Step by step guide to understand the injection moldflow analysis of plastic products

Focus on Key Analysis Items

 

Flow Results

• Fill Time: By observing the dynamic animation and contour lines of the fill time (see Figure 1), you can understand the overall time and flow sequence of the plastic in the mold. Observe the filling sequence of different areas to determine if there is an imbalance in filling. For example, if some areas fill too slowly or too quickly, it may lead to problems such as short shots or flash.
• Melt Front Temperature: Monitor the temperature change at the melt front. Avoid excessive temperature changes, which can cause internal residual stress and warpage. It may cause the plastic to cool at different rates, resulting in deformation.
• Pressure Distribution: Check the pressure distribution diagram, especially the pressure distribution at the end of the mold flow. Ensure that the pressure distribution is balanced and symmetrical. Excessive pressure may lead to inconsistent material shrinkage and insufficient packing, resulting in sink marks and other defects; while too little pressure may cause incomplete filling.
• Clamp Force: Understand the magnitude of the clamp force to determine if the clamp force of the injection molding machine is sufficient to meet the molding requirements. If the clamp force is insufficient, it may lead to problems such as flash during the injection molding process.

 

Appearance Results

 

• Air Traps: Air traps usually occur in the areas where two or more fluid fronts meet. They are the positions where air bubbles may be generated (see Figure 2). Bubbles in these areas are compressed, which may cause problems such as short shots, excessive injection pressure, and surface spots. They may also form high - temperature and high - pressure areas locally, leading to charring. Pay attention to the positions of air traps to consider venting measures in the mold design.
• Weld Lines: Weld lines are the lines formed when the plastic melt meets and fuses during the flow process. The existence of weld lines may reduce the strength and appearance quality of the product. Especially in products with high appearance requirements, it is necessary to minimize the occurrence of weld lines or make them in inconspicuous positions. Analyze the position and strength of weld lines, and improve them by adjusting the gate position and optimizing the flow path.
• Sink Mark Prediction: Sink marks are the depressions formed on the product surface due to the uneven shrinkage of different parts during the cooling and shrinkage process of the plastic. Pay attention to the possible positions and degrees of sink marks. For thick - walled areas or parts with complex structures, sink marks are more likely to occur. The sink marks can be reduced by adjusting the wall thickness distribution and optimizing the packing process.

 

Warpage Deformation Results 

 

Warpage analysis predicts the possible deformation of the plastic part during the cooling and solidification process, including the total deformation amount and the deformation amounts in each directional component. Warpage deformation will affect the dimensional accuracy and assembly performance of the product. Identify the areas and directions with large warpage deformation, and analyze the reasons for its occurrence, such as uneven cooling and inconsistent shrinkage, in order to adjust the mold design and process parameters.

 

Comprehensive Analysis and Evaluation

 

• Compare Different Schemes: If multiple molding flow analysis schemes have been carried out, compare the analysis results of different schemes to evaluate the advantages and disadvantages of each scheme and select the optimal one. For example, compare the filling conditions, air trap distributions, and warpage deformations under different gate positions, different materials, or different process parameters to determine the most suitable scheme for product molding.
• Combine with the Actual Production Situation: The molding flow analysis results are based on theoretical models and assumed conditions. In actual production, they may be affected by some factors, such as the processing accuracy of the mold, the performance of the injection molding machine, and the difference in material batches. Therefore, it is necessary to combine the molding flow analysis results with the actual production experience to reasonably evaluate and adjust the analysis results.
• Identify Problems and Propose Improvement Measures: According to the problems found in the molding flow analysis, such as insufficient filling, excessive air traps, and large warpage deformation, analyze the reasons for their occurrence and propose corresponding improvement measures. For example, adjust the gate position and quantity, optimize the cooling system design, change the product wall thickness distribution, adjust the injection process parameters, etc., and then verify the effectiveness of the improvement measures by conducting molding flow analysis again or through actual mold trials.

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Deep Mould provide the individual moldflow analysis down to $80~$100

 

If you are interested in our services, please feel free to contact us. We will support your team anytime!

 

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