Smart Design

Smart Design and
Manufacturing in
Moldex3D
MID 2019
Industry 4.0 Era : Smart Design+Manufacturing
Source :https://www.simio.com/applications/industry-40/index.php
Challenges in Manufacturing Industry
> The shortage of trained talent

– Population crisis.
– Lack of employees.
> How to maximize manufacturing performance?

– Avoid plastic injection molding defects from tooling design.
– Maximize CAE performance to improve quality and increase
productivity.
> How to share and reuse historical data?

– Data accumulation of design and injection.
– A comprehensive design guide from knowledge base.
3
Smart Design and Manufacturing in Moldex3D
Manufacturing of the Future
Smart Design Smart Manufacturing

CAD/CAE Collaboration Virtual-Reality Integration
• Attributes recognition • Machine analysis
• Defect detection • Complete mold analysis
• Smart simulation interface • Machine characterization
• Smart PVT optimizer • Machine Interface
• Customized auto report • Knowledge database
4
Moldex3D in Industry 4.0 : Simulation
From Smart Design to Smart Manufacturing
Cooling
Simulation
Filling Screw
Packing Simulation
Simulation
Simulation
Smart Design
Warpage
Simulation
Material Modeling :
Processing properties
Viscoelasticity
Micro-mechanics
Structure
…
Simulation
Smart Manufacturing
Mold Structure
Simulation
Realistic
Machine Interface
Optimization
Moldex3D in Industry 4.0 : Simulation From Molding To
Total Process
Past : CAE Simulation (Software)
Now : Simulation+Data
(Software+Material+Machine)
Future : Total Process/Factory

Simulation
( Modeling+Big Data)
System Scopes
SDM System
Smart Smart Consulting

Design Manufacturing Services
Attributes Machine Machine
Recognition Analysis Characterization
Defect Machine Material
Detection Interface Characterization
Smart Complete Mold Training&
Simulation Analysis Certificate
Smart Data
PVT Optimizer Integration
Auto Report Knowledge
Customization Database
7
Development Timetable
SDM 1.0 SDM 2.0 SDM 3.0

Process Complete Mold
Smart Functions
Optimizer Analysis
Report Knowledge Smart Manufacturing
Customization Database Parameters
Material
Characterization
Machine
Characterization
Machine
Interface
Data Integration
11
SDM System 1.0
12
Smart Report Material Machine Machine Data
SDM 1.0 Functions Customization Characterization Characterization Interface Integration
> Smart Functions: Attributes Recognition

– Recognize attributes of Standard Parts automatically.
– Set attributes of Non-Standards manually.
Runner
Reused
Standard • Attributes
Parts attached
Cooling
Reused
Attribute
Recognition
• Setting
Manually
Non- Hand
Standards Drawing
13
> Smart Functions: Defect Detection

– One-click to detect mesh problems of geometry defects.
– Manually repairing surface defects in CAD interface.
14
> Smart Functions: Smart Simulation

– Easily set material and machine data in drop-down list.
Attributes
Recognition
Defect Y
Detection
N
Surface
Repair
15
> Smart Functions: Auto Report Generation

– Automatically generate analysis report.
16
> Report Customization

– Customized service of automatic report.
17
> Material Characterization

– Measuring correct and accurate material
data for reliable CAE analyses.
• Moldex3D Laboratory
Rheograph RG25 PVT-6000 • ISO/IEC 17025
Capillary Rheometer Polymer PVT Tester
Clamping Force Shrinkage

Air Trap Warpage
Welding Line Roundness
DSC8500 Differential Instron-8966

Scanning Calorimetry Mechanical Tester
Specific Heat Residual Stress

Heat Transfer Warpage
Coefficient
18
> Machine Characterization: Machine Analysis

– Consider virtual nozzle and barrel according to machine
specification and injection speed setting.
Screw Head Hydraulic Chamber
Quick Response
Slow Response
Flow rate at screw head

Flow rate at nozzle
19
> Machine Characterization: Machine Analysis

– US8768662 B2 2014
– Molding system using
computer-implemented
simulation method
• Consider the volume variation
due to the compressibility
from molding material
• Consider the dynamic effect
of machine response
– Non-Transitory computer medium
for use in molding process
• Generate the molding conditions
from CAE to injection machine
• Support connection by using a
hard wire or a wireless between
injection machine and CAE
20
> Machine Characterization: Fitting Response

– Measure and fit machine response to achieve
virtual-reality integration.
Injection Settings
Machine Response
𝝎𝟐𝒏
𝑮 𝑺 =
𝑺𝟐 + 𝟐ξ𝝎𝒏 𝑺 + 𝝎𝟐𝒏
21
> Machine Characterization: Fitting Response

– CAE injection speed curve is consistent with real machine
response for reliable prediction of simulation.
Speed Setting
Machine Speed
Characterized Speed
> Machine Interface

– Develop machine interface to transform CAE process
parameters according to realistic machine panel.
23
Training &
SDM 1.0 Certificate
> Training & Certificate

