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Table Of Contents

1 Polymer Flow Behavior in Injection Molds
•Phases of injection molding
1.1 Phases of Injection Molding
1.1.1How Plastic Fills a Mold
1.1.2The Filling Phase
1.1.3The Pressurization Phase
1.1.4The Compensation Phase
1.2 How Do Plastics Flow?
1.2.1Material Behavior
1.2.3Viscoelastic Behavior
1.2.4Melt Shear Viscosity
1.2.5Newtonian Fluid vs. Non-Newtonian Fluid
1.2.6Shear-thinning Behavior
1.2.7Shear Rate Distribution
1.2.8Pressure-driven Flow
1.2.9Pressure Gradient and Injection Times
1.2.10Melt Flow Length
1.2.11Injection Pressure vs. Fill Time
1.2.12Flow Instability
2 Molding Conditions and Injection Pressure
•Injection pressure overview
2.1 Injection-pressure Overview
2.1.1Pressure Drives the Flow Front
2.2 Factors Influencing Injection-pressure Requirements
2.3 Equations
2.3.1Circular Channel Flow
2.3.2Strip Channel Flow
2.4 Effect of Molding Conditions
2.4.1Part Quality
2.4.2Melt Temperature
2.4.3Mold Temperature
2.4.4Fill Time
2.4.5Shear Stress Variation
2.4.6Packing Pressure and Time
2.4.8Back Flow
2.5 Using Moldflow to Determine Optimum Molding Conditions
2.5.2Molding Window Size
2.5.3Injection Pressure
2.5.4Flow Front Temperature
2.5.5Cooling Time
3 Filling Pattern
•Filling pattern overview
3.1 Filling Pattern Overview
3.1.1What Is the Filling Pattern?
3.2 Flow in Complex Molds
3.2.2Racetrack Effect
3.2.3Varying Injection Rate
3.2.4Underflow Effect
3.2.5Hesitation Effect
3.2.10Unstable Flow
3.2.11Simple Flow Pattern
3.3 Flow-front Velocity and Flow-front Area
3.3.1What are FFV and FFA?
3.3.2Flow-front Velocity Influences Filling Pattern
3.4 Using Moldflow to Determine the Filling Pattern
3.4.1Computer Simulation Can Eliminate Molding Trials
3.4.2Using a Flow Analysis
3.5 Using Moldflow to Achieve Constant FFV
3.5.1Controlling the FFV Through Ram Speed
4 Moldflow Design Principles
•Product design and Moldflow
•Sequence of analysis
4.1 Product Design and Moldflow
4.2 Sequence of Analysis
4.2.1Part Filling Optimization
4.2.2Molding Conditions
4.2.3Runner Design
4.2.4Cooling Optimization
4.2.5Packing Optimization
4.2.6Warpage Optimization
4.3 Moldflow Flow Concepts
4.3.1Unidirectional and Controlled Flow Pattern
4.3.2Flow Balancing
4.3.3Constant Pressure Gradient
4.3.4Maximum Shear Stress
4.3.5Uniform Cooling
4.3.6Positioning Weld and Meld Lines
4.3.7Avoid Hesitation Effects
4.3.8Avoid Underflow
4.3.9Balancing with Flow Leaders and Flow Deflectors
4.3.10Controlled Frictional Heat
4.3.11Thermal Shutoff of Runners
4.3.12Acceptable Runner/Cavity Ratio
5 Meshes Used In Moldflow Analyses
•Mesh types used by Moldflow
5.1 Mesh Types Used by Moldflow
5.1.1Finite Elements Used in Moldflow
5.1.2Mesh Types
5.1.3Solver Assumptions
5.2 Mesh Requirements
5.2.1Mesh Density Considerations
5.2.2Part Details
5.3 Geometry Creation
5.4 Importing Geometry
5.5 Using Different Mesh Types
5.5.1Door Panel
6 Product Design
•Material properties for product design
6.1 Material Properties for Product Design
6.1.1Plastics Are Sensitive to Operating Conditions
6.1.2Stress-Strain Behavior
6.1.3Creep and Stress Relaxation
6.1.5Impact strength
6.1.6Thermal Mechanical Behavior
