HTC10 - Moldex3D - David Hsu PDF

True 3D CAE for Injection Molding
HyperWorks Enabled Moldex3D

True 3D Injection Molding Simulation
Streamlines Plastic Part Design and Manufacturing
David C.H.Hsu
Vice President
davidhsu@moldex3d.com
CoreTech System Co., Ltd.
www.moldex3d.com
Date: 2010/4/28
1
Company Preview

CoreTech system develops and globally markets

Moldex3D for injection molding industry since 1995.
Moldex3D is the innovator in TRUE 3D molding CAE
We have a global service network through direct
offices and professional reseller in the world.
1000+ Moldex3D installed in the world.
Headquarter, HsinChu
Silicon Valley of Taiwan
2
120 employees
Global support network

Moldex3D Application Fields

Moldex3D has been used by designers and

engineers across a broad spectrum of industries
Customers List
Thousands of Moldex3D Industrial

Applications
5000+ real cases accumulated so far
Common Plastic Parts Produced by

Injection Molding Process
Product Development Cycle

by Integrating CAE
Concept
ConceptDesign
Design
Part
Partthickness/design
thickness/design
Runner
Runnerdesign
design
Gate
design
Gate design
Cooling
Coolingsystem
systemdesign
design
Part
Part Design
Design
CAE Tool
Mold
MoldBuild
Build
Molding
MoldingTrial
Trial
Optimize Process
Condition and
Trouble-Shooting
Mold Design Change
Mold
MoldDesign
Design
Part Design Change
Verify/Optimize
Design Parameters
Production
Production
Customers Challenges and Troubles
Carbon
Footprint
Shorter
Time to Market
Higher Cost
Raw Material
Energy
LightWeighted
Professional
Know-How
Development
New Process Complicated

Technologies
Design
Price
Competition
Quality
Demands
Long Product
Development
Business
Growth
Quality
Accountability
Countless
Trial & Errors
Limited
Profitability
Customer
Recognition
What Moldex3D Can Do?

Appearance and dimension

Weld line, air trap, flow mark
Flow balance, shrinkage and
warpage control
Cost down
Remove hot and cold spots for
cycle time reduction
Mold structure optimization
Reduce mold trial and tooling
cost
Production
Injection condition optimization
Clamping force reduction,
machine selection
Moldex3D Product Line

Moldex3D/eXplorer
Moldex3D/eDesign
Part design investigation for part

designer to ensure design concept
Design verification for all

product/mold designers
Moldex3D/Solid & Shell

Design optimization for all parts,

especially engineering products.
Moldex3D Modules for Professionals
Fiber
Fiber
FLOW
FLOW
PACK
PACK
COOL
COOL
WARP
WARP
Interface
Interface to
to
Structural
Structural CAE
CAE
MCM
MCM
True 3D, Parallel Computing

Viscoelastic
Viscoelastic
Plastics
Inj. Molding
Precision Parts
Optical Parts
Fiber-Filled
Multi-Shots
Optics
Optics
Reactive
Inj. Molding
Moldex3D Product Comparison in

Details
Semi-automatic
Available in
HW-enabled
Moldex3D
Moldex3D Flow Analysis

Moldex3D-Flow predicts melt front, weld line, air trap,

short shot and process window
Moldex3D Flow Analysis
Runner optimized for flow balance
14
Weld line evaluation
Moldex3D Packing Analysis

15
Moldex3D-Pack simulates the density variation and

melt flow due to material compressibility
Moldex3D Cooling Analysis

Moldex3D-Cool simulates mold temperature, cooling

efficiency, hot spot, cooling time
Moldex3D Warpage Analysis

Moldex3D-Warp simulates the part warpage due to

volumetric shirnkage and further help to control these
defects before mold is built
Moldex3D Fiber Analysis

