2013 Autodesk 2017 Autodesk
Autodesk Moldflow
Moldflow Research & Development
Dr Franco Costa
Senior Research Leader
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Research In-house24 PhD employees in Moldflow development
A Lab with state-of-the-art equipmentFour modern injection molding machines for test & validation
Establishing a network of third-party Labs
Academic Research CollaborationSix Universities with seven PhD students
Industrial Research PartnershipsOver 20 companies and institutions
Research & Development
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Solver Features in Recent Moldflow Releases
Solver & Mesh Features under development
Research Collaborations
Outline
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FeaturesApply properties of a dry fiber mat where needed.
Anisotropic permeability follows the shape of the product.
Detect areas where resin cannot penetrate.
Includes Vacuum Infusion & Gravity effect.
ResultsDegree of Cure, Volumetric shrinkage, Mat orientation, etc.
RTM and SRIM in 3D
Fiber Mat Orientation
Resin Penetration
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Improved 3D Fiber Orientation
Measured data provided by BASFBASF PA 30%GF
Implementation of a New ModelMRD (Moldflow Rotational Diffusion)
0 0.5 1 1.5 2 2.5 3 3.5
Fib
er
ori
en
tati
on
Through thickness, mm
Position C3, orientation A11
Experiment 2017 FCS 2017 R2 (MRD)
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AMI release Constitutive model BASF Bradford Delphi DSM EMS Mechanical Plaque
Number of cases 1 2 23 1 1 1
Number of locations for each case 9 3 3 6 1 1
2017FCSF-T 0.16 0.20 0.14 0.11 0.23 0.17
RSC 0.11 0.12 0.11 0.089 0.16 0.14
2017 R2
F-T 0.091 0.16 0.11 0.079 0.16 0.13
RSC 0.076 0.11 0.10 0.077 0.14 0.10
MRD 0.071 0.11 0.08 0.054 0.12 0.085
Improved 3D Fiber OrientationAverage error of predictions for different releases and constitutive models.Results for the default models are in bold
2017 R2 halves the average error of fiber orientation predictions
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Measurement (literature) Generic shrinkage model Residual stress model
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Measurement (literature) Generic shrinkage model Residual stress model
3D Residual Stress PredictionMolded-in residual stress prediction
Experimental data using layer removal method from W.F.Zoetelief, L.F.Douven, and A.J. Ingen Housz. Polymer Engineering and Science, 36(14), 1886-1896
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3D Warp using Residual Stress
Ultramid B3WG6 BK0056,BASF
Since AMI 2017.3: Residual Stress is the default 3D Warp model Extended to Thermoset materials Mesh Aggregation option enabled
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Powder Injection Molding (PIM )
9
Mold filling simulation of Metal Injection Molding (MIM) and
Ceramic Injection Molding (CIM) materials
Predict the powder concentration
Material characterization for PIM is available
Powder concentration
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Including Wall Slip for PIM
Failed to predict initial jetting without Wall Slip
With Wall Slip, predicted initial jetting in PIM simulation, which matched reality better
Critical shear stress 0.01 MPa
m Slip exponent 1
a Constant sip coefficient 1.0e-05
b Temperature dependency 0
c Pressure dependency 0
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Multi-barrel Injection Molding SimulationMaster Barrel with 4 sub-barrel
Delay time 0.25 s and 0.5 s for sub3 and sub 4, respectively
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Use numerical simulation to calculate temperature and cure changes during preconditioning stage
Either use contact conditions to automatically apply temperature boundary conditions or input value specified on elements for the thermal boundary conditions
Result: Temperature and cure distribution at the end of preconditioning stage
Preconditioning Reactive Compression Molding
Temperature and cure distribution at the end of preconditioning. Initial melt temperature: 50 C
Mold temperature: 175 C
Delay time: 10 sec
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You can now consider cooling rate and pressure effects on Solidification
Solver API - Solidification
van der Beek et. al. Inter. Polymer Processing, 20, 111-120, (2005).
Polycarbonate: Infino EH-1050; Cheil Industries
Tt(P)
Tt(P) = b5 + b6 P
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Autodesk Moldflow Simulation 2017 R21. Wall Slip
2. Resin transfer molding
3. Thermocouple-controlled cooling
4. Heater wattage specification for heater element
Autodesk Moldflow Simulation 2017 R35. CAD meshing support for Linux
6. Synergy Support for Delete CAD bodies
7. Synergy Support for Copy of CAD bodies
8. Support the exporting of STEP files
9. Powder injection molding support
Autodesk Moldflow Simulation 2018.010. Multi-step large vector deformation support (modelling)
11. Multistage support for normal deformations (modelling)
12. User defined initial strain support for Anisotropic inserts (Warp)
13. Preconditioning analysis for reactive compression molding
14. Injection compression overmolding (3D)
New Features for Recent Releases
Research
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Disclaimer
We may make statements regarding planned or future development efforts for our existing or new products and services. These statements are not intended to be a promise or guarantee of future delivery of products, services or features but merely reflect our current plans, which may change. Purchasing decisions should not be made based upon reliance on these statements.
The Company assumes no obligation to update these forward-looking statements to reflect events that occur or circumstances that exist or change after the date on which they were made.
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Extracting Center Lines of CAD Cooling System
Centerline Extraction for CAD Cooling System
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Supports Linux, & Parallelization
Use the Autodesk Flow Design Voxel CFD Solver
Faster Conformal (3D) Coolant Flow Solver
Cross section
Voxel mesh
Voxel solve
Voxel results
Moldflow 3D Channel mesh Moldflow results
Pressure
Velocity
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Underflow severity as a result
Underflow Diagnostic Plot
Underflow regionviewmold.com
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Core Shell
SkinShell
Skin Skin Orientation
Believed to be due to fountain flow
Adaptive Fiber Model Orientation Prediction
Shell OrientationStrong alignment in flow direction
Alignment controlled by fiber interactions, CI, ARD bi, MRD Di
Core OrientationTransverse or random orientation dependent on flow near gate
Width Controlled RSC factor
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sor
com
po
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ts
Normalized thickness
A11 (Data) A11 (2018) A11 (Dev) A22 (Data) A22 (2018) A22 (Dev)
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Fiber Concentration
Higher concentration at core while lower concentration at shear region.
Fiber concentration, orientation, & breakage affect mechanical properties.
Measured data: G.M. Vlez-Garca, Compos. Part A-Appl. Vol 43: 104-113 (2012)
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Warp Accuracy: Thickness Shrinkage for Warpage
MF 24mm corner mold (MAT5322 PP)
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rner
an
gle
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MF 2x4mm Corner Mold with unfilled PP
Experiment Generic shrinkage RS with thickness shrinkage
F. van der Veen corner mold (CM1160 PP)
Wrong bending direction
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ngle
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F. van der Veen Corner PP
Experiments AMI2017 Generic shrinkage TP2017 Residual Stress
with thickness shrinkage
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Warp Accuracy - Shrinkage Correction by Machine Learning
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Parallel shrinkage
Experiment No CRIMS
Machine Learning CRIMS
Use Machine Learning to estimate moldedshrinkage
Provide CRIMS correction for non-shrinkage characterized grades
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DISTANCE FROM GATE, x/L
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DIMENSIONLESS THICKNESS, z/h
Stress relaxation (viscoelastic)Long cooling time effectIn-mold shrinkageLiquid portion at ejection Solidification sequence effect
Warp Accuracy - Anisotropic Thermo-Viscoelastic Stress Model
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