6.2.2Loading/Operating Conditions
6.3 Part Thickness
6.3.1Part Thickness Drives Quality and Cost
6.3.2Cycle Time Increases with Thickness
6.3.3Thick Parts Tend to Warp
6.3.4Thin, Uniform Parts Improve Surface Quality
6.3.5Reducing Part Thickness
6.4 Boosting Structural Integrity with Ribs
6.4.1Structural Integrity: the Goal of Every Design
6.4.2Designing Ribs
6.5 Design for Assembly
6.5.1Molding One Part vs. Separate Components
6.5.2Tolerances: Fit between Parts
6.5.4Snap-fit Joints
6.5.5Cantilever Snap Joints
6.5.6Torsion Snap-fit Joints
6.5.9Welding Processes
7 Gate Design
•Gate design overview
7.1 Gate Design Overview
7.1.1What Is a Gate?
7.1.2Single vs. Multiple Gates
7.1.3Gate Dimensions
7.1.4Gate Location
7.2 Gate Types
7.2.1Manually Trimmed Gates
7.2.2Automatically Trimmed Gates
7.3 Design Rules
7.3.1Determining the Number of Gates
7.3.2Flow Patterns
7.3.3Gate Position
7.3.4Avoiding Common Problems
7.3.5Gate Length
7.3.6Gate Thickness
7.3.7Freeze-off Time
7.4 Using Moldflow for Gate Design
7.4.1Gate Location
7.4.2Molding Window Size for the Three Gate Locations
7.4.3Filling Pattern
7.4.4Gate Size Based on Shear Rate
8 Runner System Design
8.1 Definitions
8.1.1Feed System
8.1.2Runner System
8.1.3Cold Runner
8.1.4Hot Runner
8.1.5Hot Manifold
8.1.6Hot Drop
8.2 Runner System Design Principles
8.2.1Benefits of Good Runner Design
8.2.2Runner Design Philosophy
8.2.3Flow Balancing
8.2.4Flow Control
8.2.5Frictional Heating in Runners
8.2.6Thermal Shutoff
8.2.7System and Runner Pressures
8.2.8Constant Pressure Gradient
8.2.9Cold Slug Wells
8.2.10Easy Ejection
8.3 Runner Types
8.3.1Cold Runners
8.3.2Hot Runner Systems
8.4 Runner Layout
8.4.1Determining the Number of Cavities
8.4.2Planning the Runner System Layout
8.4.3Partially Balanced Runners
8.4.4Geometrically Balanced Runners
8.5 Initial Runner Sizing
8.5.1Determining Sprue Dimensions
8.5.2Designing Runner Cross Sections
8.5.3Determining Runner Diameters
8.6 Runner Balancing
8.6.1How Runner Balancing Works
8.6.2When Are the Runner Sizes Optimized?
8.6.3Validating the Balance
8.6.4Processing Window
8.7 Using Moldflow for Runner Balancing
8.7.1Runner Balancing a 48-cavity Tool
8.7.2Runner Balancing for a Family Mold
8.7.3Runner Balancing for a Multigated Part
9 Cooling System Design
•Mold cooling system overview
9.1 Mold Cooling System Overview
9.1.1Importance of Cooling System Design
9.1.2Mold Cooling System Components
9.2 Cooling-channel Configuration
9.2.1Types of Cooling Channels
9.3 Alternative Cooling Devices
9.3.1What Do They Do?
9.3.4Thermal Pins
9.3.5Cooling Slender Cores
9.3.6Cooling Large Cores
9.3.7Cooling Cylinder Cores
9.4.1Cooling Time
9.5 Design Rules
9.6.1Example Setup
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MoldFlow Design Guide , 1st Edition [2006]

MoldFlow Design Guide , 1st Edition [2006]



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Autodesk MoldFlow Design Guide
Autodesk MoldFlow Design Guide

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Categories:Book Excerpts
Published by: Ανδρέας Ψύχος on Sep 16, 2013
Copyright:Attribution Non-commercial


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