18
Moldex3D-Fiber simulates the 3D fiber orientation and

calculates the process-induced anisotropic properties
Moldex3D Fiber Analysis
W/ Fiber
W/O Fiber
Multi-Component Molding (MCM)

Moldex3D-MCM simulates the Multi-Compoent Molding,

Inser molding and over molding process.
Moldex3D-Visoelasticity
Moldex3D-Viscoelasticity predicts the flowinduced residual stress and prevent the

potential design problem.
Predicated Residual stress
Residual stress observed

by Chemical Test
Moldex3D-Optics
Moldex3D-OPTICS can precisely predict the

birefringence caused by complicated process-induced
anisotropy in the space
Predicted Birefringence
22
Experiment
Moldex3D-I2
Moldex3D-I2 is a series of interface modules to integrate

Moldex3D and structural CAE software, including
ABAQUS, ANSYS, MSC.Nastran, NENastran, LS-Dyna,
Marc and DigiMat.
Part with fiber filled
Part without fiber filled
X5
X5
Unique Features of Moldex3D
Quick 3D CAE
for Designer
Versatile
3D Meshing
Leader in
3D molding CAE
High Accuracy
With TRUE 3D
24
Parallel
Computing
Moldex3D Technology Road Map

R10.0
Moldex3D Road Map
3DGas
3DGas
ICM
ICM
eDesign+
eDesign+
R9.1
R9.0 eXplorer
eXplorer
eDesign
eDesign
BLM
BLM
R8.1
Hybrid
Hybrid Mesh
Mesh
Solid-I2
Solid-I2
TetraEx
TetraEx
R7.1
VE
VE
TransCool
TransCool
Voxel
Voxel
95
90
RHCM
RHCM
R7.0
R6.0
Fast-Cool
Fast-Cool
AutoGate
AutoGate
Shell-F/P/C/W
Shell-F/P/C/W
R5.0
AutoRunner
AutoRunner
R4.0
R3.1
1995
80
75
400
800
1200
1600
Time(sec)
IC-Package
IC-Package
Enh-Flow
Enh-Flow
Solid-Flow
Solid-Flow
Gas-C/W
Gas-C/W
85
70
Fast-Cool
Fast-Cool
DOE
DOE
R6.3
RCS
RCS
Optics
Optics
R8.0
3DMesh
3DMesh
Stress
Stress
Tempearture (oC)
Technology
Solid-I2+
Solid-I2+
Solid-Fiber
Solid-Fiber
Solid-Pack
Solid-Pack
X64
X64
Solid-RIM
Solid-RIM
MCM
MCM
Parallel-Cluster
Parallel-Cluster
Solid-Cool
Solid-Cool
Solid-Warp
Solid-Warp
Parallel-SMP
Parallel-SMP
LM
LM
SA
SA
Enh
Enh Fast-Cool
Fast-Cool
Year
2000
2005
2010
Versatile 3D Meshing Technologies

26
Hexahedron, Prism, Tetrahedron, Pyramid, and a mixture of any of

the element types mentioned above.
Boundary Layer Mesh (BLM)

Typical temperature profile
-Can fit all geometry

-Poorer numerical property
-Automatic is possible
Tetra Element
Prism/Hexa Element
Hybri
d
27
-Hard to mesh for complicated geometry

-Better numerical property
-Hard to automatic
-Used to capture great gradient near boundary
BLM
(Automati
c Hybrid)

Meshing Technology
Boundary Layer Mesh (BLM) - To get more

accurate temperature resolution through
thickness direction
CPU socket is built in BLM (2,241,955)

BLM produces more sensible and consistent temperature
distribution
Tetra
29
BLM
High Accuracy with True 3D Simulation
Measured position (mm)
2.5
2
7.5 sec
1.5
8.5 sec
9.0 sec
1
0.5
0
0
50
100
150
200
250
Temperature (oC)
Experiment
30
Simulation
High Temperature Resolution Across

