Success Story
The Japanese injection molding manufacturer Nippo mechatronic (Thailand) Co.,Ltd, wanted to match the Autodesk Molflow simulation results with the in-mold cavity pressure sensors in the injection molding trial and production. Nippo aimed to match the cavity pressure results between the Moldflow simulation and the real moldings.
Matching an Autodesk Simulation Moldflow Insight analysis to an actual molding process requires ensuring the injection machine experience and deep knowledge of both theory and practical of Moldflow software.
The challenge was not only to match the simulation results with the real machine parameters, but also to make this correlate between the cavity pressure result. The goal aimed for to make the initial systematic of an injection molding work for the first time trial by utilized the Autodesk Moldflow software capability. And target the cavity pressure sensors is the standard procedure which can help to decrease the trial and error, saving time and raw materials in the process, and monitoring of the quality in the production.
FLUENT has a direct experience in cavity pressure sensor and the cavity pressure simulation with Autodesk Moldflow. The simulation was done with very strict in the workflow following these;
1) Optimize of part filling - the simulation worked with the exactly same of part design, optimization of filling the part must be achieved first.
2) Optimize the Cooling design - ensure that the thermal distribution show the good balance for both core and cavity.
3) Optimize the Packing - The volumetric shrinkage achieved the shrink specification.
4) Summarize the initial injection molding parameters for the 1st shot reference and input to the injection molding machine.
5) Produce the part and record the cavity pressure compare to the cavity pressure from the Moldflow pressure XY Plot result. Adjust some parameters at the machine for to get the best part.
The traditional injection molding work at Nippo was not installing the cavity pressure sensors to the mold, most used the molders experience. Autodesk Moldflow software simulation results were not taken into account during the injection molding machine setup. With FLUENT consultant, Autodesk Moldflow simulation know-how can now be systematically used for the first time in machine setting and process optimization on the machine. In addition, the behavior of the actual injection molding machine can be compared with the simulation. As Moldflow software has the capability to measure the cavity pressure inside the mold at the exact position of sensors located inside the real mold. And with the right workflow from FLUENT's consulting, Nippo can effectively achieve their goal of aiming to make the initial systematic molding by utilizing the Moldflow software capability with the cavity pressure sensors.
FLUENT with the Autodesk Moldflow Associate Certificate assisted Nippo with technical support and training in Autodesk Moldflow and practical injection molding.
"When making molds for new items, we cannot afford to fail. Therefore, the mold is verified by Moldflow at the design stage. And we visualize design concerns and use them effectively to explain to our customers." Mr. Yusuke Fujii, GM Engineering quoted.
And "Incorporating the results of flow analysis into the mold design will lead to shortening of mold correction time and reduction of troubles during mass production molding". Mr. Matsuura , mold manager, quoted.
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