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1 CoreTech System Co., Ltd.

Contents

Advanced Support for Intelligent Workflow

Improved User Interface ……………………………………

Expanded Gate Types ………………………………………..

Enhanced Runner Wizard ………………………………….

Customized Cooling Channel Templates …………….

Parameterized Mesh Generator ………………...........

Mesh Engines Supports Multi-core ……………………

Accuracy Improvements for Simulations

Modeling for Crystalline Material ………………………

Added Support for HTC Effect …………………….........

Added Support for Heater-Sensor Coupling ……….

Added Support for Viscoelasticity ……………………..

Improved Analysis for RIM …………………………………

Improved Analysis for IC Packaging ……………………

Enhanced Efficiency for Simulations

Rendering Enhancement for Shell Project ………….

Enhanced Support for XY-Plot ……………………………

Improved Project Model Manager …………………….

User Defined Copy Run Contents ……………….........

Binary Format of Result Files ……………………………..

Remote Computing ……………………………………………

Material Database Updates ……………………………...

New Simulation Capabilities

Injection Compression Molding …………………………

Fluid-Assisted Injection Molding ………………………..

Stress Analysis on Injection-Molded Parts ……......

Industrial Vertical Integration

Optical Integration with CODE V ……………………....

NX Nastran Added into I2 Modules ……………………

Your Feedback Is Important to Us …………………....

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Moldex3D is a suite of professional CAE tools for plastic

part design validation and mold optimization. It not only

helps global manufacturers produce plastic parts with

better quality and lower cost, but also enables them to

implement a more efficient design-for-manufacturing

workflow.

The official release of Moldex3D R10.0 brings several

breakthroughs on developing solver capabilities and

improving user friendliness and efficiency, such as

enhanced workflow, added support for analysis, remote

computing, etc, to help users solve problems more easily

and more efficiently. In addition to the new modules

added for customers’ needs, Moldex3D has also integrated

with more industrial-leading software, including CODE V

and NX Nastran, to provide advanced CAE solutions for

design verification and optimization.

Moldex3D R10.0 builds upon the capabilities of past

releases and adds innovation for performance and

functionality, offering the following new features and

benefits:




Material Database Updates





Moldex3D R10.0 highly improves user friendliness for the

pre-processing work and develops a variety of powerful

tools to help users handle the meshing work and mold

design settings, such as gates, runners, cooling, etc.

Improved User Interface

❙ The improved user interface provides an intuitive and

task-oriented workflow, improving its functionality and

shortening users’ learning curve.

The improved user interface of Moldex3D Designer

❙ The compact and easy-to-navigate tool menu provides

a consistent logic to guide users to access to the

simulation workflow step by step easily. With only a

few clicks, the improved user interface helps finish the

meshing process efficiently.

Expanded Gate Types

❙ New gate types are now available in the Gate Wizard,

including pin gate, sprue gate, edge gate, fan gate,

lapped edge gate, tunnel gate, cashew gate, tunnel

gate with ejector pin and cashew gate with ejector pin.

Using the gate-aware Runner Wizard, users can build

single or multiple gates quickly and consecutively.

Additionally, seeking for appropriate gate locations,

users can apply Gate Location Advisor to set up one or

more gate locations according to the part geometry.

The tool menu of Gate Wizard

Enhanced Runner Wizard

❙ More runner cross section types are added, including

trapezoidal, U-shape and semi-circular, to better

describe the real runner geometry with true 3D solid

mesh. To solve the mesh distortion problems of

curvature runners, Moldex3D R10.0 allows to use

curve objects as runners and to construct a complete

runner system with mixed STL topology and runner

lines. This feature will enhance mesh quality, modeling

flexibility and calculation efficiency.

Curvature runner and runner mesh displays

❙ When simulating multi-cavity models, users can apply

Runner Symmetrical Configuration to configure the

single cavity and associated runner system, with the

emulated symmetrical cavities displayed. It reduces the

effort to setup symmetric boundary conditions and


avoids ambiguity. This feature supports half and

quarter symmetrical systems. Compared to a full

model, it provides better mesh resolution and reduces

memory requirement for multi-cavity analyses.

Multi-cavity symmetrical simulation

Customized Cooling Channel Templates

❙ The intelligent Cooling Wizard enables users to define

cooling channels by cavity side or by core side. New

cooling channels templates, including straight lines,

U-shape lines and auto-loop, help users quickly setup

essential cooling channels and save time of

restructuring the previously designed cooling system.

Edited cooling channels can be saved as users’

proprietary templates or as default directly for the

next design.

Settings of different cooling systems

Parameterized Mesh Generator

❙ In response to users’ expectation to create high quality

structure mesh for some generic geometry, the

parameterized mesh generator has been developed to

help users define the model parameters in 2D and

then generate 3D structure mesh. Furthermore, users

can specify nodal parameters on each edge of model

to optimize mesh density and result accuracy.

