The report generator currently provided with the Moldflow Insight software user interface is powerful but somewhat inflexible. In this class you will discover how you can combine the Moldflow Insight software API with applications within the Microsoft Office Suite (PowerPoint, Excel, and so on) to produce highly customization, visually stunning reports. You will learn how to simply extract geometry, mesh material data, images, animations, and screen output data into a report. We will show several example reports.

Resin transfer molding (RTM) is a relatively established technique for manufacturing continuous fiber composites. As lightweighting initiatives continue in automotive, new techniques for RTM are being established to reduce cycle time. Join the Moldflow and OCTO Teams for a discussion and demonstration of the RTM capabilities within Moldflow software, including forming simulations to acquire fiber orientations for the flow simulation in Moldflow software. This session features Moldflow and TruPlan.

In one of our projects, we encountered difficulties molding the parts due to air trap, and all of the cavities did not get filled completely. Short filling was noticed in all 64 cavities, along with flow marks. The gate location was near the core side, so the cavity side was expected to fill last. We used Moldflow software to simulate the molding scenario. With full mold setup, 64 cavities were modeled in Moldflow simulation. We noticed flow hesitation due to a drop in the temperature and pressure of the molten material. Venting was recommended to relieve the air or gas trap, and the cavity was split into two. We finalized the cavity modification drawing proposal with gas vent clearance of 0.02mm and 3mm landing. It was also suggested that we increase runner dimensions to 4mm/4.67mm to aid the flow. After tool modification, the filling results were excellent, and we achieved 100% filling. The hole that formed due to the earlier filling issue no longer exists.

Often, you run several to dozens of results on a given part to optimize the results. Often, the changes in results are minor and subtle. However, these small changes are often the difference between a good design and great design. The maximum and minimum values for a result are usually outliers that don't tell the whole story; instead, value distribution is critical. Volumetric shrinkage is a case in point: The range of shrinkage may be 1% to 10%, but most of the part is between 2.5% and 4%. You can see this trend when you look at the graphical results, but you can't quantify it. But when you export your data using an API script, you can use a tool such as a spreadsheet program to create a histogram. Histograms become exceptionally useful when you compare them between studies. In this class, we’ll explore the use of histograms for looking at many types of Moldflow results.

The optimization of injection molding process parameters and part designs is usually a manual process, utilizing ad hoc methods and dependent on user expertise. OmniQuest’s Iliad Design Exploration and Automation Studio now features a dedicated interface with Moldflow Insight software, bringing enhanced optimization and design automation capabilities to injection molding simulation. This interface creates the opportunity for design space exploration through studies such as 1) optimization, 2) response surface modeling to establish mathematical relationships between process parameters, 3) design of experiments, and 4) reliability analysis. By using Iliad’s integration capability and direct interfaces to Ansys Workbench, Python, and other CAE software, you can also control the complete design cycle using a single platform, including running macros and additional stress analysis. We will showcase how Iliad delivers real cost benefits to Moldflow Insight users through multiple case studies.

This class will describe the benefits of using PowerShape software and Moldflow Insight to model and simulate a conformal cooling tool. With 3D printing on the rise, conformal cooling is becoming a more widely available option to create cooling channels in metal in order to more evenly cool a plastic component during the molding process. Utilizing the modeling power of PowerShape to build a mold with channels following the geometry of the plastic part-and then validating the channels using Moldflow-can save time and money by eliminating the need to 'build it and hope it works."

Sabic is a major manufacturer of long fiber filled polypropylene. These long fiber filled plastics can be used to produce light weight structural components with excellent structural properties. Light weighting products is particularly important in the Automotive and Transportation industry, where weight reduction is a major driver for improving fuel economy and reduces the overall carbon footprint over the product life. To leverage the high strength-to-weight ratio, the design of the products have to account for the manufacturing process. The Autodesk Moldflow 2012 release includes the ability to calculate the orientation of long fibers during the injection molding process, which is the main component in understanding the strength characteristics of the products. The understanding of the strength of the products can then in turn be fed back into the design to optimize the design of a lightweight, yet strong, plastic product.

A transformer's external insulation cover is an important part that has a significant influence in the transformer's security and reliability. During recent years these covers have been manufactured using traditional processes that do not incorporate much technology in the design process. However, we can use Simulation Moldflow software in a way that would enable us to optimize the process and the design of the cover, thereby achieving a suitable design that could still comply with the electrical isolation needs and mechanical and shape objectives, as well as reduce the current cost of the material and the process. In this class we'll explore how well the module correlates with real-world molded samples, we'll determine the most effective approach for using the thermoset module to optimize an electrical component, and we'll discuss any current solver limitations.

This class will review new functionality in Simulation Moldflow Insight software and discuss current research directions in the development of Simulation Moldflow software. Capabilities covered will include microcellular foaming, improved fiber orientation and fiber breakage calculations, enhanced wall slip calculations, velocity-controlled valve gates, induction heating, particle traces, user routines, the influence of mold deflection, and meshing enhancements. There will also be an overview of new research collaborations in the area of injection molding simulation research.

