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Abstract
Moldflow has been used extensively in Injection Molding Simulation (IMS), however the mesh
preparation time has been unacceptably long in the current development. In this study, we propose a
simplified mesh model for Moldflow to improve the computation efficiency without compromising the
original results. A laptop front cover is modelled and tested to evaluate the influence of simplified mesh
model on the IMS of flowing, cooling, and shrinkage respectively. Simulation results show that, the
mesh preparation time and computation time can be reduced by 70% and 50% respectively without
changing the original interpretation of IMS, and some minus geometrical features such as short shot,
air trap and weld lines are ignorable. In this way, the whole development cycle of injection mold can
be greatly shortened.
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(1) If the mesh size is determined based on the main cover, it will be too big to represent correctly
the small-size geometrical features in the mesh model.
(2) If the mesh size is set based on the small size features, it will be too small, the more number of
nodes will be generated, resulting in longer mesh preparation time and simulation time.
(3) Since the geometrical features on the front cover model differ a lot in size and they are in a
plurality of different orders of magnitude, it is difficult to guarantee each of the features can be
represented precisely in the mesh model. Therefore, it requires considerable amount of time to do the
mesh preparation before it can be simulated with Moldflow[5].
For the convenience of comparison, we prepare two set of different mesh models, one of which
includes all the geometrical features, the other contains only the bigger size features and the smaller
ones are ignored, Figure 1 shows the difference between the two models. It can be seen that, the overall
sizes of the mesh within two models are similar, however, model 1 needs much longer time to prepare
the mesh, considerably slowing down the whole simulation process[6,7,8].
number of nodes
matching rate
Model 1
14348
8141
81.3%
Model 2
9500
5716
85.2%
RatioModel 2/ Model 1
66%
70%
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From the analysis we can see that, the numbers of units and nodes of model 2 are only 66% and
70% of model 2 respectively. Furthermore, the matching rate of units within model 2 is clearly better
than model 1. All these parameters can be optimized so that the simulation can be a better
approximation to the reality[9].
610
From Figure 3 (a) and (b) we can see that, the lower bound of the flow front material temperature of
model 2 is 42higher than model 1. However, if the upper bound and the lower bound of the flow front
material temperature of model 1 are set to be the same as model 2, their temperature distributions will
be very similar, as shown in Figure 3 (b) and (c). Further monitoring the flow front temperature
distribution of model 1, it is found that only the temperature of the ignored small size features has a
remarkable decrease, as shown in the magnified part of Figure 3 (c). The fall in material temperature
would increase the stickiness of the molten material, and it will require bigger pressure to continue
filling up the cavity. Since most of the small-size geometrical features appear at the end of the flow
path, when the pressure and velocity transfer takes place, it results in an obvious difference in the
maximum filling pressure between the two models[10].
It can be seen that, for the common part of the two models, the distribution results of pressure and
temperature are similar if the small-size geometrical features are ignored. Since most of the ignored
features are at the end of the flow path, the problems like insufficient fill and air cavity may not be
predicted, especially when the flow front temperature is approaching the transferring temperature.
Based on the above analysis, other flow analysis results from the two models can be explained in the
same way. Examples like this can be seen from the solidification layer fraction distribution when the
filling is finished. For model 1, the solidification layer distribution range is [0.0, 0.28], while for model
2, the range is [0.0, 0.06]. If the result from the model 1 is scaled to the range of model 2, it is found
that the two model have very similar solidification layer fraction distributions. Model 1 has a relatively
wider solidification layer distribution than model 2 only at the ignored small-size geometrical features,
but this difference of the two models does not affect the overall understanding for the simulation
resultsexcept impacting such as insufficient filling flow analysis[11,12]
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(c) The flow front material temperature distribution of model 1 after adjusting the ratio
Figure 3. The flow front steam temperature comparison of the two models.
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6. Conclusion
In this paper, a simplified mesh model for Moldflow was proposed to speed up the simulation
process and shorten the development cycle of injection mold. In the simulation, a simplified model of a
laptop front cover in Moldflow is tested and compared with the original model. Flowing, cooling and
shrinkage simulation results are analyzed and comparedIt is shown that
1Many small and complicated sized geometrical features lying on the different order of
magnitude with body characterized of the cover can be ignored when carrying out the IMS with
Moldflow without compromising the simulation correctness. This can greatly shorten the model
preparation time and analysis calculated timeFor analysis example of a laptop front cover in this
paperthe computation time can be reduced by 50%.
2If the ignored geometrical features are distributed at the end of the flow path, and the material
temperature of the end of flowing path decreases dramatically and approaches the transfer temperature,
the cavity filling may not be adequate, and the air cavity and weld line positions cannot be predicted.
3However, if the exterior conditions of the model are required strictly to be the same as the
original model, these small-size features can be maintainedotherwise it is impossible to predict the
air cavityweld line position of these geometric features.
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Acknowledgment
This work was financionly supported by Shanghai Leading Academic Discipline Project (Project
NO. J51501).
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