– Cultivate Integrated talents and advanced CAE engineers of
mold industry to enhance core competencies of enterprise.
• Design & Analyses • Advanced analyses
Surface Area:A
Moving Wall (velocity V)
 y At steady state, laminar flow condition

H v V 
 H linear velocity profile:
y
Stationary Wall
25
SDM System 2.0
26
Process Knowledge
SDM 2.0 Optimizer Database
> Process Optimizer

– Automatically optimize flow rate profile to obtain uniform
melt front and proper clamping force.
Clamping Force(Ton)
Original 1563
Optimized 1049
difference 514
27
Process Knowledge
> Process Optimizer

– Automatically optimize injection pressure profile to obtain
uniform shrinkage and minimize warpage.
Injection Pressure Standard Deviation Shrinkage

Profile Setting of Shrinkage(%) (Max-Min)(%)
1 Section 0.52 1.37
3 Sections 0.49 1.09
Optimizer 0.38 0.51
28
Process Knowledge
> Process Optimizer

– US Patents applied and received.
NO. United State Patent Types

Display Screen With an Animated User Interface for a Molding Process
1 (US D790,582 S)
Design
Display Screen With an Animated Graphical User Interface for a

2 Molding Process(US D784,392 S)
Design
Display Screen with an Animated Graphical User Interface

3 (US D817,970 S)
Design
Method for Operating a Molding Machine with a Predicted In-Mold

4 PVT Waveform of a Molding Resin(US 9,555,571 B1)
Invention
Molding System and Method for Operating the Same

5 (US 9,684,295 B2)
Invention
Molding System
6 (US 10,076,862 B1)
Invention
29
Process Knowledge
> Knowledge Database

– Create a knowledge database to share and reuse historical
simulation data to provide design recommendations.
• Design Guideline
• Types
• Thickness
• L/T ratio
• Runner
geometry
• Material
• Machine
30
SDM System 3.0
31
Complete Smart Manufacturing
SDM 3.0 Mold Analysis Parameters
> Complete Mold Analysis

– Build complete mold mesh model including mold plates and
screw through non-matching mesh technique.
32
> Complete Mold analysis

– Complete mold analysis with non-matching mesh
technology has developed.
– Support different mold inserts/core/cavity/parting
displacement/mold plate(movable or fixed).
33
> Complete Mold analysis

– Real complete mold analysis including Part, Runner, Cooling
system, mold base, injection machine, machine interface…etc
34
Successful Story
35
Success Story: CM Technology
> Customer Profile
– Customer: SuZhou CM Technology Co., Ltd
– Country: China
– Industry: lighting, home appliances, electronics, automotive
and medical.
SuZhou CM Technology Co., Ltd. is an industry leader in the field
of the intelligent mold factory, which has achieved
standardization, informationization, intelligence, and
automation.(Source: http://www.cmjm365.com/sy)
36
> Pain Points Analysis
– The shortage of trained talent.
– To maximize performance of Moldex3D.
– A process for knowledge reuse.
• Mold Design/Analysis
> Solution
– SDM 1.0
• It makes 11 of mold designers easily
and fast to get started in CAE analysis.
• Characterizing material and machine
for realistic integration.
– SDM 2.0
• knowledge database is creating to
share and reuse historical simulation
data to provide design
recommendations. Characterized
37
> Testimony
– We know CAE analyses have become the key
factor to develop intelligent manufacturing
and enhance core competencies in a fast-
changing industry.
– Due to the benefits and advantages, we
choose Moldex3D as our first choice.
Charlie Chen
> Profitability Independent
– CAE performance extended from 1 engineer to Director
11 mold designers.
– Extended simulation capability to every mold.
– Increased production capacity from 30% to
70% in T0-stage.
– Sales revenue growth 100%.
> Machine Characterization
39
> Training & Certificate
40
41

Smart Design

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Smart Design and

> The shortage of trained talent

> How to maximize manufacturing performance?

> How to share and reuse historical data?

Smart Design Smart Manufacturing

Future : Total Process/Factory

Smart Smart Consulting

SDM 1.0 SDM 2.0 SDM 3.0

> Smart Functions: Attributes Recognition

> Smart Functions: Defect Detection

> Smart Functions: Smart Simulation

> Smart Functions: Auto Report Generation

> Report Customization

> Material Characterization

Clamping Force Shrinkage

DSC8500 Differential Instron-8966

Specific Heat Residual Stress

> Machine Characterization: Machine Analysis

Screw Head Hydraulic Chamber

Flow rate at screw head

> Machine Characterization: Machine Analysis

> Machine Characterization: Fitting Response

> Machine Characterization: Fitting Response

> Machine Interface

> Training & Certificate

• Design & Analyses • Advanced analyses

 y At steady state, laminar flow condition

> Process Optimizer

> Process Optimizer

Injection Pressure Standard Deviation Shrinkage

> Process Optimizer

NO. United State Patent Types

Display Screen With an Animated Graphical User Interface for a

Display Screen with an Animated Graphical User Interface

Method for Operating a Molding Machine with a Predicted In-Mold

Molding System and Method for Operating the Same

> Knowledge Database

> Complete Mold Analysis

> Complete Mold analysis

> Complete Mold analysis

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