinforced plastics parts

– To find the optimized geometry within allowable stress

Case Study

Moldex3D

RADIOSS

27

Topology Optimization with Optistruct

> Original model imported in OptiStruct

28

Topology Optimization with Optistruct

> Result of Topology Optimization

29

HyperMesh

> Develop Solid mesh with optimized geometry and quality

criteria

30

> DOE Class:

– 16-run Fractional Factorial

> Initial Design Variables

– Filling Time: 6.27 sec

– Injection Pressure: 155 MPa

– Packing Time: 20 sec

> Design Variables

– Number of Variables: 3

– Filling Time: 5-10 sec (16 levels)

– Injection Pressure: 50-200 MPa(16 levels)

– Packing Time: 10-30 sec (16 levels)

> Response Variable

– Total Displacement (Moldex3D)

Molding Process Optimization through

Moldex3D and HyperStudy by DOE

31

DOE Study: Optimization Output

Initial run

DOE run

Optimized Response

32

> DOE analysis is performed by

HyperStudty cooperating with

Moldex3D

> Optimal process condition as

result to reduce part deformation

during injection molding

DOE Optimal Results

Variables Initial Results DOE Results

Design Variables

Filling Time (sec) 6.27 6.9

Injection Pressure (MPa) 155 170

Packing Time(sec) 20 22

Response Value Total Displacement 2.331 2.250 3.4%

33

Structural Analysis for Fiber-reinforced

product

> Traditional structural analysis

– Assume isotropic materials.

– Neglects molding effects,

– Results not reflect real situation.

> Moldex3D FEA interface + RADIOSS

– Provide the following material information

to non-linear stress solver:

• Stiffness matrix

• Thermal expansion coefficient

• Density

34

Export FEM file to RADIOSS

Through Moldex3D FEA Interface,

Export fem file for RADIOSS Set B.C. in RADIOSS:

Initial Strain + External force + Constraints

NOTE:

Initial strain output from FEA interface has

considered fiber-induced anisotropic

mechanical properties.

35

Structural analysis with Radioss

> Validation with Max. displacement result

> The weight decreased by 15% with acceptable deformation

Original Design Modified Design

Max. displacement= 0.166 mmMax. displacement= 0.190 mm

36

Structural analysis with Radioss

> Validation with Max. von Mises stress result

> Evaluate the structure strength

Max. von Mises stress = 14.2 MPaMax. von Mises stress = 20.7 MPa

Original Design Modified Design

37

Conclusion

> OptiStruct helps to rapidly develop lightweight, structurally

efficient designs by creating innovative concepts

> By iteration between Moldex3D and HyperStudy, Optimal

process condition for fiber-reinforced product can be obtained

> Simulation results from Moldex3D for the optimum process

conditions can be analyzed

> Moldex3D FEA Interface provides material information

considering fiber-induced anisotropic properties, while

RADIOSS use this to perform non-linear FEA

> Moldex3D, along with HyperWorks, helps find potential

problems, provide optimized solutions and make competitive

products