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



Autodesk Financing

Stream Engeneering

HRS Flow

Volume Graphics GmbH




2013 - A Strong European Community - Be In Sight! - Final Call

11. June 2013 to 12. June 2013


4. European Moldflow® User Meeting


in Frankfurt/Main organized by MF SOFTWARE


Anyone who has not yet known whether he / she could participate, has still the chance to register.
We are pleased to announce further lectures for the CONNECT! European Moldflow User Meeting 2013 (see below). All presentations will be translated by live translators from English into German and vice versa. tl_files/connect_template/bilder/news/2013/Uebersetzer.jpg
In the training room decorated especially for you, you have the opportunity to test new features from the Moldflow Release 2014, to obtain practical insights into CFD and Digimat or to clarify questions from everyday use during the consultation hours. tl_files/connect_template/bilder/news/2013/ATC-Trainingsraum.png
In addition to professional topics you can also appreciate other program points.

As evening program we invite you to "Casino Royale". Professional croupiers will guide you through the rules of roulette, blackjack or craps, an exciting dice game.

The second day is traditionally opened with a running club before breakfast. Also in this year, employees of PEG and MF SOFTWARE are looking forward to seeing you at the joint jogging session.

Remember your running shoes!




Further presentations:

Gayle Rose, BD Technologies (USA)
Impacting Mold Development with ASMI2013


A new tool was being designed for BD’s 60 mL Syringe Barrel. Analyses with Autodesk Simulation Moldflow Insight 2013 (ASMI2013) were conducted during mold development in order to explore the new mold’s capabilities before it was brought into production. The mold used a dual gate design which was new for this part.

  • The effect of a blocked gate showed good agreement with short shots from the press.
  • Recommendations for a staged pack phase were documented. When the tool came on line, in cavity sensor’s showed agreement with analytical results and a version of the recommended pack phase was implemented. These results streamlined the process development phase, allowing the mold to come on line faster and with less scrap.
  • Results showed that some regions of the part were difficult to cool. During initial mold trials, the decision was made to change the water layout. These changes were implemented during process development and resulted in a shorter cycle time.

Dr. Guido Tosello, Technische Universität Dänemark
Micro Injection Molding High Accuracy Three-Dimensional Simulation and Process Control


Part 1 - Micro Injection Molding High Accuracy Three-dimensional Simulation and Process Control

Data analysis and simulations of micro-molding experiments have been conducted. Micro molding simulations have been executed by implementing in the software the actual processing conditions. Various aspects of the simulation set-up have been considered in order to improve the simulation accuracy (i.e. decrease deviations from experimental values): injection speed profile, cavity injection pressure, melt and mould temperatures, three-dimensional mesh parameters, and material rheological characterization. Quality factors investigated for the quantitative comparisons were: short shot length, injection pressure profile, molding mass and flow pattern.
The importance of calibrated micro molding process monitoring for an accurate implementation strategy of the simulation and its validation has been demonstrated. In fact, inconsistencies and uncertainties in the experimental data must be minimized to avoid introducing uncertainties in the simulation calculations.
Simulations of bulky sub-100 milligrams micro molded parts have been validated and a methodology for accurate micro molding simulations was established.

Part 2 – Performance evaluation of an engineering software tool for automated design of cooling systems in injection molding

A method for automating the design of cooling systems for injection molding has been developed and implemented into a software engineering tool. A performance evaluation of the design tool was performed by carrying out injection molding process simulations using the Autodesk Moldflow Insight package. The quality of the molded parts was assessed. The cooling system design was automatically generated by the proposed software tool and by applying a best practice tool engineering design approach. The two different design methods (i.e. automatic and manual) were applied to the mould design of two thin-walled products, namely a rectangular flat box and a cylindrical container with a flat base. Different cooling systems produce different warpage conditions in the part and therefore different geometrical form error. The process simulation results in terms of part accuracy (e.g. form error such as flatness and cylindricity) obtained from both cooling systems designs were compared in order to actually evaluate the validity of the cooling design system proposed by the automatic solutions. Preliminary results produced by the newly developed engineering software tool validation are presented.

