Solving Part / Mold Design and

Manufacturing Issues with

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SOLIDWORKS Plastics
Omar ZOHNI, Dassault Systèmes SOLIDWORKS Corp.
Ramesh LAKSHMIPATHY, Dassault Systèmes SOLIDWORKS Corp.
 Welcome
Using GoToWebinar
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1. Viewing Full Screen

2. Exiting Full Screen
3. Asking Questions
4. Answering Poll Questions

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Welcome
Gotowebinar - Downloading Handouts
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POLL QUESTION #1
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POLL QUESTION #2
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
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


Q&A
Agenda

Why SOLIDWORKS Plastics?

SOLIDWORKS Plastics Demo
Validation Example Discussion
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Plastics are everywhere…
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Unanswered Questions…
 Historical Plastics Development Process
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Influence on Manufacturability and Quality Decreases

Responsibility for Meeting Launch Requirements Increases

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 3DS.COM/SOLIDWORKS © Dassault Systèmes | Confidential Information | 10/1/2015 | ref.: 3DS_Document_2014

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Old Way #1 – Fix Existing Problems

Problems are fixed after the fact. This is costly and inefficient.
 Old Way #2 – Validate Existing Designs
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Limited application provides benefits to a small number of parts and there are
hidden costs due to the lack of optimization.

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 Preferred Way – Optimize Part & Mold Design
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Using simulation as an integral part of the part and mold design

process provides the ability to optimize designs for manufacturability.

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 SOLIDWORKS Plastics
 Predict and avoid manufacturing defects
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 Eliminate costly mold rework

 Improve part quality
 Decrease time to market
Value Proposition
 >80% of plastic parts are injection molded
 Injection molding is a complex mix of time,
temperature, pressure, material & tooling variables
 Injection molds range in cost from >$10K to $1M+
and mold rework is costly and time-consuming
Using SOLIDWORKS Plastics Simulation to
Avoid Just One Round of Mold Rework can result in a
Positive Return on Investment

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 3DS.COM/SOLIDWORKS © Dassault Systèmes | Confidential Information | 10/1/2015 | ref.: 3DS_Document_2014

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 SOLIDWORKS Plastics Demo
3DS.COM/SOLIDWORKS © Dassault Systèmes | Confidential Information | 10/1/2015 | ref.: 3DS_Document_2014

Getting a Window into

your Mold

What if scenarios

Multi Cavity / Family

Molds.

Cooling Lines /
Warpage.

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 SOLIDWORKS Plastics
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Getting a Window into  Identify Key Manufacturability Issues…

your Mold
 Will it
fill?
 What's the Optimal Wall Thickness?

What if scenarios  Where are the Weld Lines? Will it affect function?
 Where are the Air Traps? Will specialized tooling be
required?
Multi Cavity / Family  How about
Molds.  Cooling time?
 Pressure requirements?

 Sink Marks?
Cooling Lines /
Warpage.  Volumetric Shrinkage?

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Solve
Mesh
Setup

Review
Simulation Workflow

Mesh with AUTO refinement

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Mesh

Solve
Setup

Review
Simulation Workflow

Material: Generic ABS

Specify Injection Location
 3DS.COM/SOLIDWORKS © Dassault Systèmes | Confidential Information | 10/1/2015 | ref.: 3DS_Document_2014

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Mesh
Setup
Solve
Review
Simulation Workflow
Real-time Feedback
 3DS.COM/SOLIDWORKS © Dassault Systèmes | Confidential Information | 10/1/2015 | ref.: 3DS_Document_2014

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Mesh

Solve
Setup

Review
Simulation Workflow
 3DS.COM/SOLIDWORKS © Dassault Systèmes | Confidential Information | 10/1/2015 | ref.: 3DS_Document_2014

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Mesh

Solve
Setup

Review
Simulation Workflow

WELD LINES
AIR TRAPS
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Time
Cooling
Shrinkage
Volumetric
Review Results

Injection
Pressure

Engineering Data
Sink Marks
 Getting Started Wizard
Plastics Advisor tool - Answer Simple Questions
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 Step by step guidance through the SOLIDWORKS Plastics workflow

 Model setup, Mesh and Run, Process Settings
 Results Interpretation,Report generation

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 3DS.COM/SOLIDWORKS © Dassault Systèmes | Confidential Information | 10/1/2015 | ref.: 3DS_Document_2014

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 SOLIDWORKS Plastics
3DS.COM/SOLIDWORKS © Dassault Systèmes | Confidential Information | 10/1/2015 | ref.: 3DS_Document_2014

Easily identify
Getting a Window into
Manufacturing issues
your Mold
upfront

What if scenarios

Multi Cavity / Family

Molds.

