Moldex3D, Structural Analysis, and HyperStudy

Integrated in HyperWorks Platform

Anthony Yang
Moldex3D
CoreTech System and Moldex3D

The worlds largest injection molding CAE ISV

80% experienced engineering professionals
50% of employees involved in R&D activities
9 global offices, local support from Michigan
1,200+ global customers
6,000+ industrial projects validation
1,200+ Global Customers in various industry
Moldex3D leads the way of Technology development

2003: 1st complete 3D CAE for plastic molding(Solid)

2005: 1st SMP/DMP 3D CAE for plastic molding

2007: propriety automatic 3D meshing (eDesign)

2009: exclusive compatibility with multiple 3D CAD

How Moldex3D Can Help?
Aesthetics and dimensional concerns
Weld line, air trap, flow mark
Flow balance and part weight
shrinkage and warpage control
Fiber orientation

Being more competitive

Cycle time reduction by removing
hot & cold spots
Mold structure optimization
Reduce mold trial & tooling cost

Reaching Lean Production

Injection conditions optimization
Clamping force reduction
Machine selection
Moldex3D Flow Analysis

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

short shot and process window
 Moldex3D Packing Analysis
Moldex3D-Pack simulates the density variation and melt
flow due to material compressibility

7
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 shrinkage

and further help to control these defects before mold is built
 Moldex3D Fiber Analysis
Moldex3D-Fiber simulates the 3D fiber orientation and calculates the
process-induced anisotropic properties

10
MCM Analysis in Moldex3D

Moldex3D-MCM simulates the Multi-Component Molding, Insert molding

and over molding process.
Exclusive Moldex3D Features
 Quick True 3D Analysis in Minutes:

Create Runner Create Run

Import STL Meshing
Set Melt Etrn Cooling System Simulation

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Automatic 3D hybrid meshing capability
eDesign:
Intelligent Gate Wizard
eDesign:
Intelligent Runner Wizard
Accuracy - by running FULL 3D analysis

High temperature resolution in runners

eDesign:
Intelligent Cooling System Wizard

Support the ALL cooling

system in 3D
SMP/DMP Parallel Computing with excellent
acceleration ratio

Moldex3D R9.1 Solid-Flow Parallel Computing Performance on an Intel Core i7 Cluster - Speed Up Ratio

1.00 Car Grill (elements: 713,558, R9.1 Solid-Flow Enhanced)

1 Core (1 CPU) 1.00 16-cavity Lens (elements: 1,066,448, R9.1 Solid-Flow Standard)
1.00 Tray (elements: 1,422,416, R9.1 Solid-Flow Standard)
Benchmark Hardware - One BoxClusterNX (www.boxcluster.com)
2.01 - 4-node PC cluster
2 Cores (2 CPUs) 1.89 - one Intel Core i7 940 CPU on each node
- 12 GB DDR3 RAM on each node
- Gigabit network

4.00
4 Cores (4 CPUs) 3.65

6.98
8 Cores (4 CPUs) 6.81
7.64

10.40
16 Cores (4 CPUs) 10.92
11.75

0.00 4.00 8.00 12.00 16.00

Speep Up Ratio

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 Moldex3D Application Examples

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BASF New material development for automotive
bumper

Fllverhalten bei 50% Fllung

Fllverhalten bei 75% Fllung

 Moldex3D:Danfoss

Improve design from one

material molding into two
color molding

Reduce cycle time of the

molding by 43%. Shorten
time to the market.

Reduce material cost by

11% via product geometry
optimization

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 Moldex3D User: Connector Case

The area
suggested to
be cored out

Warpage improved by 20% after

thickness cored out

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 Moldex3D User: Unilever

Temperature difference :45oC ->15oC

Cooling time reduced by 25% (from 5 to 3 sec)
24Save 4 million sec
FEA Integration Analysis
What can Moldex3D-FEA Interface to Abaqus do?

To consider the process-induced variation during the processes

Mesh output
Original / deformed mesh
Mesh mapping
Material properties output
Anisotropic properties
Fiber Orientation tensor
Result output
Thermal/Residual stress
Temperature (Part/Mold)
Pressure history (Part/Mold)
 Moldex3D-FEA InterfaceAnisotropic material
properties

Based on the fiber orientation and proper micro-mechanics models,

Moldex3D-FEA Interface can output
Stiffness matrix
Thermal expansion coefficient

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Moldex3D-FEA Interface Orientation tensor (for
Digimat)

Orientation tensor can be output to composite modeling software

(Digimat) to perform more accurate micro mechanical properties
calculation
 Moldex3D-FEA InterfaceMaterial Reduction

Material Reduction
Moldex3-FEA Interface can reduce the anisotropy scale by homogenizing the
similar anisotropic properties so as to improve the computational efficiency

Total material number from Total material number from

76,150 to 1,866 3,392 to 668

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Technology Link of FEA Interface
Structure
Moldex3D Simulation Ejection Application
Analysis

Flow Pack Cool Warp

FEA-
ANSYS
Warpage
FEA-
ABAQUS Mold Deform

FEA-MSC Structural
Nastran

FEA-MSC Modal Analysis

Marc
Drop Test
FEA
LS-DYNA Impact

FEA-NX Paddle-Shift
Nastran
Core-Shift
FEA-
RADIOSS
Moldex3D-FEA InterfaceInterface to Abaqus

3. Select output meshtype

2. Select Abaqus Solver

4. Select output
data

1. Click FEA
Interface Icon

5. Export .inp file

 Tensile Bar - Wend Line strength reduction

Weld Line Location

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 Fiber Orientation around the weld line

Weld Line Location

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 Major Modulus

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 Tensile Bar Stress
30MPa Load Applied

