CONNTECT! Moldflow® User Meeting 2011 - Tuesday, 17. 05. - Wednesday, 18. 05. 2011 Frankfurt


CONNECT! - Refreshing Ideas


9. CONNECT! European Moldflow® User Meeting


5th - 6th June 2018, Frankfurt/Main


Don’t miss this opportunity


Get valuable information about using the injection molding simulation software Moldflow. During the two-day conference you can learn about the latest features and network with other Moldflow users from industry or research and development. Share your experience with the software directly with responsible Autodesk Moldflow staff.


The registration for the CONNECT! 2018 is open.


The event will take place at the Lindner Congress Hotel in Frankfurt Höchst where a room contingent at discounted rates is available if you mention the password “MF SOFTWARE”.

Please find here the announcement of the first presentations:





Simulation of insert deformation for thermoset materials

Injection moulding is one of the most important processes for manufacturing thermoset materials. In order to be able to produce high-quality parts and thus meet the standards of the automotive industry, but at the same time to have a mass-production capable manufacturing process, optimal process parameters have to be determined. These process parameters and boundary conditions are identified by means of systematic process simulation.



Florian Wittemann, KIT - Institut für Fahrzeugsystemtechnik (D)

Florian Wittemann studied mechanical engineering at the Karlsruhe Institute of Technology (KIT) where he also received his Master of Science degree in materials and structures for high-performance systems in September 2016. After graduating, Florian Wittemann worked for six months as a research assistant at the KIT - Institute for Vehicle Systems Technology, Institute for Lightweight Construction Technology. Since March 2017 he has also been working on his doctorate at this institute in the field of thermoset injection moulding simulation.





Numerical and experimental study of the powder injection molding (PIM) process

Powder injection molding (PIM) is a well-established process for the production of sintered ceramic or metal parts. Ceramic or metal powder is mixed with a thermoplastic binder system to form a flowable feedstock, which can be processed on an injection molding machine. After injection molding the binder is removed and the part is sintered. The final part quality is strongly influenced by the injection molding process. Specifically, phase separation between binder and powder frequently occurs resulting in voids in regions with higher binder concentration. Additionally, PIM feedstocks feature special flow phenomena like yield stress or wall slipping effects.

In this study the PIM feature of Autodesk Moldflow Insight (AMI) was used to simulate the PIM process for a metallic tensile testing specimen. Selected process conditions as well as part properties were measured experimentally and compared with simulation results.

The viscosity curve showed a yield stress, which was described with a Cross-WLF equation with Herschel-Bulkley extension. As this material model was not available in the standard software, it had to be implemented using the Application Programming Interface (API) option in AMI. A filling study was performed experimentally and the shape of the flow front was compared with simulation results. The experimentally observed jetting phenomena could not be well reproduced by AMI, and also the pressure prediction significantly deviated from experimental values – the exact reason for that is not yet clear, but it seems that the complex rheological behavior of metal feedstocks is not yet fully understood and adequately described. The powder volume concentration was simulated based on the so called “suspension balance model” (SBM) implemented in AMI. The powder volume concentration was evaluated at two selected positions in the real moldings using thermogravimetric analysis (TGA). The simulated results showed relatively good agreement with the experimentally obtained values.



assoz. Prof. Dr. Thomas Lucyshyn, Montanuniversität Leoben (A)

Assoc. Prof. Dr. Thomas Lucyshyn studied Polymer Engineering and Science at Montanuniversitaet Leoben (A), focusing on polymer processing. After his diploma, he did his doctorate in the field of pvT measurement close to the process and its impact on injection molding simulation with Moldflow at the Chair of Polymer Processing in 2009. Since 2010 he is Head of the Injection Molding Division at the Chair of Polymer Processing in Leoben and habilitated as a professor for polymer processing in 2016. His habilitation thesis focused on injection molding with a special focus on the tool. He is currently Associate Professor of Polymer Processing at the chair of the same name at Montanuniversitaet Leoben and head of the divisions of injection molding and compounding. He started to work with Moldflow in 1998 and has thus 20 years of experience in the application of Moldflow, which he also teaches to students in his own course. A special focus of the scientific work with Moldflow is the relation between material data and simulation results.



Thermomechanical Simulation with Moldflow & Ultrasim

Fibre-filled plastics behave thermomechanically very complex. The mechanical properties of plastics are strongly influenced by temperature. For example, the stiffness decreases with increasing temperature but the elongation at break increases. Plastics also expand with increasing temperatures which can lead to dimensional changes and thermal deflection of components. This thermal deflection depends on the local temperature and fiber orientation in the component. This is particularly critical for E&E components with integrated switching elements. The highly sensitive electronics must not be damaged. Precise prediction of thermal deformation is therefore very important. In this lecture a method is presented that describes the simulation of the manufacturing process by means of Moldflow and calculates the fiber orientation and residual stress. Thermal deformation is then simulated with a FE simulation program, using BASF's own material modelling software Ultrasim.



Dr. rer. nat. Andreas Wonisch, BASF SE (D)

Dr. Wonisch studied physics at the University of Bielefeld. After completing his diploma at the Fraunhofer Institute for Mechanics of Materials IWM in Freiburg, he received his doctorate in the field of simulation of granular media and complex fluids and was awarded the Materials Mechanics Prize of the Plansee Mitsubishi Group for this work in 2009. Until 2011 he was a research assistant at the Fraunhofer IWM and has been working for BASF SE since then, focusing on the rheological behaviour of technical plastics, numerical optimization and model development. In 2015 he assumed the position of Team Leader Process Analysis.




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