Stefan Schmidseder, Dräxlmaier Group
Interpretation and Visualization of Warpage Results with AMI2reality


Misinterpretation of warpage results often leads to wrong decisions and thus to high costs and the loss of confidence in simulations. In order to prevent that the software AMI2reality has been developed at Dräxlmaier Group, which allows a clear comparison between reality and simulation, creating a uniform basis for all project parties.

Dr.-Ing. Franco Costa, Senior Research Leader for Autodesk® Moldflow® Simulation Codes
New Capabilities in Moldflow Insight and Technology Previews


Review of new functionality in Autodesk Moldflow Insight and Scandium Technology Preview which represent the current research directions in Moldflow development. Capabilities discussed will include: 3D Injection Compression Molding, Conformal Cooling Support, 3D Heater Elements, Buckling analysis for 3D Warp, Crystallization analysis, Breakage of Long Fibers and properties of LFT Composites, Bi-Injection Molding, Multiple Cylinder Support for 3D Gas, Improved wall slip calculation, Viscoelastic Residual Stress, Ejection force prediction, Analysis of Mold fatigue.

MA.-Ing. Hanno van Raalte, Product Manager for Autodesk® Moldflow® Insight
Autodesk® Simulation Moldflow® 2014 –
What's New?


Also the last year many new developments have been implemented in the Autodesk Moldflow Software. During this presentation you will get an overview of new features of the CAD import, speed improvement, mold cooling capabilities and material behavior.

Dr. rer. nat. Andreas Wonisch, BASF SE (D)
Numerical Optimization of the Gating Points of Injection Molded Plastic Parts


The position of gating points has a great relevance for injection molded plastic parts. It influences the flow behavior and thereby pressure loss, weld lines and fiber orientation. The exact position impacts directly the mechanical behavior and especially the general tendency of Warpage. This talk shows how to use Autodesk Simulation Moldflow and special optimization software to perform a fully automated numerical optimization of the gating position – given any user-defined specification. In addition to the underlying workflow two sample applications will be presented. The first one will demonstrate how the Warpage of the sealing face of a two-component-lid can be reduced significantly by optimizing the gating position. The second example shows the successful balancing of a multi-cascade of a LBS part (Lower bumper stiffener).

Prof. Gerrit W.M. Peters, TU Eindhoven (DK)
Modeling flow induced crystallization during injection: - what about the parameters?


We have made substantial progress with modeling of flow induced crystallization (FIC) of polymers in the last decade. It includes detailed information on the time evolution of number and size of different types of crystallites for, when applicable, different crystalline phases. Moreover, the model incorporates the influence of the rheological behavior, i.e. the molecular weight distribution, and processing conditions such as temperature, pressure and deformation histories. The model is based on a large number of experimental observations of which synchrotron X-ray scattering gives not only the possibility to measure quantitatively at different length scales of the different crystalline structures, but also allow for time resolved results, i.e. follow the kinetics at time scales of the order 10-2 - 10-1 sec. With the more detailed and complicated experimental methods physical insight is gained, not only for deep understanding of underlying processes and relations, but also for motivated simplifications of the model; an important issue when striving for real processing applications. This model was implemented in a finite element code for the numerical simulation of the injection molding process. Predictions of the distribution of, for example, the specific shish number and length were compared with experimental results for an iPP grade.
However, the success of such models, i.e. if people are going to use them in codes like MOLDFLOW, depends strongly on the ease with which the many parameters in model can be determined. Standard lab equipment or relatively easy to operate new methods should be sufficient to do the job; not everybody has weekly access to a synchrotron. Moreover, these experiments should be feasible within reasonable times.
In this presentation, I will briefly discuss the FIC-model and then present examples of how to determine parameter values for real processing conditions and show in which direction we are moving to reach this goal. Next to optical methods and (Flash)-DSC, rheometry and extended dilatometry are two important examples of experimental methods used because the effect of flow can be included.

