How to Optimize Your Injection Mold Designs with SOLIDWORKS Plastics

and everyone I am going to be showing you solidworks plastics and like Enid mention we’re gonna look at the fist pack and then you did a couple of the Warped cool module so there are three modules plastics comes in it is the appropriate Vance the pro is your fill module the premium has fill and pack and then the advanced has the fill pack and then warp and cool added to it so solidworks plastics is an add in module that I’m going to set here from aliens down here it is of the plastics and I’m going to have that load in it gives us a tab over here in the called the plastics manager and we’ll talk about it in a second plus another tab up here on the command manager for 39 options and getting into different aspects of this leading with the left side over here where we see the mesh first thing we have to do with any simulation is generate a mesh there are two types the shell and solid shell is for parts that have a constant wall thickness and then solid are for parts that of course don’t like you see on here where we have a difference in thicknesses as we go through I’m going to run this in a shell mesh and once we have this generated we will see much more information in that menu so this basically kind of acts as a wizard as we step through here these options down here have to do with cooling and and the warp setup so we’re going to skip those for right now I’m just going to hit next and on the next screen here in this category if we have multiple domains or multiple solid bodies in a single part plastics does not work on an assembly so we would need to build in a save that assembly out as a multi-part body to bring them to use it in here but we can have where we would label this as a cavity we can also have insert and then if we were doing morph and cool we would have a coin channel in mold so it can use inserts such as if you have a brass insert or steel or even the insert can be used as a secondary like if you’re doing a multi shot mold where the insert would be your first shot and then your cavity would be your second we only have one so we’re just going to next again and now we get into our meshing module here where we generate a mesh and you can kind of see on the screen I put in 50 file we are in English units right now generate across there the thing what I got to look at here is does it pick up the detail that I need outside and inside I do have some other options that are available to me so if I even loosen this up select a 1/4 mesh you can see it becomes really kind of jagged on the details that you see inside of here and outside the wall looks more like a chamfer than it does a natural filler we do have the ability to set a model local refinement set set allows me to localize so if I wanted to have these surfaces on this mesh right here to be a tighter value I can set those up and then it would use the triangle size for everything else or I can set Auto and Auto has a basically a slider down here that I can set up and when I do that you can see kind of based on the two values from the triangle size and this Auto it tries to put in some deviation changes where it needs to do that so if I tighten this up even more Gale gets a little tighter and tighter as far as the mesh follows so there is a kind of a balance act that you have to do between this because you don’t want to set this so tight that you have an overabundance of mesh elements that you would not necessarily need to generate the output for the fill or pack or whatever we’re doing but you do want it tight enough that it does follow the contours of the shape so one could even maybe loosen this up a little bit here the more yeah that looks pretty good I’m going to sit next to that because summary and the biggest thing is that it is waterproof that’s good and one thing to note on this this part is an imported part into cell alert it’s not necessarily a native part so it can work on both of those transforming gives us kind of a cross-section view through we can see the internals of the mast and see if everything looks good and it does in this case and I’m going to hit okay to that so now that that’s written up it’s files

that it needs for the mash you can see we have over on the right here for doing a solid type elements of 28,000 and a node so if we look at the mesh again this element the little leg you see the line and then a note is the connection point of all those together next thing you see the menu has has expanded a lot more because we have that mesh built and the material we can kind of step down here so SolidWorks plastic has over four five thousand different material types we can’t add to the library but it’s not available in there we can also search so if I’m looking for like a peek you can see I just type in a keyword and it gives me the different values that I have also I can go in and search by options so if I want to have a certain fiber count or mold temp that I’m looking for or melt I can do that underneath also peak I wanted to do that you it’s hard to kind of see there but the solid has a little green check so does the polymer the next thing I can do is is look at the fill pack and warp settings if that’s where I want to take those to notice down here on the run I do not have any cool because I skipped that section at the very beginning when I was creating the mesh so if we just briefly look at my fill settings I’m gonna use all the defaults here and let it figure out the filling time for me also but notice here it also has a fiber orientation calculation because the material contains 30% weight of pipe so we will actually see that calculation put into a into it also let’s go down to our injection location and we’re going to inject here at the tab o’clock right there I can actually run a predictive flow pattern on that after I added here to kind of give me an idea what that looks like tools if I want to up to ten gates have it predict for me and place the gates on the part and a lot of times it puts it in areas that you would not necessarily gate but it gives you an idea of the region maybe that you need to have that gate at it so to run this first flow analysis on this so if we start with our solid we’ve got that done we’ve got our polymer we’ve got our fill settings and we have our injection location so now we can actually let this run and start looking at some results I’m fairly really quick this does use all your course and threads on your computer that you have so it is using I’ve got a quad-core that I’m running so it actually is running eight threads and this screen right here has kind of given us a iteration view as it steps through here so we’ve got iterations we’ve got seconds we’ve got pressure temperature and then the percentage now one thing that gave me was a little warning up here that we’re getting very close to our max injection pressure which is I believe it’s 100 mega Pascal’s and I can set that I can vary it but by default that’s what it was and it’s still trying to fill it out to that level and we’ll see if it does it or if it actually short shot you you you don’t let this run just a little bit more here I said about 58% coming up on 60 now it should refresh the TUF again or at ninety nine points to to megapascals so we’re approaching our limit but it is still calculating out becomes seventy percent you you you and it looks like it actually shorted so let’s take a look at the summary here text file and read on the very bottom in there but let’s take a look results see what we get yeah full-time at the go all the way to the end so what we can