Parameterized mesh generator

Mesh Engines Support Multi-Core

❙ The meshing kernels, both in Designer and Mesh, will

automatically detect and fully utilize the modern

multi-core CPU to speed up meshing without any

additional settings. Users will save significant amount

of time on mesh preparation.


Moldex3D R10.0 has improved and expanded its solver

capabilities to satisfy users’ demands to acquire more

accurate and more advanced CAE solutions for

manufacturing problems and industrial challenges.

Modeling for Crystalline Material

❙ An increasing cooling rate generally shifts the

transition temperature of semi-crystalline polymer

towards lower temperature and increases the final

specific volume of the material. In consideration of the

impact of cooling rate, Moldex3D solvers now support

the analysis of injection molding with high cooling rate

characteristics.


Added Support for HTC Effect

❙ The thermal contact between polymer and mold varies

throughout the different phases of a typical injection

molding cycle. Heat Transfer Coefficient (HTC)

variations are now considered and well simulated

when the mold detachment happens in the packing

phase. This feature improves packing and warpage

prediction.

Added Support for Heater-Sensor Coupling

❙ An added support of Transient Cool analysis

capabilities is to provide the heater controller settings

to help users control the heaters by the sensor node

temperature. This enables more accurate simulations

for the realistic heater control system. Moldex3D R10.0

also supports the cooling analysis of hot runner effects

to provide more accurate part warpage prediction with

more precise moldbase temperature distribution.

Heater control system by sensor node temperature

Moldbase temperature distribution and part warpage

prediction

❙ Moldex3D R10.0 supports the pipe network analysis to

analyze the mold cooling efficiency with its coolant

flow rate and cooling channel design. Additionally,

users are able to define the convergence criteria for

different analysis purposes. The convergence condition

and cycle time will be logged in the log file for users to

observe the steady state of the cycle temperature

easily. Three tolerance criteria are available:

Average part surface temperature

Maximum variation of part surface temperature

Maximum variation of mold temperature

Cooling temperature distribution of the pipe network

analysis

Added Support for Viscoelasticity

❙ Moldex3D R10.0 supports multi-mode PTT and

Giesekus models. While the single mode is sometimes

inadequate to describe the viscoelasticity behaviors,

this feature can reflect the effects of multiple

relaxation times and bring more accurate polymer

viscoelasticity prediction.

The simulations of multi-mode PTT and Giesekus

compared with real viscoelasticity distributions


Improved Analysis for Reactive Injection Molding (RIM)

❙ Moldex3D R10.0 provides the mold thermal analysis of

the RIM process. Its simulation results, cycle average

and transient approach, are well visualized for users to

revise their mold design. Moreover, the scorch-index

calculation enables users to simulate rubber injection

molding with long induction time by Deng-Isavev

model. It helps users optimize runner design and

process parameters to avoid premature vulcanization.

Improved Analysis for IC Packaging

❙ With the newly-developed Moldex3D stress solver,

users now can run full simulations for IC Packaging,

including wire sweep and paddle shift, without

accessing to external structural solvers. Additionally,

Moldex3D R10.0 expands supports to more drag force

models for wire sweep calculation.

Wire sweep prediction with Moldex3D-Stress


Moldex3D R10.0 improves user friendliness for the

pre-processing work and enhances user efficiency for the

post-processing work.

Rendering Enhancement for Shell Project

❙ The rendering efficiency for graphic performance of

Shell Project has been enhanced by 2-3 times with

entry-level graphic cards. Its performance increases

much more with high-end graphic cards.

Enhanced Support for XY-Plot

❙ The redeveloped user interface of XY-Plot function

helps users save different plot settings and review the

simulation analysis results more easily, especially for

sensor data. It also adds a toolbar for XY-Plot viewer.

Improved Project Model Manager

❙ The improved model manager enables users to control

the object display status faster and more easily. Users

are able to turn on/off each object and define their

colors; moreover, the settings can be directly saved as

default for the next project.

User Defined Copy Run Contents

❙ With this feature, users can choose to copy partial or

full run data for CAE analysis. The flexibility of copy run

contents will save disk space and copy time to build

additional runs for simulations.

Binary Format of Result Files

❙ The analysis result files have been changed from ASCII

to binary format in Moldex3D R10.0. Compared to

R9.1 Project, it is estimated to reduce 40-50% project

file size, highly improving the efficiency of result

loading and storage.

Remote Computing

❙ Moldex3D R10.0 expands supports of remote

computing to enable users to submit or download

analysis jobs from the client computer to the remote

computing server across intranet. With the parallel

computing cluster, the server can automatically assign

analysis jobs to different computing nodes, and the

completed jobs will be downloaded to the client

computers automatically. It not only saves users’ time

for running simulation analyses but also enhances the

calculation efficiency by the computing cluster.