Dr. Camilo Cruz, Robert Bosch GmbH (D)
In the Development of a Simulation-Based Weld-Line Strength Criterion


Weld-lines are commonly weak spots in thermoplastic injection-moulded parts. In fact, given the rapid cooling rates usually employed in injection moulding, complete healing between the encountered melt fronts cannot be guaranteed. In addition, flow-induced molecular orientation and parallel fibre orientation are typical issues at the weld-line position inducing clear disadvantages in terms of mechanical performance. Hence, predicting the healing degree (mechanical strength) between polymer interfaces at the weld-line is important in terms of product design. Healing degree between polymer interfaces can be physically modelled based on the reptation theory. Such modelling depends fundamentally on the thermal evolution at the weld-line interface. Injection-moulding simulation software can be employed then for recovering the thermal information used afterwards in the model estimating the local healing degree of a given weld-line. A description of the physical modelling as well as an exploitation of the model based on process-simulation results will be covered during the presentation. Finally, a first correlation attempt between a simulation-based weld-line strength criterion and the experimental mechanical performance at the weld-line will be showed.

Dr. Alan R. Wedgewood, DuPont (USA)
Accurate Fiber Orientation Prediction for Injection Molded Short Glass Fiber Reinforced Thermoplastic Part


To accurately predict many key performance properties of parts made by injection molding fiber reinforced thermoplastic polymers, correct predictions of the fiber orientation and aspect ratio are required. Since experimental determination of the fiber orientation throughout a part is impracticable at this time, mold filling simulation models are necessary to predict the fiber orientation throughout a part. Autodesk Moldflow® simulation software offers various models for prediction of the fiber orientation. The fiber interaction parameters in these models are determined by making comparisons between Moldflow® simulations and experimental measures of the fiber orientation. Optimization of the model parameters requires an advanced understanding of assumptions made by the Moldflow® simulation software and experimental orientation measurement method. Likewise, a similar understanding is required for the assumptions made by other verification calculations, such as anisotropic modulus. This presentation provides new insights into the optimization of the Moldflow® model parameters and offers improvements of the experimental fiber orientation measurement. These advancements are illustrated with measurements made on DuPont Zytel® products.

Tony Amende, Fraunhofer IZM (D)
Microchip Encapsulation and Wire Sweep Simulation with Autodesk Simulation Moldflow


State of the art control units are typically placed in hermetic housings. Therein the electronic board is placed and the active and passive components are commonly connected with bonding wire technologies to achieve the electronic functionality. The requirements on the reliability of hermetic houses are very high especially as the product lifetime is long and the bonding wires are progressively thinner in diameter for future applications. One major failure source in these state of the art housings is the malfunction caused by vibrations. Here, the unsupported bonding wires can short cut easily as the distance between wires is only about two times the wire diameter. This problem can be overcome when the whole package is encapsulated in future applications. Therefore reactive moulding compounds can be used and processed within the transfer moulding technology at low pressures. This process has the advantage that sensitive components can be encapsulated without destruction. The generation of the non-trivial 3D constructions and the transfer into Autodesk Moldflow with first results will be treated in this presentation so that future fabrication processes can be evaluated and optimized virtually.

Dr. Gilles Robert, Solvay - Rhodia Engineering (F)
Use of Moldflow for Integrative Simulation: Accuracy in Different Situations


Integrative simulation of fibre reinforced polymers requires an information about local fibre orientation which is most of the time generated by Moldflow, and constitutive models for matrix behaviour. It appears that for complex structures, accuracy of computations made with Molflow is good enough to ensure a very good global performance of integrative simulation, when constitutive models are reliable enough. However, identification of such models cannot be done using orientation data generated with Moldflow : measured microstructures are the only one which ensure a satisfying performance of identifications.

Uwe Frigge, Phoenix Contact GmbH (D)
Automated evaluation of warpage


The simulation of deformation with a model of 1.6e6 tetrahedra and 300000 nodes only takes a few minutes. In comparison, much time must be spent on the evaluation of the deformation of only a few edges and surfaces. This paper covers how the evaluation of the deformation can be considerably simplified through automation, independent from mesh and position.