Cooling Lines /
Warpage.

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 SOLIDWORKS Plastics
3DS.COM/SOLIDWORKS © Dassault Systèmes | Confidential Information | 10/1/2015 | ref.: 3DS_Document_2014

Easily identify
Getting a Window into
Manufacturing issues
your Mold
upfront

 NOW WHAT?
What if scenarios
 Fillpattern not acceptable?
 Sink Marks large?
 Cooling time too high?
Multi Cavity / Family
Molds.  Injection Pressure too high
 Weld Lines in Functional Spots
 Try a different Gate Location?
Cooling Lines /
 Try a different material?
Warpage.

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 3DS.COM/SOLIDWORKS © Dassault Systèmes | Confidential Information | 10/1/2015 | ref.: 3DS_Document_2014

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 SOLIDWORKS Plastics
3DS.COM/SOLIDWORKS © Dassault Systèmes | Confidential Information | 10/1/2015 | ref.: 3DS_Document_2014

Easily identify
Getting a Window into
Manufacturing issues
your Mold
upfront

What if scenarios Reduce / Fix Errors

Multi Cavity / Family

Molds.

Cooling Lines /
Warpage.

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 SOLIDWORKS Plastics
3DS.COM/SOLIDWORKS © Dassault Systèmes | Confidential Information | 10/1/2015 | ref.: 3DS_Document_2014

Getting a Window into

your Mold

What if scenarios

Multi Cavity / Family

Molds.

Cooling Lines /
Warpage.

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Additional Setup
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Runner Balancing Optimization Setup
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Runner Balancing Optimization Results
 3DS.COM/SOLIDWORKS © Dassault Systèmes | Confidential Information | 10/1/2015 | ref.: 3DS_Document_2014

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 SOLIDWORKS Plastics
3DS.COM/SOLIDWORKS © Dassault Systèmes | Confidential Information | 10/1/2015 | ref.: 3DS_Document_2014

Easily identify
Getting a Window into
Manufacturing issues
your Mold
upfront

What if scenarios Reduce / Fix Errors

Detailed setup, same

Multi Cavity / Family Workflow
Molds.
Optimization

Cooling Lines /
Warpage.

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 SOLIDWORKS Plastics
3DS.COM/SOLIDWORKS © Dassault Systèmes | Confidential Information | 10/1/2015 | ref.: 3DS_Document_2014

Getting a Window into

your Mold

What if scenarios

Multi Cavity / Family

Molds.

Cooling Lines /
Warpage.

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 SOLIDWORKS Plastics– Cooling and Warpage
3DS.COM/SOLIDWORKS © Dassault Systèmes | Confidential Information | 10/1/2015 | ref.: 3DS_Document_2014

Cooling Analysis Capabilities

• Design / Analyze simple or complex
mold cooling line layouts
• Achieve uniform temperature
distributions across mold core and
cavity surfaces to minimize part
warpage
• Model / Analyze baffles, bubblers and
mold inserts
• Optimize cooling system design to
minimize cycle times and decrease
manufacturing costs

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 SOLIDWORKS Plastics - Cooling and Warpage
Warpage Analysis Capabilities
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• Predict warpage (part

deformation) due to molded-in
stresses / quenching thermal
stresses

• Optimize part and mold design,

material selection and processing
parameters to reduce or
eliminate molded part warpage

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 3DS.COM/SOLIDWORKS © Dassault Systèmes | Confidential Information | 10/1/2015 | ref.: 3DS_Document_2014

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 SOLIDWORKS Plastics
3DS.COM/SOLIDWORKS © Dassault Systèmes | Confidential Information | 10/1/2015 | ref.: 3DS_Document_2014

Easily identify
Getting a Window into
Manufacturing issues
your Mold
upfront

What if scenarios Reduce / Fix Errors

Detailed setup, same

Multi Cavity / Family Workflow
Molds.
Optimization

Optimize Cycle
Cooling Lines / Times. Ensure
Warpage. Manufacturing
tolerances

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 Benefits Summary
Easily identify
3DS.COM/SOLIDWORKS © Dassault Systèmes | Confidential Information | 10/1/2015 | ref.: 3DS_Document_2014

Getting a Window into

Manufacturing issues
your Mold
upfront

What if scenarios Reduce / Fix Errors

Detailed setup, same

Multi Cavity / Family Workflow
Molds.
Optimization

Optimize Cycle
Cooling Lines / Times. Ensure
Warpage. Manufacturing
tolerances

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 Radon Detector Validation Example
3DS.COM/SOLIDWORKS © Dassault Systèmes | Confidential Information | 10/1/2015 | ref.: 3DS_Document_2014