Thickness
Accurate temperature
resolution guarantees
correct filling, shrinkage
and warpage predictions
[31]
Short shot pattern

34
Short shot prediction of Moldex3D

High Fiber Prediction Accuracy
Fully 3D Modeling for Whole Mold System
36
Quick True 3D Analysis in Minutes:

Moldex3D-eDesign
Import
Import STL
STL
Create
Create Runner
Runner
Set
Set Melt
Melt Etrn
Etrn
Meshing
Meshing
Create
Create
Cooling
Cooling System
System
Run
Run
Simulation
Simulation
37
Quick True 3D Analysis in Minutes:

Moldex3D-eDesign
3D Solid
STL
3D Solver
Filling
Warp
Packing
Cooling
High Performance Parallel Computing
Parallel Computing
by
The entire parallel computing support in Flow,
Cluster & PC
Pack, Cool, Warp, Fiber, MCM, and so on.
W
W
O
R
K
O
R
K

1,066,448 Elements
Moldex3D Flow
Mode
Computing
Time
Speedup
1x1
core
14932 sec
(4.1Hr)
1.000
4x4
core
1487 sec (0.4Hr)
10.042
Computation time can be reduced from hours to minutes!

Comprehensive Interfaces to
Thermo-Mechanical FEA
Warpage
Mold Deform
Modal Analysis
Moldex3D/I2 with
3D Mesh and Data
Core-Shift
Drop Test
Impact
Seamless Integration Analysis

Paddle-Shift
Wire-Sweep
Complete Polymer Material Solution

Material Database
CoreTech/NTHU Lab.
Intl Database/Lab.
Material Supplier
GE, Dow, Bayer,

Dupont, BASF
DSM
Rheology, PVT, Thermal Conductivity, Heat Capacity, Mechanical
Customized database
Moldex3D Application Examples
44
Moldex3D User:
SAMSUNG
Part Design and Cooling Optimization
Optimize part design

and cooling system
Warpage prediction
and control
Cycle time reduced
by 16 sec, material
cost reduced by 9%
45
Moldex3D User:
LEGO
46
Moldex3D User:
LEGO

47
Runner balancing
Cycle time estimation
Process optimization
Tool optimization
Moldex3D User:
Unilever
Temperature difference :45oC ->15oC

Cooling time reduced by 25% (from 4 to 3 sec)
Save
48 4 million sec
Moldex3D User:
Unilever
Hot Runner Modeling
49
Moldex3D User:
Grundfos
Part
Part 7
7 mm
mm cold
cold runner
runner
Melt
Melt core
core 13
13 sec.
sec.
Gab
Gab in
in flow
flow in
in packing
packing fase
fase
Improved
Improved Part
Part 8
8 mm
mm cold
cold runner
runner
and
and flowleader
flowleader
Melt
Melt core
core at
at 18
18 sec.
sec.
Moldex3D User:
SimpaTec GmbH
Conventional cooling
Conformal cooling
51
Moldex3D User: Connector Case
The area
suggested to be
cored out
Warpage improved by 20% after

thickness cored out
52
Moldex3D User: (MCM case)

Through the optimization of runner, warpage can be reduced by 20%
Moldex3D User:
G-Plast
Meter Panel
Moldex3D User:
HYUNDAI
Engine Cover
HyperWorks-Enabled Moldex3D
Moldex3D is now a member of HyperWorks Enabled

Community (HWEC)
With Moldex3D in HWEC, you can prepare

Moldex3D/Solid and Moldex3D/Shell models directly
in HyperMesh.
You can experience the most unique advantages of

