B01-01-01-01

Introduction to NX Easy Fill

Mold Flow Analysis
By
Shahbaz Khan
Sr. Application Engineer

www.moldex3d.com
CoreTech System Co., Ltd.│Copyright© 2019 Moldex3D. All rights reserved.
 What to learn

> Learning objectives

– Benefit of NX EasyFill for Part Designer

> Moldex3D version

– Supported since NX8.5

> Recommended user

– NX user

2
 Outline

> Preface

> Key Issues for CAE in Injection Molding

> What’s NX Easy Fill?

> Functionality highlights in NX Easy Fill

> What can NX Easy Fill benefit you?

> Functionality Matrix

3
Preface
 Challenges for Plastic Part/Mold Designers

Varied New plastic materials

product geometry (LCP,GF/CF..)

Minimize Precision
the design cycle molding

Shorten
Higher requirements
time-to-market
Lower cost

5
 What Does Designer Really Need?

> Easy design tool

– Easy-to-learn, easy-to-use
– Easy to do design

> Fast design tool

– Fast to check design results

> Effective analysis tool

– Effective to provide analysis results

> Reliable analysis tool

– Correct to predict potential problems

6
Key points for CAE in Injection
Molding
 General Workflow of CAE Simulation

8
 Keys to Success CAE Simulation

> Good Mesh

– Right element resolution in key geometry
– Good mesh quality

> Right Material Selection

– Right material selection
– Correct material parameters

> Correct Process Conditions

– Correct process conditions
– Reasonable boundary conditions

Moldex3D

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 Bottleneck of General CAE Workflow

> However, construction of mesh of product geometry is the

major difficulty.
– 80% man-hours are spent in constructing the mesh.
– Construction time and mesh quality are highly dependent on
users experiences.

1 day? Or 1 week?

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What is NX Easy Fill?
“Easy and Fast 3D CAE solution fully embedded
in NX for CAD users”
 NX Easy Fill

> NX Easy Fill, developed by Moldex3D, is an integrated

injection molding simulation tool for designers to
analyze plastic part design for malleability during the
early stage of the product development process.
> Product designers can easily perform plastic flow
simulations within the NX environment.

Fill: 75%

12
Functionality highlights in
NX Easy Fill
 Advantages of NX Easy Fill

> Easy and fast injection molding analysis

– Designers can easily set up and perform an analysis with only a
few clicks.
– Avoid file conversion error
> NX users don’t have to learn another software.
– fully embedded in NX with intuitive injection molding simulations

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Benefits and Features of Moldex3D/
EasyFill
 Benefits

> Optimizes plastic part designs and manufacturing process

parameters
> Optimizes wall thickness for profitability
> Avoids short shot
> Manipulates weld line and air trap
> Reduces pressure drop
> Checks gate distribution for flow balance
> Recognizes part and mold design options early in the process

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 Features

> Fully embedded in NX so no additional training is needed

> Automatic 3D mesh is generated so no user intervention or
CAD conversion is required
> Comprehensive plastic materials database (over 5,000 material
grades)
> Intuitive interface for specifying molding parameters
> Pioneering 3D technology for more accurate results rendering
and smart animations
> High performance 3D filling simulation supported by parallel
computing

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 Capabilities

> Simulation Capabilities

– Filling Phase (1st stage injection) - 8 results
– Multi-Gates
> Results (Indicators)
– Melt Front Time
• Air Trap
• Weld Line
– Gate Contribution
– Pressure Drop
– Melt Front Time Temperature
– Max. Temperature
– Average Temperature
– Frozen Layer Ratio
– Max. Cooling Time
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Functionality Matrix
 Functionality Matrix

Capabilities NX Easy Fill NX Easy Fill Advanced

PLASTIC MATERIAL DATABASE
Number of Commercial Plastics 7,000+ 7,000+
Customizable O O
MESH
eDesign Mesh
Mesh Type BLM Mesh
(Level - 2)
Mesh Density Control X Mesh Size
MOLD GEOMETRY SUPPORT
Multi-Cavity Molds X O
Sprue & Runners (Curve & Solid) X O
Hot & Cold Runners X O
Melt Entrance(On Part or Runner) X O
Parting Direction X O
Multi-Gates O O
(Specify Position)
ADVANCED ANALYSIS
Valve Gates (sequential injection) X O

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 Functionality Matrix

Capabilities NX Easy Fill NX Easy Fill Advanced

WIZARD
Gate Wizard X O
Runner Wizard X O
Melt Entrance Wizard X O
INDICATOR TOOLS
Gate Location Adviser X O
Cooling Time Indicator X O
L/t Indicator X O
Sink Mark Indicator X O
SIMULATION CAPABILITIES
Filling Phase (1st stage injection) O O
Filling & Packing Phase (1St+2nd stage injection) X O
Full Analysis X O
PROCESS CONDITION
Max. Injection Pressure O O
Filling Time O O
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 Functionality Matrix (Cont’d.)