Experimental work by Prof. Stephen Johnston,

UMass Lowell
Renowned Plastics Engineering Department
 PP material
Arburg, Sumitomo injection molding machines
 Family mold (imbalanced)
Pressures taken from machine display, not
 Interestingtool
instrumented cooling
cavity system
sensors
Clamp forces estimated from machine displays,
flashing studies

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 Filling
Radon Detector Short Shot Series
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• Short shot simulated experimentally by

varying dosage volumes
• Validation of filling pattern evolution

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 Filling
Radon Detector Short Shot Series
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• Short shot simulated experimentally by

varying dosage volumes
• Validation of filling pattern evolution

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 3DS.COM/SOLIDWORKS © Dassault Systèmes | Confidential Information | 10/1/2015 | ref.: 3DS_Document_2014

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Filling
Radon Detector Short Shot Series
• Dosage volume: 20 cc
• Filling time: 0.47 sec (.40 Sim)
 3DS.COM/SOLIDWORKS © Dassault Systèmes | Confidential Information | 10/1/2015 | ref.: 3DS_Document_2014

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Filling
Radon Detector Short Shot Series
•
•
Dosage volume: 60 cc
Filling time: 1.48 sec (1.40 Sim)
 3DS.COM/SOLIDWORKS © Dassault Systèmes | Confidential Information | 10/1/2015 | ref.: 3DS_Document_2014

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Filling
Radon Detector Short Shot Series
•
•
Dosage volume: 70 cc
Filling time: 1.72 sec (1.68 Sim)
 Filling
Gate Imbalance
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• Larger cavity fills first

• “hesitation mark” defect

visible defect in actual finished part flow front central temperature filling time animation

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 • Flow rate control selected
Filling
• Profile defined to reproduce test
Inlet Flow Rate (Machine Set Point: 40cc/s)
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 Filling
Inlet Pressure (Maximum Test Fill Pressure: 50.9 MPa)
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• Computed pressure to
produce required flow rate
• Spike at end of 40 cc/sec
interval
• Max Pressure
Simulation = 48 MPa
Test = 50.9 MPa

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 Packing
Holding Pressure (Maximum Test Packing Pressure: 43 MPa)
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• Absolute pressure
control selected
• Test pressure input

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 Packing
Gate Freeze Prediction
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• Plot temperature at several

node in gate cross-section
• Compare to Glass Transition
Temperature (Tg)

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 Cooling
Non-Uniform Cavity Temperature
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• Sprue inlet temperature = 207°C

Measured in “purge shot”
Test(°C) Sim(°C)
Location 1 25.2 26.4
Location 2 26.2 29.0
Location 3 29.4 27.4
Location 4 27.4 30.4
Location 5 30.6 27.8
Location 6 28.1 29.9

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 Warping
Part Shrinkage (1 mm warpage on actual part, 0.9345 mm - Simulation)
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warping(magnified deformation)

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 Manufacturing Objectives & Problems
 Reduce cycle time
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 Open tools as soon as possible

 Cooling system design
 Avoid hotspots that delay solidification
 Uniformity in multi-cavity tools temperature cross-section in mold tooling
 3x3 array of parts in one tool
 Part appearance
 Incomplete filling, weld lines, overheated regions
 Part net shape (shrinkage & warpage)

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 SOLIDWORKS Plastics Delivers Value…
Streamlined Communication with Mold
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Manufacturers

Eliminate costly mold rework

Decrease time to market – Cut down cycle

times, machine downtime

Improve product quality

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 SOLIDWORKS Plastics - Packages
SOLIDWORKS Plastics
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SOLIDWORKS Plastics Professional

SOLIDWORKS Plastics Standard(Fill) Premium (Warp + Cool)
(Fill + Pack)
Surface & Runner Shrinkage &
Filling Short Shots Multi-Cavity Cooling Time Warp
Solid Meshing Balancing Sink Marks

Multiple Insert Gas-Assist & Fiber Analysis &

Weld Lines Air Traps Co-Injection Cool
Gates Overmolding Valve Gates Birefringence

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 Thank You!
 Visit the SOLIDWORKS website at http://www.solidworks.com to learn more about
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SOLIDWORKS and its product offerings.

 Contact your local SOLIDWORKS reseller for information on pricing and training. To
find a reseller in your area call:
 1-800-693-9000 (US and Canada)
 +1-781-810-5011 (Outside the US and Canada)

[email protected]
[email protected]

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POLL QUESTION #3
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