Simulation aided design
Extrusion
The simulation of the overall extrusion process for plastics is decomposed into various steps. A first step consists of simulating the granules (pellets) feeding and melting processes. Then the melted mixture flow under temperature and microstructure effects is considered. The last step consists of simulating the material flow in the die where the shape of the extruded product is defined. A structural post-analysis of the final product can be also performed if mechanical properties are to be assessed.
Simulating the extrusion process: Various steps
Injection molding
The first two steps of the injection molding simulation are similar to those of the extrusion process. The last step consists of simulating the flow and cooling of material in the mold as dsecribed in the following section. A structural post-analysis of the final product can be also performed if mechanical properties are to be assessed.
Simulating the overall injection molding process: Various steps
The analysis of the injection molding process is carried out following the guidelines shown in the figure below. Once the process goal and feasibility have been assessed, a preliminary analysis of the mold filling capabilities is performed after the mesh generation. If a satisfactory is observed, then the second step consists of refining the filling analysis and including the post-filling stage without considering cooling effects, is carried out. After estimating the shrinkage and solidification time, a first design of the mold cooling system is suggested. The cooling system is then improved in order to optimize temperature distributions at the walls. A simulation of the integrated filling, cooling and packing stages is then performed taking into account all the coupled effects in the mold. The final analysis is dedicated to the produced part shrinkage and warp.
Analysis of the injection and solidification processes in the mold: study canvas