Computer simulation and shape testing

The production of high-quality injection-molded parts in a short time, in order to guarantee the lowest possible mold and production costs at the same time, is a challenge that is best accepted in the design phase of the tool, the mold and the process. KLGS offers its customers a simulation of the injection molding process with the latest version of Autodesk Moldflow software, which is highly valued by advanced injection molding manufacturers.

The simulation enables the project to be carried out, taking into account the optimization of the deformation size (compliance with the required tolerances), the production cycle time and the strength of the molded part. The scope of support provided by Autodesk Moldflow injection molding simulation software includes the following areas:

Part geometry

Analysis of the shape technology and the influence of a certain shape modification on the process
Optimization of the geometry of the molded part in compliance with customer specifications (no changes to certain points, weight reduction, increased rigidity)

Mold filling

Position of the connecting lines and their offset
Compensation of nest and shape
Choice of the filling system with dimensions (cold and warm runners)
Selection of the injection point and their number
Selection of the door diameter and its geometry
Determination of injection and mold closing pressures
Selection of material temperature and injection speed
Determination of the optimal speed profile of the screw conveyor
Determination of the optimal pressure profile to compensate for the shrinkage
Reduction of the internal stresses in the molded part
Analysis of the shape-forming core bending
Analysis of mold ventilation
Analysis of the fiber orientation

Cooling the mold

Possibility of analyzing simplified (rod elements) and full cooling (three-dimensional elements), which shows the exact distribution of the flow velocity, important for complex channels and conformational channels
Location of the hot spots
Determination of the heat dissipation capacity of individual cooling channels
Proposal to change the existing layout
Complete construction of the new cooling system including ejector system
Optimization of flow parameters, fluid type, channel geometry for a shorter cooling phase time

Troubleshooting

Choosing the right material for the molded part
Analysis of the partial demolding and its correction:
Changes to the clamping profile
Changes in the location of the injection point
Changes to the cooling system
Changes to the casting geometry With the help of Design of Experiment techniques