In the second step, the thermal histories of all the elements during processing are obtained after the processing simulation, which are further exported to equation to calculate the yield stress. In this case, the calculated yield stress from the thermal processing history can be directly adopted in the mechanical simulation without interpolations.
Note that the meshes of the product in the processing simulation model should be exactly the same as the meshes of the mechanical simulation model. In the first step, the finite element model of the product, developed in LS-DYNA, is imported into Moldflow for simulation of the injection molding process.
For a color version of this figure, see – Illustration of the integrated simulation framework. (For example, consider the example of radial flow pattern, in which the core layers of fibers will align in the circumferential direction because of the expansion flow characteristic.)įigure 4.7. Even though it is possible to create a surface mesh for any 3D geometry, not every geometry is accurately solved by the dual domain method.ĭual domain analysis also includes fiber orientation (for fiber-filled composite materials). In any region where the solid geometry has a 3D nature (no clearly identifiable thickness direction) the flow assumptions become invalid. The weakness of the dual domain methods is that it is still using the flow assumptions of thin-walled (shell-like) parts. Its strength is the ease of meshing from solid geometry (when compared to midplane mesh preparation from solid geometry) and the high resolution of field variables through thickness (where they are changing very rapidly) (when compared to 3D meshes). Then the two surface meshes are synchronized. It is a clever way to automate the process of meshing a solid model into a surface mesh on each surface. This method is patented by Moldflow and used exclusively by them. Fischer, in Handbook of Molded Part Shrinkage and Warpage, 2013 9.6.3 Dual Domain FEA Regarding tool surface temperature determination in Moldflow, thermal analysis of ANSYS at permanent phase and Moldflow at the transient phase was conducted according to the ANSYS User Manual, Version 6. Running different simulations resulted in the most favorable setting appropriate to produce 100 wax models per hour, whereas in conventional tooling these two parameters are 5 s and 10 s, which results in 300 shots per hour. Among injection setting parameters, injection time was set at 10 s and freeze time at 30 s. Therefore, by consulting the Moldflow Company, similar wax data from Argueso Company were provided to the Moldflow database. While providing wax model and tool data to the Moldflow, the proposed wax data did not exist in the Moldflow database. Parameters investigated include filling patterns, temperature profiles, residual stresses, tool clamping force center of gravity, the pressure at different time intervals, tool temperature at any time, and freeze time, providing correct data input results in appropriate analysis. The Moldflow package was applied to simulate and predict different scenarios and investigate the optimum tool design and injection parameters. Rahmati, in Comprehensive Materials Processing, 2014 10.12.5.2.1 Wax Injection Process Simulation