During this class we will address major issues related to 3D shrinkage and warpage analysis in injection molding. We would like to start with an introduction of mechanism of shrinkage and warpage. We will discuss the generic shrinkage model and its limitations. We will also present 3D thermo-viscous-elastic residual stress model and thermo-viscoelastic residual stress model. Finally, we will explore some advanced topics, such as corner-effect, in-mold shrinkage, stress relaxation, buckling, and large deflection analysis.

Come and learn about runner and gate optimization using Moldflow Insight software and third-party optimization software.

This class has two parts. First, we will review a study on using corrected residual in-molded stress (CRIMS) data to predict warpage. In this study, we selected five parts of increasing complexity and material flow path. We simulated five different materials with various process parameters. From the simulated data, we selected high-warp scenarios for molding and warpage and compared the results with CRIMS and without CRIMS. The study showed the importance and effect of warpage. Statistically, we found that using CRIMS to predict warpage showed a 10 times better probability of being accurate and a 29% improvement in accuracy. Next, we will look at using supplemental data. CRIMS data is specifically measured/generated by Autodesk® Simulation Moldflow® software by molding trails. The test method is expensive. Therefore, for selected materials, we can supplement CRIMS with equivalent material in the existing Moldflow data base. The experiment shows the effectiveness of method.

Compression molding is a process by which pressure is applied to a material by a heat mold. In the case of thermoset elastomers (rubber), the heat and pressure initiate cross linking of the polymer. A specific weight and shape of a material (called a preform) is placed into an open mold, after which the mold halves close. This compression stroke forces the resin to flow and fill out the cavity. After the mold is filled and pressure is applied for a given time (cure time) the mold is split open and the part is removed either by hand or by ejection methods. This process can be applied to both thermoplastic and thermoset materials, both with or without fiber reinforcement. Compression molding simulation can help determine the feasibility and conditions of the manufacturing process, including the size and placement of the preform(s), the internal cavity pressures, and temperatures during the process. These factors enable us to determine how tool and process design affect product quality. During this class, we will discuss an application of compression molding and compare it with compression molding analysis results.

This class reviews new functionality in Autodesk Simulation Moldflow Insight software and discusses recent and current research directions of Moldflow development. We cover the following capabilities: viscoelastic warp calculations, improved wall slip calculations, the influence of mold deflection, ejection force predictions, analysis of mold fatigue, flow imbalances (airflow), 3D compression molding, 3D conformal cooling, 3D hot runner elements, crystallization analysis, long fiber composites, and mesh preparation.

This class will review new functionality in Moldflow Insight software and discuss current research directions in the development of Moldflow Insight software. Capabilities covered will include multi-shot overmolding and mold cooling; composite overmolding; the effect of fiber orientation on viscosity; the effect of material degradation on viscosity; microcellular foaming; improved fiber orientation and fiber breakage calculations; and user routines for viscosity, core-shift and more. There will also be an update of research collaborations in the area of injection molding simulation research.

The University of Bradford has been using Autodesk Simulation Moldflow software for many years to investigate key injection-molding effects such as fiber orientation, residual stresses, warpage, post-injection product performance, heat transfer, and feature replication. This class builds on our Autodesk University 2011 class and covers the experimental and computational analysis of short- and -fiber reinforced components during injection molding, along with thermal investigations of the micromolding process.

Do you use CAD models with Autodesk Moldflow products? If yes, then don't miss this class. We will discuss how to leverage Autodesk Inventor® Fusion technology as the front-end modeler and idealization tool for Autodesk Moldflow. We will show how to use Inventor Fusion to import CAD data, then edit and simplify it in preparation for Autodesk Moldflow simulation. We will discuss the techniques to simplify a part model and make design changes, such as modifying the part thickness and adding ribs, using Inventor Fusion. We will also discuss the alternative workflow of starting the simulation process in Autodesk Moldflow Insight, launching Inventor Fusion from Autodesk Moldflow Insight to modify geometry, and then rerunning the solver analysis in Autodesk Moldflow Insight.

In this class we will discuss the new capability to map fiber orientations and material properties from Simulation Moldflow software to structural finite element analysis (FEA). We will also cover how to use Simulation Composite Analysis software to simulate nonlinear material behavior of the fiber-filled material.

Injection mold designers and mold makers are facing increasing challenges due to newly developed molding technologies such as rapid heating and cooling molding (RHCM) or rapid temperature cycle (RTC), as the mold lifecycles could be shorter or uncertain. Even for traditional mold design and making, the lifecycle is typically based on experiences only. We have developed a new tool for mold fatigue analysis. It analyzes the progressive and localized structural damage that causes mold failure due to cyclic loading during the injection molding process. In this class, we will present the complete simulation sequence: transient thermal analysis, mold filling analysis, core-shift analysis, clamping influence, mold stress analysis, and eventually fatigue analysis. This sequence is automated in Autodesk® Simulation Moldflow® Insight software to identify where mold damage could happen first and how many cycles a mold will last.

Find out how Simulation Moldflow Insight software was used in the successful investigation of gate and runner design optimization. We will give special focus to automatic geometry morphing and optimization through use of optimization software. Anyone interested in learning more about applying the powerful and specialized modules of Simulation Moldflow Insight software in the early stages of product design will gain from this lecture.