Capabilities NX EasyFill NX EasyFill Advanced

Packing Time X O
Melt Temperature O O
Mold Temperature O O
Cooling Time X O
COMPUTING SETTING
Max. Task Count 4 8
Batch Run X O
RESULTS (Filling)
Fill Time (Melt Front Time) O O
Air Traps O O
Weld Lines O O
Welding Angle X O
Weld Line Meeting Angle X O
Gate Contribution O O
Ease of Fill (Moldability) X O
Pressure at End of Fill (Pressure) X O
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 Functionality Matrix (Cont’d.)

Capabilities NX EasyFill NX EasyFill Advanced

Pressure Drop O X
Temperature at End of Fill (Temperature) X O
Shear Stress X O
Max. Shear Stress X O
Shear Rate X O
Max. Shear Rate X O
X, Y, Z-Velocity X O
Volumetric Shrinkage X O
Density X O
Melt Front Temperature O O
Viscosity X O
Total Velocity X O
Velocity Vector X O
Frozen Layer Fraction at End of Fill
O O
(Frozen Layer Ratio)
Max. Temperature O O
Bulk Temperature X O
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 Functionality Matrix (Cont’d.)

Capabilities NX EasyFill NX EasyFill Advanced

Central Temperature at End of Fill
X O
(Center Temperature)
Average Temperature at End of Fill
O O
(Average Temperature)
Max. Volumetric Shrinkage X O
Average Velocity Vector X O
Max. Cooling Time O X
Fiber Orientation In X,Y,Z Direction X O
Fiber Orientation X O
Fiber Orientation (Skin) X O
RESULTS (Packing)
Melt Front Time X O
Pressure X O
Temperature X O
Shear Stress X O
Shear Rate X O
X, Y, Z-Velocity X O

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 Functionality Matrix (Cont’d.)

Capabilities NX EasyFill NX EasyFill Advanced

Volumetric Shrinkage X O
Density X O
Viscosity X O
Total Velocity X O
Velocity Vector X O
Frozen Layer Ratio X O
Max. Temperature X O
Center Temperature X O
Average Temperature X O
Bulk Temperature X O
Sink Mark Indicator X O
Sink Mark Displacement X O
Max. Volumetric Shrinkage X O
Average Velocity X O
RESULTS (Cooling)
Temperature X O
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 Functionality Matrix (Cont’d.)

Capabilities NX EasyFill NX EasyFill Advanced

Time to Reach Ejection Temperature X O
Frozen Layer Ratio X O
Max. Temperature X O
Max. Cooling Time X O
RESULTS (Warpage)
X,Y,Z – Displacement X O
Total Displacement X O
Volumetric Shrinkage X O
X,Y,Z - Fiber Orientation Effect Displacement X O
Total Fiber Orientation Effect Displacement X O
X,Y,Z - Random Fiber Orientation Effect Displacement X O
Total Random Fiber Orientation Effect Displacement X O
Density X O
RESULTS (X-Y Plots)
Sprue Pressure (Filling & Pack) X O
Clamp Force (Filling & Pack) X O
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 Functionality Matrix (Cont’d.)
Capabilities
Flow Rate (Filling & Pack)
Volume Fraction (Filling & Pack)
Total Weight (Filling & Pack)
Cavity Weight (Filling & Pack)
Flow Rate Gate (Filling & Pack)
RESULTS VIEW TOOLS
Slicing
Clipping
Iso-surface
Result Criterial Advice
Save animation as file
REPORT GENERATION
Microsoft® PowerPoint
PLM SUPPORT
Siemens Teamcenter®
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NX EasyFill NX EasyFill Advanced
X O
X O
X O
X O
X O
X O
X O
X O
X O
X O
X O
O O
www.moldex3d.com
CoreTech System Co., Ltd.│Copyright© 2019 Moldex3D. All rights reserved.