8:00 am – 11:30 am:
TH7-Injection Molding: Simulations
(Moderator: David Okonski)-Room S320H


8:00 am – 8:30 am:
Deformation and Stress Prediction of Injection Molded Components After Being Mounted Into Designed Position

Zhiliang Fan, Moldflow R&D Center, Autodesk
In many industrial applications such as automobiles,aircraft and home appliances, it is essential to meet tight dimensional tolerances after injection molded components are mounted into the designed position. The prediction of the final deformation and stress of the components after the assembly normally requires a combination of warpage analysis, an interface between warpage analysis and structural analysis and a separate structural analysis, as the process-induced and assembly-induced deformation are calculated sequentially. A much simpler approach is developed for predicting the final deformation and residual stress, which only requires a warpage analysis with specially calculated boundary constraints. It has been implemented in three widely-used modelling methods in injection molding simulation: the midplane shell model, dual-domain shell model and three-dimensional tetrahedral model. Two numerical examples are given to illustrate the effectiveness of the approach. This proposed approach provides an easy and valuable tool for predicting the amount of geometric deviation between the final mounted component and the original design.


8:30 am – 9:00 am:
Moldflow Optimization of Micro-cavities Filling During Injection Molding Process

John Coulter, Lehigh Univeristy
This paper investigates the fabrication of micro-molded features using Moldflow analysis to optimize processing parameters. Melt temperature, mold temperatures, injection velocity, and packing pressure were all examined to help understand the process of microinjection molding. Micro pillar type features with different cross sectional shapes, diameter, and height were investigated using Moldflow® analysis to optimize filling. Critical processing parameters were identified for common thermoplastic polymers such as Polystyrene (PS) and Thermoplastic Polyurethane (TPU).


9:00 am – 9:30 am:
Deep Learning on CAE Based on the Integration of the Taguchi Method and Neural Network

Yu-Wei Chen, Postdoctoral Researcher, Chung Yuan Christian University
Plastic injection molding has become an important technique in traditional industry in recent years. In the process of injection molding, many manufacturers rely on the experiences of skilled workers, rather than utilizing an efficient method to eliminate processing defects, resulting in difficulties in quality control and increased total cost. To solve the problem of defect removal effectiveness, computer-aided engineering (CAE) is often employed, which can eliminate molding defects, through simulation analysis, before manufacturing. However, some unpredictable problems remain during the actual molding, which require the assistance of field technicians. The outcomes of injection molding, which involve injection pressure, cooling time, and warping deformation, have an intricate connection with control factors, which cannot be classified by regular linear programming. Back Propagation Neural Network (BPNN) has excellent predictive ability in solving non-linear problems. It can accurately predict the results after executing a series of training data. This study combined the orthogonal Taguchi Method and BPNN to construct a computing system for predicting the analysis result of CAE, and analyze the influence of multi-layer structure on prediction accuracy. The results showed that using the Taguchi Method to optimize the parameters of BPNN can increase the accuracy of prediction. Using the optimized network parameters can reduce the prediction error of the maximum injection pressure and maximum cooling time to less than 1%. However, there is still an error of 7.26% for the prediction on warping deformation, which demands further investigation of training data.


9:30 am – 10:00 am:
How to use CAE to Diagnose the Under-performance Problem of the Existed Machine in Injection Molding to Face Automation Challenge

Chao-Tsai Huang, Tamkang University
Recently, many automation technologies and equipment are applied for new injection molding systems to execute automation for Industry 4.0. However, there are also a huge numbers of the existed injection machines or systems which are not ready for automation yet. Indeed, before automatic manufacturing, how to retain good quality is one of the crucial factors in injection molding. In this study, we have focused on how to discover the under-performance problem of some existed injection machine to face the automation challenge using CAE technology. In the real testing case, we have demonstrated that CAE simulation prediction can be regarded as the ideal target for manufacturing. Furthermore, it is also estimated the difference between simulation prediction and real experimental result quantitatively. However, after careful comparison on the amount of the driving force to generate deviation from the target, the real experimental result presents almost the same trend and the same amount as numerical prediction did. Moreover, we also tried to compensate the under-performance of the real experiment using a series of packing pressure settings suggested by numerical simulation. Results showed that quality can be improved significantly.