Sascha Pazour, Part Engineering GmbH (D
Interconnection of Simulation Moldflow and Structural Mechanics


The process-structure interaction allows the consideration of the anisotropic mechanical behavior of short fiber reinforced injection-molded plastic components in the FEM calculation. This enables significantly better evaluation of component stiffness and failure occurrence. With conventional isotropic calculation methods the influence of the fiber reinforcement is not detected. By means of transmission of pressure and / or temperature statements can be made regarding tool deformation, especially core shift or thermal-mechanical stresses of inserts during filling. With the ability to transfer shrinkage, deformation and residual stresses, there is the possibility to use the real component geometry including frozen stresses for structural analysis.

Thibault Villette, e-Xstream Engineering (L)
Processing and the Final Performance of Parts: Looking Beyond Injection Molding


The production of composite parts relies on an ever increasing number of processing technologies. Production has a large impact on the performance of the part. Processing is usually optimized for the usage with specific materials. Commonly used technologies are injection molding, (injection-) compression molding and even innovative technologies such as MuCell®. They combined with short or long fiber reinforced polymer materials. For MuCell® the advantages of foam structures in the polymer matrix are sought.
To reach the best possible design for some specific performance of the composite part under a given constraint such as e.g. the overall weight, it is important to go through optimization cycles for the processing step, the structural design and even of the material itself. The final performance of the part will depend on all three of them at the same time. Today it is possible to set up multi-scale simulations where all three influences are fully coupled. Thus, they can be investigated in one unique approach.
The presentation will deal with the role of micromechanics in such coupled analyses. All mentioned processing technologies and materials will be covered. Stiffness, failure and fatigue of reinforced plastics will be discussed. Specific needs of the areas of Automotive and Aerospace will be highlighted, covering the approach to material modeling as well as the introduction of coupled in an industrial context.

Stefan Kühne, Autodesk Inc. (D)
What's New - Some Features in Use


Workflow to create Conformal Cooling models
In diesem Teil des Vortrags geht es darum, die neue Berechnungsmöglichkeit in Moldflow Insight 2014 für den User näher zu beleuchten: Alle Arbeitsschritte werden ausführlich in logischer Reihenfolge dargestellt, vom Modell einlesen bis zum fertigen Cool(FEM) Modell mit 3D Channels für eine konturnahe Kühlung. Die Erzeugung des 3D Channel Solids wird mit Hilfe des Inventor Fusion anschaulich mit einfließen. Um eine optimale Netzdichte zu erzielen, werden die Vernetzungsoptionen beleuchtet und ebenso die Einstellmöglichkeiten der neuen CDF Vernetzung erläutert. Für eine bessere Interpretierbarkeit der 3D Channel-Ergebnisse werden die Einstellungen in den Properties besprochen.

Workflow zum Erstellen von 2fach-komponenten Verfahren
This part of the talk is about the new calculation option in Moldflow Insight 2014 and gives the user a closer light: All steps are in a logical sequence, starting from reading in the model to the finished Cool (FEM) model including 3D channels for the conformal cooling analysis. The generation of the 3D channel solids in Inventor Fusion will be shown. The meshing options are highlighted in order to achieve an optimal density distribution. The setting of the new CDF meshing are also explained. For better interpretability of the 3D channel results the settings are discussed.

Helmut Schmitz, Autodesk Inc. (D)
Simulation on the Cloud - Introducing Autodesk Simulation 360


The necessary reduction of development time in order to remain competitive on the market, has resulted in many companies using simulation products today as a strategic means to achieve this goal. With Autodesk Simulation 360 we are now driving the next step in this development. With the help of cloud-based simulations, the user has the option, especially at peak times, to implement projects efficiently and promptly due to the almost unlimited capacity of a cloud system. The presentation gives an insight into how Autodesk integrates the already known and proven simulation solutions in the ecosystem of the cloud and what possibilities arise from that.


We are looking forward to your participation!

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