do then is right here the injection pressure limit I can set that a little bit higher and we can set this up to to go by machines so if you have a an Engel or oil or or something like that that you want to utilizes the machine you can set that up also you just run through here one more time and see if we can get that pressure limit running peak with just a little bit call material to try to pack out and fill out you you coming up here 40% you so the task manager here can see the BP user all of them are being used you you you when I plus 60 percent you warning again that we’re getting close to the Injection temp by injection picture sorry that will see if we can achieve full fulfil here what happened you you maybe and there’s 100 so we made it that time with a little bit more pressure behind it so now that we have some results we can see when this gets completed here a couple different things on the screen will happen one is this results advisor on the right side and at that red which means we can successfully fill it but we’re at or over 90% of the maximum injection pressure so we’re way up there and you can see it’s causing good cause filling packing problems the molding machine so maybe we need to change the temperature maybe we need to change the material we don’t we don’t know and that’s what plastics allows us to do is analyze that digitally before even making a prototype mold and finding the results start going to work at that level so we good things different things that we have in our flow results in this case one is the actual full front and this is because we did it in solid this is actually in three dimensions and if I scroll it back and forth you you can kind of see you it’ll go up and fill through that rib and continue on down the channel come on or thumb up the end you and then finally filling out a little tab at the very end of it but there’s a lot more to it that we can view also one is our pressures pressure the packs which time that occurs our temperatures now this looks like it’s all blue down here in this temp but we also have the ability to put in clipping planes and we can actually look internally through the Parker and see that of course with a lot hotter core inside of there in certain areas and just on that outside okay a lot of analysis that you can do right here on screen in the digital side of things in bulk tamp blow front shear stress is a very important shear rate cooling time that it would take again and cross-section that and look at the internal core of it temperature attic end of cooling that is calculating out even though we didn’t do a cooling analysis but this is kind of making a prediction sink marks you can see where a sinking flex will occur on the detail so what you see in red areas there are two file that it’s predicting if we had a multi gate it would show us the gate filling contribution we only have one gates of course everything is green then ease of Phil is allowing us to see where the problem areas are and it happens to be down here so what tells me

is that material is probably starting to solidify as it’s trying to push and get down to this area well that’s not necessarily a good thing in that case we can look at our velocity vectors and a little bit here gives you an idea of what the velocity looks like going through there vector lengths and their changes and because we had fiber we can also look at fiber orientation I can control what those links look like look for any weld lines any of them we can look for air traps you you a lot of the results we can we can view of course the flow results that we ran now if I ran pack we’d have flow and pack side of things but the other thing we can do outside of the result the actual like full flow results is the an XY plot which gives us a little bit more information of what’s going on here in that you can look at the pressure you can see it’s you know it’s kind of climbing pretty steadily as it goes up we can look at the inlet flow rate and when it gets out here 2 point 1 3 seconds it starts to taper off we can look at the x y&z clamping so they what allow us to know what our tonnage would be and then under node pressure down here in the bottom I can actually put in points pulled points that I want along and have it give me information on the graph you the other thing I can do with these probe points is if I put in a reference plane and on which plane so like right there and jump in here and put in points that would be sprite through the cross-section of that plane so right there I can add one maybe I want another one down here one there and one out here let’s say and points reside on that plane itself so it’s nice when you maybe have an insert and you want to view it cross-section and through the insert and then through the part itself the other that’s pressure side that I’m showing I can switch to actual temperature and you can see where the flow front comes in as these little spikes occur right here as it ramps up on the different points across so it gives us too nice a lot of different ways to view the actual output information from this the other thing we can do is actually generate a word or PowerPoint it’s going to generate a power point of our results you you something like that action if we want special notes then I can tell it to generate all the image files of those result and I’ll let this give it a second here – I’ll put everything you I’m going to open up where the data would be now it’s writing the actual PowerPoint and in a second tell us that it’s done and we can view it so it’s all completed here’s the PowerPoint and we can bring it up and review it and you can see all the output that it gave automatically for us all the different graphs we looked at the cross-sections no time is the actual animation and all those different image sets that I just went through and show you you that is a template that can be customized so it fits into your business model and with your own logo and all that type of stuff awful so that can be done very easily now the next thing is talk about PAC on this part PAC settings again I can have it automatically or I can put in the holding time and temperature one other thing also is that I can have it took a profile and I can actually