Material Database Updates

Moldex3D material database in R10.0 has been updated

with 437 thermoplastic materials modified and 98

materials added. Users can add a material from Moldex3D

material bank, user bank or Project settings into Material

Comparison List to easily compare its properties with

different materials. Additionally, Moldex3D R10.0 supports

Matereality 4.0. Users can directly download material

properties, including anisotropic mechanical properties,

from http://www.matereality.com.

Materials compared by Material Comparison List.


Considering industrial customers’ demands for specific

simulation capabilities, Moldex3D R10.0 has developed

new modules to in-depth help users simulate the plastic

injection molding processes.

Injection Compression Molding (ICM)

❙ Moldex3D-ICM helps users accurately simulate the

injection compression molding process, which is

generally applied to thin and flat products such as light

guide plates or CD disks. The effects of key process

conditions, including delay time and compression gap,

on cavity pressure and volume shrinkage distribution

can be simulated and visualized.

More uniform volume shrinkage of ICM simulations

Fluid-Assisted Injection Molding (FAIM)

❙ Moldex3D-FAIM is a true 3D CAE simulation tool to

visualize flow behaviors when fluid (gas or water) is

injected directly into the cavity through melt entrances

or specific fluid entrances in the injection molding

process. Typical molding issues for FAIM, such as

fingering effect, blow-through, or corner effect, can be

predicted to help users investigate the real production

process and increase manufacturability.

Filling simulation of the FAIM process

Stress Analysis on Injection-Molded Parts

❙ Moldex3D-Stress provides users with the complete

stress simulation analyses for parts and part inserts.

This feature is especially useful when the fiber-filled

material is employed. As a result, mapping between

Moldex3D and other general purpose structural CAE is

no longer necessary.

http://www.matereality.com/


Simulation results of stress analysis


Moldex3D R10.0 has integrated with a wide variety of

industrial leading software to benefit users with advanced

CAE solutions for injection molded product design.

Optical Integration with CODE V

❙ Integrated with CODE V, Moldex3D has developed

advanced optical solutions to help designers analyze

the manufacturing feasibility of part design by

injection molding simulation analyses and export the

deformed shape and refractive distribution into CODE

V for verification and optimization. This feature gives

designers the power to overcome the difficulties

between ideal product design and real production and

enables them to satisfy the market demands.

The process of the optical solution with CODE V

NX Nastran Added into I2 Modules

❙ The integration with NX Nastran provides users with a

CAE solution for structural analyses. Critical analysis

results, such as pressure, temperature, or material

reduction, can be precisely simulated and predicted for

different mesh types of parts and part inserts. More

features for I2-NXNastran are as the following:

Your Feedback Is Important to Us

Thank you for your continuous support of Moldex3D. We

added new and enhanced functionalities to Moldex3D

R10.0 to help you become more productive and more

competitive and return true value to your investment. We

sincerely invite you to provide feedback to Moldex3D

research and development team. Please don’t hesitate to

discuss with your Moldex3D authorized resellers and

support staffs near you. Alternatively, you can always

provide your feedback to [email protected].

© 2010 CoreTech System Co., Ltd. All rights reserved.

© 2010 CoreTech System Co., Ltd. All rights reserved.

mailto:[email protected]

True 3D CAE for Injection Molding

Moldex3D R10

New Temperature Results: Filling

Moldex3D – TIPs_10032

2010/08/20


Filling: Maximum Temperature

Shows the maximum

temperature in the thickness

direction of the part.


Filling: Center Temperature

Center temperature is the melt temperature of the middle layer (part line)

in the thickness direction at current instant. Center temperature is an

indicator of thermal energy supply of the fresh hot melt.

In general, the center

temperature is an indicator of

incomplete filling (short shot). If

the center temperature is too

low, flow hesitation happens and

there will be a short shot

problem.


Filling: Average Temperature

Average temperature is the averaged temperature across the part thickness at current

instant. It considers the effect of mold cooling and viscous heating of melt. Therefore,

average temperature is representative for the part temperature

This data can be used to check

the combined effect of viscous

heating of polymer melt and

mold cooling. One should

examine if there is any hot spot

that will cause burning problem

and the possibility of short shot

due to flow hesitation and

excess mold cooling.


Filling: Bulk Temperature

Bulk temperature is a velocity-weighted averaged temperature of plastic melt

across the thickness at current instant. The contribution from frozen layer that is

stationary is ignored in this data. The effect of heat convection and viscous

heating can be displayed from this data.

Therefore, it can apparently

demonstrate how heat convection

affects the melt temperature and

the temperature distribution of

hesitation area and viscous

heating area. Normally, bulk

temperature distribution can

reflect the trends or paths of

filling flow.

