Moldflow - Connection to Tool

MoldFlow: How is cooling + warp managed?

• Can Moldflow help pre-solve warp and cooling issues?

• How can the gap between Moldflow and Tool be reduced?

• Is there a methodology for obtaining maximum value?

Read on to learn more.

Let’s go.

Yes.

There is a lot that can be virtual-trialled in MoldFlow.

If the Moldflow analysis is built by an expert using capable software (+ hardware), then the gap between reality and simulation decreases.

Virtual vs Reality correlation needs to be directionally accurate.W

hat do I mean by “directionally accurate” ?

When Virtual and Reality have directional correlation, you can change a value in MoldFlow

and know how (not how much) it will affect the Real molded process/part.

Now, that is a powerful connection to have in your toolbox.

Wanna investigate warpage in your part?

Moldflow is an ideal sandpit.

A safe, inexpensive and “metal safe” sandpit.

Carry out DOE's using MoldFlow.

Create several cooling scenarios.

Find out what knobs affect warp.

Maybe cooling is just one factor. Hmmmm . . ?

Injection speed or steel temperature could be bigger contributors.

Moldflow can help you find the most influential factors.

Sometimes, your initial suspicions can get turned upside down.

Be ready for the . . “oh, didn’t expect that” . . moment.

Don’t be too connected to your mental projections.

So, what’s next?

C’mon, you know the answer.

Build a tool.

It's important to have a tool + machine + process that speaks the same language as the simulation.

Compare the results to your simulation.

• What’s different?

• Do you need to redo or tweak the simulation?

• Does the simulation help you make tweaks to the molding process?

There’s an interesting game here where the team has to determine which is closer to TRUTH.

The Virtual (moldflow). Or the Reality (tool).

Cooling specs and resulting data get over simplified by most tooling professionals.

It usually takes the form of a single number . . .

"cooling is set at 80 degC"

This leaves a whole list of factors to be checked and investigated.

A long, long shopping list is missing.

Cooling can not be assessed and categorized in this way.

What do you mean?

Let’s dig a bit deeper.

1. Is the cooling flow turbulent?

Yes or No?
How do you know?

2. How is the cooling connected to the tool and to the temp controller?

Sometimes, the controller is in a different zip code.

3. Check the tool with a thermometer to ensure that cooling is doing what it's supposed to do.

4. What's the input and output temperature of the cooling?

5. How is the plumbing?

Are tubes too long, too bendy?
Any short cuts - cooling looping?

Cooling is not a single variable consideration.

Eyes on the process is a key action.

Check all the things questioned on the last page.

Discuss these with your operator, toolmaker and vendor.

Go for a walk. See these things in action.

Cooling can be well assessed in Moldflow.

It can point you in the right direction and then guide you through the improvement process.

MoldFlow is a tool.

A powerful tool.

It’s up to you to build the connections to your tool and your overall process.