input a profile and match what I would see on a press I can also do that on the fill side and the other thing is residual stress calculation an interesting thing about that is when we have that calculated we can output that information or the in-mold stress when we would run a warp we can bring that back in to SolidWorks Simulation tools and have that as a pre process setup in simulation that this part already has these stresses built into it from the molding cycle so I’m just going to let the PAC side of things run here this should run fairly really quick and then adult quick and then I will show you an example that has the warp and cool module added into it the nice thing with the the way this runs is that if I am NOT like seeing the results that I want especially if you’re running the flow I can stop this at any time can stop the whole procedure instead of having to wait for it to get completely done all right so they’re the pack results are in so there’s the pressures at the end of pack now we can look at the temperature Trustin here still kind of come down on the bottom here of course and Coulee pop down in the end there we can also control these clipping planes back and forth so we can cross section through it bulk temp shear stress shear rate volumetric temperature and so forth all of them you know kind of similar to what the flow results were but this was at the end of the filling only this is at the end of pack now so now we’re into the cool stage of thing speaking of that let me load in the other example that I have you yeah let’s get the other results loaded so Moll there we go all right so this one’s set up very similar to what I just showed in the last example except in this case instead of just getting down here I actually have a sprue and runner and gate system in and I’m getting at the top of the sprue to stimulate actually the whole system now of how this is going to going to work so if we look at the fill time in this case run it back and forward here and kind of see the way it advances through through those open sections there kind of does little backfill through the ribs again we concern zoom up analyze it like closer see what’s going on with everything you and then you know kind of wrapped all the way down looking at the pressures temperatures and again just like before we can do cross-sections through it take a look at what’s going on you sheer stress see raid again we can look at the to the vectors patience in this case we actually have some wild lines and those appear here from blue to green green or red green to red can be come basically a meld situation where it’s not necessarily as strong what you have to do again is analyze it view where that does it make sense that that’s you know gonna cause an issue with stress or a failure on the model but at least it gives you that idea and you can see it on the model Oh of course we can look at hair traps so forth so same things type of thing is we have before you look at the pack results quickly and you cross section and again you can see the temperatures people temperature at end of pack all the temperature a lot of us being in the core here of our sprue and runner system and we can get into warp now this is where we can actually look at the total

direction and this is everything overall it is at a deformed scale of just one so this is actually the way it’s going to to warp the wireframe to see is the act to model and then the actual warps model is shown in there and if we can play this and let it shrink itself and warp itself out now the reason it’s doing on one side versus the other has to do with our reference origin and warp reference plane which we can set so if I wanted that to be more in the center I can certainly do that and have it warped that way and it could also be warping naturally in that because of the way these ribs are all exposed here versus being a lot more solid on this side so that might be just the way it is but you can switch that around for those different planes now if it happened to be too small of a warp detection we also exaggerated it which I put it at three times now you can kind of see how that side and actually this corner is is curling itself we can look in the x value and the y and in the Z directions independently or overall look at the in mold residual stress and this is the one that I was talking about that we can actually have output then this information from here can be saved out brought into simulation and used as kind of the precursor of running the simulation on it quenching and then we’ve got total stress without the fiber in there of this calculation you you you and then from the cooling side of things this introduces in an actual cooling line that is either developed with just a simple sketch which is the way this one is you look at this model that’s all that is right there is that simple sketch that you see sketch 49 and I declare how the diameter is and then also the inlet and then what temperature will kind of fluid is it that’s going through is a water and oil something like that and then this will actually utilize this with what we call a virtual tool which is just a big block built around it and what that allows for is when we do a cross-section of like the and of cooling you the cross-section through and see cavity visibility disability section through there and see what the part looks like and along with the the actual cutter I’m sorry the cooling lines and see how they are dealing test the temperature that is being pulled from the park from the injection method through into the actual block you he’s loading you can see how the coin lines are hot in these areas is nothing in the center of it of course but if I turn off its you can get this one clean off here clean up back one one of these other planes I go so there you can kind of get an eye what that looks like from the cooling sense so it gives you an idea if the design is correct do we need to put in a bubbler or a cascade or something else to help pull more heat out of the part maybe there’s something I’ve got to put in there to help pull heat out of the core down in this area but the cooling options allow you to do that again all those tools that we had available before here the XY plot also available this gives us a little bit more information at this time because we did a full full run-through so we have to flow the pack and then the actual cooling down here now do we need almost 21 seconds full cycle on this maybe not maybe so but the tools allow us to analyze that and see what is what is going on

so here’s clamping force and the X enforcing the why and envy then of course again I can put in values that I want to probe along here and send that in so that the point at that point right there and keep adding them in those are pressures in this case it could be temperatures and that’s on the part if I add another one there you can see temperatures and then it can also look at the actual node temperature of the actual cooling process so this is all filling before this is the actual cooling process here you you couple things before we wrap up is some more visibility analysis tools that you can have here let me turn off of things down on the bottom here is this ISIL surface manager which allows me to basically create kind of an array of cuts through you want to basically like a time stamp what it looks like I’m doing 24 account gives you a quick snapshot of what the flow front looks like without hassle to run the flow front and the other one that is available on the bottom here is the path line which basically allows us to kind of trace a a molecule of plastic as it enters to where it stops on the surface of the mold what is exactly going on inside of the of the plastic tool all digital all done before you know we have to make any design changes in the tool which can get expensive we can take care of that and handle that upfront here inside of SolidWorks and make the designs and test our theories out