Moldex3D/eDesign. Moldex3D/eDesign provides users
with easy-to-use interface, advanced functions and
accurate plastic injection molding simulation results.
56
Partnership Commitment
The addition of Moldex3D into the HWEC demonstrates our
continued commitment to providing our HyperWorks users with
innovative technologies to increased flexibility shorten the
product development process and save money.
Martin Nichols, Executive Vice President
Altairs Global Partner Programs.
By leveraging the mutual strengths of HyperWorks and
Moldex3D, Altair customers can obtain high quality simulation
results efficiently and effectively without any additional cost.
Manufacturing companies will be able to simulate the most
advanced processes to optimize their product design and
manufacturability and maximize their return on investment
Venny Yang, President of CoreTech System
From the Press Release, 2010/2
57
HW-enabled Moldex3D GWU Draw

Advanced
2000 GWUs
Advanced
1500 GWUs
Viscoelasticiy/Optics
GasIn
Performance
1500 GWUs
Performance
2000 GWUs
Performance
1500 GWUs
Fiber/MCM/I2
5-8 CPU-cores
Fiber/MCM/I2
5-8 CPU-cores
Fiber/MCM/I2
Base
3500 GWUs
Base
6000 GWUs
Base
3500 GWUs
F/P/C/W/RIM
1-4 CPU-cores
F/P/C/W/RIM
1-4 CPU-cores
F/P/C/W/RIM
eDesign
58
Solid
Shell
Moldex3D HW-Enabled interface

Export MFE from HyperMesh directly
Execute Moldex3D HW-Enabled.
59

Export MSH from HyperMesh directly
Execute Moldex3D HW-Enabled
60

Execute Moldex3D HW-Enabled Designer
Execute Moldex3D HW-Enabled
61
Join the 3D Winners Camp
Thank you for your attention!
CoreTech System Co., Ltd.

:+886-3-5600199
:+886-3-5600198
:mail@moldex3d.com
:http://www.moldex3d.com

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True 3D CAE for Injection Molding

HyperWorks Enabled Moldex3D

CoreTech system develops and globally markets

Global support network

Moldex3D Application Fields

Moldex3D has been used by designers and

True 3D CAE for Injection Molding

True 3D CAE for Injection Molding

Thousands of Moldex3D Industrial

True 3D CAE for Injection Molding

Common Plastic Parts Produced by

True 3D CAE for Injection Molding

Product Development Cycle

Mold Design Change

Part Design Change

Customers Challenges and Troubles

New Process Complicated

True 3D CAE for Injection Molding

What Moldex3D Can Do?

Appearance and dimension

Moldex3D Product Line

Part design investigation for part

Design verification for all

Moldex3D/Solid & Shell

Design optimization for all parts,

True 3D CAE for Injection Molding

Moldex3D Modules for Professionals

True 3D, Parallel Computing

True 3D CAE for Injection Molding

Moldex3D Product Comparison in

True 3D CAE for Injection Molding

Moldex3D Flow Analysis

Moldex3D-Flow predicts melt front, weld line, air trap,

True 3D CAE for Injection Molding

Moldex3D Flow Analysis

Runner optimized for flow balance

Weld line evaluation

True 3D CAE for Injection Molding

Moldex3D Packing Analysis

Moldex3D-Pack simulates the density variation and

True 3D CAE for Injection Molding

Moldex3D Cooling Analysis

Moldex3D-Cool simulates mold temperature, cooling

True 3D CAE for Injection Molding

Moldex3D Warpage Analysis

Moldex3D-Warp simulates the part warpage due to

True 3D CAE for Injection Molding

Moldex3D Fiber Analysis

Moldex3D-Fiber simulates the 3D fiber orientation and

True 3D CAE for Injection Molding

Moldex3D Fiber Analysis

True 3D CAE for Injection Molding

Multi-Component Molding (MCM)

Moldex3D-MCM simulates the Multi-Compoent Molding,

True 3D CAE for Injection Molding

Moldex3D-Viscoelasticity predicts the flowinduced residual stress and prevent the

Predicated Residual stress

Residual stress observed

Moldex3D-OPTICS can precisely predict the

Moldex3D-I2 is a series of interface modules to integrate

Part without fiber filled

True 3D CAE for Injection Molding