Moldex3D R10 New FunctionMoldex3D R10 New Function

Cooling Channel Layout Template


2010/08/27

Introduction

In Moldex3D 10, Designer will support using Cooling Channel Layout Template to describe the cooling layout. There are three types of template, which are Straight line, U-Shape line and Auto-Loop.

Benefits:1. Users may create more complex cooling channel

automatically in Designer.2. Reduce the time for creating the cooling channel in

designer for initial verification.

Straight line

U-Shape line

Auto-Loop


Moldex3D New Development:

3D Sink Mark prediction


2010/09/03


Introduction

Sink mark is important for the product appearance.

Therefore it is essential to understand the location

and the depth of sink mark.

These slides show the current progress on 3D sink

mark prediction. This function is scheduled to be

released in R10 SP1.

As is in Shell To be in 3D


Some examples

T-shaped part:

Far from the gate, higher sink

mark value is observed


Some examples

Mechanical part

(eDesign mesh)

Sink mark locations are

well predicted.


AutoProfile Function


2010/09/24

Introduction

In Moldex3D R10, Project will support AutoProfile Function. Theprogram will provide suggested Flow rate and Packing pressure profiles based on the analysis result . This function is available in Shell, eDesign and Solid modules.

Benefits:1. A reference for us to optimize the Filing and Pac king

profiles, and reduce the number of trial and error for process condition setting.

AutoProfile Results

Original flow rate Suggested flow rate

Original packing pressure Suggested packing pressure


Cooling Channel Layout Template

Part II


2010/10/22

Introduction

• In Moldex3D R10, Moldex3D-Designer supports users to apply cooling channel layout template. When designing cooling channel system, users can load the templates in the database and modify its dimension more conveniently. There are 3 template types as default, including Straight Line, U-Shape, and Auto-Loop. However, users can follow below steps to design their own cooling channel layout can follow below steps to design their own cooling channel layout template.

Main Concept

• The main concept used in Moldex3D for cooling channel layout creation is vector. Below figure is a simple example displaying three vectors and lengths represented cooling channel layout.

Cooling Channel Layout File Format

• To create a cooling channel template, follow the procedures listed below.– Step 1: Create Cooling channel template csv files

Open a new Microsoft Excel file or word pad file. Enter following required values for each item.

• Cooling channel layout file format:• Cooling channel layout file format:– Head:

» VERSION: template file version.» NAME: template name display on UI.» CCTYPE: define cavity/core side or slider side» CAVITY: along parting direction» SLIDER: perpendicular to parting direction

Cooling Channel Layout File Format cont.

– PATH:» ID: path ID» VECTOR: path vector» LENGTH: path length» TYPE: path type» LINE: straight line path type

– CONSTRAINT:– CONSTRAINT:» DUPLICATE: silder side layout directions

+X1, -X1, +X2, -X2: the silder side layout direction definitions are depending on the parting direction, as shown in the table

Cooling Channel Layout File Format cont.

• View the setting:

Apply Template to Moldex3D-Designer

• After setting all values, save it as a *.csv file in Moldex3Ddestination folder where Moldex3D main programs install. For example, if Moldex3D main programs are installed in C disk. The path for the saved *.csv file should be “C:\Moldex3D\R10.0\Moldex3D-Designer\templates.

• Note: if there is no folder named templates in Moldex3D-Designerfolder, create one manually and name it “templates” by lowercase. folder, create one manually and name it “templates” by lowercase. *.csv must be saved in template folder to be read by Moldex3D-Designer .

– Step 2: Cooling channel template bitmap:• Create a bitmap (*.bmp). The *.bmp is just a symbolic figure for

cooling channel layout, which will be displayed on UI of the cooling channel template. It is not restricted to figure content, but the file type must be *.bmp.

Apply Template in Designer cont.

• Note: The file name for both the cooling channel template file (*.csv) and the bitmap (*.bmp) must be the same and both of these two files must be save in the same folder.

• After finishing the above template steps, the file info and UI figure will shown as below.

• After setting all related properties of the cooling channel, click to go back the main setting panel for other setting.

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Moldex3D R10 Viewer is

Officially Released


2010/10/29

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Introduction

> Moldex3D Viewer is the light version of “Project” which allows

any users without a license to open a Moldex3D simulation case.

> The projects opened with Viewer will be in “Read Only” mode,

but users can still create a HTML or PPT report.

> For any prospects interested in Moldex3D Viewer, we suggest

that they get the download link through our website after

registering.

> For all our resellers, our support teams could provide the

download link directly. There is no need to register.

> The R10 Viewer download link will be put on our official website

on November 10. If you would like to have it upfront, please

contact your support team.

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Moldex3D R10 Viewer

The “Read Only” will be shown on the title

Report Generator available

New R10 results display

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Thank you!

Documents

· PDF fileCustomized Cooling Channel Templates ... default for the next project. User Defined Copy Run Contents ... computing to enable users to submit or download