Why need to do Mold CAE Before mold Production?

In today’s mold design process, CAE technology is more and more important, before that, Our designers cannot ensure that their design is completely correct, Process simulation is the core of CAE technology. because Simulation of both the induction heating and injection molding processes optimizes cycle time and final part results.

What's the Moldflow for plastic product?

Plastic Moldflow Analysis refers to the simulation and analysis of the flow channels, nozzles,injection process through moldflow analysis software ,in order to detemine the optimal injection molding parameters and optimize the mold structure,thereby improving the quality and production efficiency of injection molded parts. 

Moldflow analysis can effectively evaluate the fluidity,filling ability, compressibility and other properties of plastic when injection. Moldflow can identify flowtime,bubble, warpage and other defects in advance and optimize the injection process parameters and mold design to ensure the stable molding quality of injection molding parts.

Fill/Pack Analysis

Manufacturing a quality product starts with an optimized filling and packing stage. Fill/Pack analysis allows the designer to see the resin behavior in the mold and determine the process parameters required to fill the part. The Madison Group can provide the following information from performing a fill and pack analysis:

• Runner/gate sizing
• Tonnage requirements
• Weld line placement
• Molding optimization
• Gas trap locations
• Material selection
• Sink marks
• Gate positioning
• Molded-in stresses
• Pressure requirement

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Cooling Analysis (Steady State And Transient Analysis)

> Cycle time optimization

 > Transient cooling analysis 

 > Optimized coolant conditions

 > Conformal vs traditional cooling line comparison

 > Selection of high-conductivity inserts

 > Effect on warpage

 > Evaluation of baffles and bubblers

 > Circuit pressure drops

Warp Analysis

Designers use injection molding to mass produce high precision intricate parts. After designing the part it is important to ensure the part can be manufactured within tolerance and will not exhibit excessive warp. Warp is related to several factors including part design, resin selection, fiber orientation, the molding process, or cooling system.

Performing a warp analysis helps isolate the reasons for part distortion after molding and creates a solid foundation for making changes to reduce or eliminate the distortion. Using warp analyses can assist in identifying design and process variations that cause warp, conduct material comparison, and find solutions to ensure the manufacturing quality parts

Metal Forming Simulation

In metal forming simulation, the forming of sheet metal is simulated on the computer with the help of special software. Simulation makes it possible to detect errors and problems, such as wrinkles or splits in parts, on the computer at an early stage in forming. In this way, it is not necessary to produce real tools to run practical tests. Forming simulation has become established in the automotive industry since it is used to develop and optimize every sheet metal part.
To illustrate the metal forming process, there must be a model of the real process. This is calculated in the software using the finite element method based on implicit or explicit incremental techniques. The parameters of the model must describe the real process as accurately as possible so that the results of the simulation are realistic.