Yield at 80 Mpa
47 MPa

30 MPa Load

Yield at 80 Mpa
79 MPa
30 MPa Load

35 0-80 MPa Range displayed

 Thrust Pedal Filling Animation

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 Thrust Pedal Fiber Orientation

37
 Thrust Pedal Major Modulus

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 Thrust Pedal Minor Modulus

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 Thrust Pedal Model Setup

Fix the pin slot

Apply a force on
the Pedal

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 Thrust Pedal Displacement & Stress
200lbf (900 N) Force Applied
Displacement Stress

isotropic

anisotropic

41 0-50 mm range 0-100 MPa range

Integration between Moldex3D and

HyperStudy

Improving Part Quality for Injection

Molding
Introduction: Moldex3D and HyperStudy

Moldex3D
Moldex3D is the world leading CAE product for the plastics injection molding
industry

HyperStudy
HyperStudy is software to perform Design of Experiments (DOE), optimization,
and stochastic studies in a CAE environment
HyperStudy is a member of the HyperWorks suite of software products

Benefits of Moldex3D and HyperStudy Integration

Users can employ HyperStudy to perform a series of Moldex3D analyses
systematically for improving part qualities
Process conditions can be optimized automatically
Moldex3D supports all study types for HyperStudy
Workflow between Moldex3D and HyperStudy

Create an initial run and perform a preliminary analysis

Copy new design factor file and Do Study setup, DOE setup and
call Moldex3D as the solver others setups
through script function

Output response factor

Finish all runs and obtain optimal results
Integrating Moldex3D and HyperStudy:

DOE Study
Case Study

An injection molded part from a speed meter shows potential warpage

problem from preliminary Moldex3D analyses.
Dimension: 400 x 126 x 76 mm
The target is to reduce warpage through optimizing process conditions
with HyperStudy and Moldex3D using DOE study.
Design of Experiments Conditions

DOE Class: 9-run Fractional Factorial

Initial Design Variables
Filling Time: 2 sec
Melt Temperature: 230C
Mold Temperature: 70C
Packing Pressure Profile %: 75%

Design Variables
Number of Variables: 4
Filling Time: 1.7, 2, 2.3 sec (3 levels)
Melt Temperature: 220, 240C (2 levels)
Mold Temperature: 65, 75C (2 levels)
Packing Pressure Profile %: 70, 75, 80 % (3 levels)

Response Variable
Standard deviation for total displacement (mm)
In other words, the target is to have as uniform displacement as possible
DOE Study: Create a DOE Study

Select DOE Class

Detail setting of the Study setup is shown in appendix

DOE Study: Controlled Variables

Define Design Variables:

Select Design variables

Setup Design variable

bounds and level values
DOE Study: DOE Run Table
Design of Experiments: Run Results
Run Summary

This chart indicates the melt

temperature and packing
pressure profile are the most
sensitive factors

Main Effects
DOE Optimal Results

Variables Initial Results DOE Results

Filling Time (sec) 2 2.3
Melt Temperature (C) 230 220
Design Variables
Mold Temperature (C) 70 65
Packing Pressure Profile (%) 75 80
Response Variable SD for Total Displacement (mm) 0.354 0.262

HyperStudy DOE study will lead to minimum standard deviation (SD) for Total
Displacement. It implies that the part deformation will become more uniform in
general.
Initial Results DOE Results
Integrating Moldex3D and HyperStudy:

Optimization Study
Create an Optimization Study

The same optimization target can be achieved by employing an

Optimization Study. For example: Adaptive Response Surface Method
(ARSM)

Select Optimization Engine

Other optimization engines available in

HyperStudy are
Optimization Study: Define Design Variables

Define Design Variables:

Filling Time (Range: 1.7, 2.3 sec)
Melt Temperature (Range: 220, 240C)
Mold Temperature (Range: 65, 75C)
Packing Pressure Profile % (Range: 70, 80 %)
Settings for Objectives

Objectives:
Goal: Minimum Standard Deviation (SD) for Total Displacement
Maximum Iterations: 20
Absolute Convergence: 0.001
Relative Convergence: 1.0%
Optimal Results

History Plot

History Table

Optimized design factors

Optimal Results

Variables Initial Run Optimal Run

Filling Time (sec) 2 2.3
Melt Temperature (C) 230 220
Design Variables
Mold Temperature (C) 70 65
Packing Pressure Profile( %) 75 80
Response Variable SD for Total Displacement (mm) 0.354 0.262

Recommended optimal results will lead to the minimum standard deviation (SD)
for Total Displacement. It means that the part deformation will become more
uniform in general.
Initial Results Optimal Results
Summary
Comparison

Variables Initial Results DOE Results Optimal Results

Filling Time (sec) 2 2.3 2.3
Melt Temperature (C) 230 220 220
Design Variables
Mold Temperature (C) 70 65 65
Packing Pressure Profile( %) 75 80 80
Response Variable SD for Total Displacement (mm) 0.354 0.262 0.262
Warpage Improvement
0% 26% 26%
{[0.354-(Other results)]/0.354}*100%

Initial results DOE/Optimal results

Upper and lower limit values fixed to initial results

Conclusion

The integration between Moldex3D and HyperStudy helps users to find out the
optimal process conditions for injection molding systemically.

Both DOE Study and Optimal Study can reduce maximum displacement from 1.4
mm (initial design) to 1.0 mm (optimal design), which is a 27% improvement.

According to the DOE Study results, melt temperature is the most important and
filling time is the least important factor for warpage of this case.

Both DOE Study and Optimization Study can reduce warpage by 26%. However,
please note its likely to find different optimization studies lead to slightly
different optimized results.