10:00 am – 10:30 am:
Using New Anisotropic Rotational Diffusion Model To Improve Prediction of Short Fibers In Thermoplastic Injection Molding

Alexander Bakharev, Autodesk
In the article, we discuss a new fiber orientation model (Ci-D3) for prediction of fiber orientation in plastic composites during injection molding. We also compare fiber orientation predictions of the new model with: Folgar-Tucker (FT) and Reduced Strain Closure (RSC) with two different closure approximations (Hybrid and Orthotropic). Ci-D3 with Orthotropic closure approximation has shown predictions closest to the experiment followed by RSC with Orthotropic closure. Using Ci-D3 with Orthotropic instead of FT with Hybrid closure allows to halve average discrepancies between experimental measurements of fiber orientation and computer predictions.


10:30 am – 11:00 am:
Empirical Modeling and Simulation of the Microstructure Replication in Injection Molding

Torben Fischer, Institute of Plastics Processing (IKV) at RWTH Aachen University
Microstructured surfaces offer a high potential for use in the injection molding process. On the one hand, structures can be utilized to functionalize molded parts during the molding process and on the other hand, to manipulate the flow properties of the plastic melt in the mold. The following work addresses the development of an integrative simulation methodology, which will allow for predicting the replication quality of structures from steel to plastic part, thus enabling the efficient development of customized microstructures. The selected model approach achieved a good representation of the structure replication in plastics based on process settings and structure geometry. Furthermore, the main influencing factors on the structure replication were determined and statistically evaluated. Using this model and an integrative link to a commercial injection molding simulation software, it is already possible to predict the local degree of replication of microstructured surfaces.


11:00 am – 11:30 am:
Simulation Study of Injection Compression Moulding Process for a 0.6mm Thin Polymeric Microfluidic Chip

Ge Chen, Singapore Institute of Manufacturing Technology
Thin polymeric microfluidic chip design (chip thickness 0.6mm or less) is desired for lab-on-chip device due to rapid heat transfer across thickness direction. This feature results in better bonding property and temperature control during diagnostic analysis. It also offers good optical properties for the observation of fluidic mixing, filtering and reaction in the multi-layer and multi-functional chip design. However, polymer melt filling for thin chip poses great challenges as the frozen layer along melt flow path is built up rapidly for conventional injection moulding process. Some moulding defects may associate with thin chip design such as short shot, warpage, thickness variation and birefringence etc. In this paper, a series of Moldflow simulation studies were conducted to virtually investigate the effects of thin chip melt filling characteristics for both conventional injection moulding (CIM) and injection compression moulding (ICM) processes. The simulation results show that injection compression process is an enabling moulding technique for a polycarbonate (PC) based 0.6mm polymeric micro reactor chip design. Compared to CIM process, there is more than 30% improvement on chip micro feature replication accuracy and chip deflection.


8:00 am – 11:30 am:
TH8-Mold Technologies Session
(Moderator: Brenda Clark)-Room S320F


8:00 am – 11:30 am:
KEYNOTE: The Evolving and Involving Role of the Toolmaker

John Berg, Director of Marketing, Sussex IM
The many fundamental skills and attributes that make someone a successful toolmaker will never change. Problem solving, resource and time management, hands-on craftsmanship, a thorough understanding of metrology, the ability to see inside the steel, the practical application of mathematics… these qualities and more are a combination of educational and learned experiences along with inherent instinctual knowledge. Tool making – the fabrication of implements and machines to build and create other things – has been around as long as humans. It is a science and art that improves itself as part of its course of application. Technology has impacted and improved toolmaking for every generation. Machining equipment has increased speeds, precision and repeatability since its inception. The development of different grades of steel and alloys to address specific performance-related needs… Techniques and equipment for measurement… the advent of two, then three dimensional electronic data – for both design and programming… and recently, the quickly growing capabilities of additive machining – each of these caused somewhat of a paradigm shift in the constantly evolving world of the toolmaker. What do today’s toolmakers – young or old – mean to the manufacturing world in general? How important are the lessons from the past – the tribal knowledge acquired with over 30 or 40 years in the profession? This presentation will discuss how toolmaking and mold making is not only a smart career move for today’s emerging workforce – but an absolutely essential one.


