Definition Flow analysis provides the ability to accurately simulate the filling phase of the injection molding process.

Definition

Flow analysis provides the ability to accurately simulate the filling phase of the injection molding process. The ability to simulate any number of part designs, runner sizes, gate locations, process, etc. creates a “what if” design environment before initiating the mold building process. The result eliminates typical trial-and-error methods.

What can a flow analysis determine?

  • Uniformity of Fill
  • Determine gate location(s)
  • Determine gate size
  • Determine fill time
  • Cold runner size & balance
  • Evaluate hot runner
  • Hot to Cold
  • Bore diameter sizing
  • Sequential valve gating
  • Valve gate timing sequence
  • Evaluate filling pattern
  • Pressure to fill
  • Flow induced shear stress
  • Part temperature
  • Weld line prediction
  • Air trap prediction
  • Fiber alignment
  • Processing conditions

What processing information is provided?

  • Injection time
  • Injection pressure
  • Melt temperature
  • Mold surface temperature
  • Minimum clamp tonnage

 What benefits can be realized through a MoldFlow analysis?

  • Elimination of trial-and-error methods prior to cutting of steel
  • Reduced set-up time
  • Solutions to existing filling problems
  • Material savings
  • Improved part quality
  • Optimized processing conditions
  • Evaluate different materials

Can the software predict fiber orientation?
Yes, the software can predict the orientation of fiber throughout the cavity.

Can Moldflow determine if high shear is present?
Yes, we can illustrate the shear stress and shear rate for a given material.

Can you predict part warpage?
Yes, warpage is caused by internal stresses within the part. Internal stress is primarily caused by excessive shear during fill, which in turn, can be magnified by differential cooling. The warpage module can illustrate and identify the main causes of warpage.

What other factors can cause part warpage?
Uneven melt and mold surface temperatures can lead to excessive part warpage and other problems such as poor weld lines.

Can you tell me what shrinkage to cut the mold?
By doing a complete warpage analysis, we can run a shrinkage determination algorithm that will determine the shrinkage factor to which mold steel should be cut based on the processing conditions run in the filling, packing, and cooling analyses. This shrinkage algorithm also determines the level of validity of those shrinkage calculations.