8:30 am – 9:00 am:
PLENARY:Research Credits for the Plastics Industry

Michael Devereux, CPA, Mueller Prost CPAs + Business Advisors
In this ever-changing world of tax laws, the plastic industry must keep abreast of tax incentives that will benefit their business. This presentation will explore the following topics: R&D Tax Credit One of the most under-utilized tax savings opportunities for companies in the manufacturing sector is the U.S. Credit for Increasing Research Activities (R&D tax credit). The R&D tax credit rewards companies who invest resources in innovation, developing new designs, new techniques, and process development or improvement. The types of activities that may qualify for the R&D tax credit include, but are not limited to the following: Developing new part designs for manufacturability. Experimenting with manufacturing variables to improve processes Improving manufacturing processes through automation. Developing new fixturing or other tooling. Testing new part or tool designs through testing, sampling or trials This presentation will also explore new legislation that will allow eligible small businesses (less than $50 million in sales) to offset the Alternative Minimum Tax (AMT), as well as new treasury regulations that expand upon eligible expenditures for custom plastic processors.


9:00 am – 9:30 am:
Effect pf Different Mold Coatings on Flow Resistance in Thin-wall Injection Molding of Polystyrene Parts

Marco Sorgato, University of Padova
Injection molding of thin-wall parts is a challenging task due to the large cavity pressure gradient required during the filling phase. Low-friction mold surface coatings can be used to improve outcomes in such scenarios through reduction of the melt flow resistance by causing wall slip at the part-mold interface. This work investigates the effects of different mold coatings (DLC, CrN and CrTiNbN) on the melt flow resistance of polystyrene in thin-wall injection molding. The design of the mold allowed high-speed visualization of the molten polymer flow, measurement of the velocity profile across the cavity thickness and characterization of the wall-slip phenomenon. The results indicate that the DLC deposited on a chrome substrate can significantly reduce the melt flow resistance of polystyrene by increasing the slip velocity.


9:30 am – 10:00 am:
Induction Heating for Mold Filling – RocTool

Steven Verschaeve, Roctool
Roctool offers a patented technology that can change the way people design plastic parts. The technology uses induction heating to rapidly heat the tool surface thus providing many benefits including; – eliminating common molding defects such as gate blush and flow lines – cosmetically appealing parts with fillers such as glass or talc – great reduction of molded in stress – increase in flow length for thinner wall molding The company has been around since the year 2000 and has installed hundreds of systems worldwide. Although the technology has been adopted mostly in consumer electronics and automotive markets it can bring benefits to nearly every industry.


10:00 am – 10:30 am:
Standardized Components Economically in Large Molds

Brenda Clark, Hasco


10:30 am – 11:00 am:
Advantages of CT Scanning for Industrial Applications

Melissa Butrie, Business Development, 3D ProScan
After a brief explanation of how CT scanning works, advantages and examples of its applications in manufacturing and industrial environments will be reviewed. Focus will be on the efficiency of CT scanning versus traditional metrology methods for first article inspections. We will also discuss applications that can be used for mold builds and steel modifications, for the identification of assembly issues, and for CAD model creation of legacy parts.


11:00 am – 11:30 am:
Change Molds for Efficient Customer Development / Prototype

Tom Worcester, Meusburger USA
Improving the capability of the Mold Maker to be able to add R&D and Prototyping to their portfolio of services. Through the use of the “Change Mold” and the options of inserts that are available or possibly manufactured by the MoldMaker. These could include SLM Additive Manufactured with possible Conformal Cooling, Polymer based inserts for minimal volume of parts. This benefit would decrease the overall timeline for “Time to Market” for the end user.