Products - Moldex3D Shell
Mesh : Flow/Pack : Cool : Warp : Fiber : RIM
Moldex3D-Shell performs the fill, pack, cool and warp analysis for Standard injection molding, Gas Assisted injection molding, Thermoset Injection molding and insert molding. Shell module is used to simulate and analyze thin parts where the thickness variation is not high.
Features of Moldex3D/ Shell
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Capability to analyze the fill, pack, cool and Warp stages of injection molding procedure. Transient-state calculation based on more reliable 2.5D Hele-Shaw flow model is adopted. |
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Capability to analyze hybrid mesh composed of triangular elements and rod elements so that the complicated geometry features (part, cold runner, hot runner, etc.) of the part can be adequately modeled. |
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Capability to predict flow phenomenon in multi-cavity molds by performing analysis on single cavity with symmetry setting. |
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Capability to read a system-embedded or user-specified material data bank that characterizes the physical properties of the plastic materials. The material data bank contains more than 5,700 different grades of plastic material. |
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The viscosity model of the material is modeled as a function of temperature and shear-rate. For user defined materials, the parameters of viscosity model can be easily specified in the user data base. The well-proven theoretical model of viscosity, such as Cross model, is adopted in the software. |
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The PVT model of the software is modeled as a function of temperature, pressure, and specific volume. For user defined materials, the parameters of PVT model can be easily defined in the user data base. The well-proven theoretical model of PVT, such as double domain Tait model, is adopted in the software. |
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The process-conditions include filling/ packing/ cooling time, packing pressure, melt temperature, mold temperature, switching-over point, pressure profile and ram-speed (injection rate) profile. These conditions are the necessary parameters to specify a particular machine and process. |
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Batch run function is provided for running multiple analyses. |
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The analysis results are accurate and reliable. Practical case studies or experimental results are provided confirming the accuracy and reliability of the software. |
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The robustness of the software is good so that there is no iteration convergence problem. |
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Capability to generate report automatically. The format of the report can be either ASCII or HTML so that users can interpret the results with anyone without resorting to particular visualizer/ viewer. |
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Can be with a personal computer (PC) under standard windows OS such as MS-Windows 95/98/2000/NT. |
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Has no theoretical limitation on the numbers of elements/ nodes of analysis. |
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Moldex3D/ Shell - Mesh
Moldex3D - Mesh is the pre-processor for Moldex3D solver. Moldex3D Mesh is available as a Plug-In to Rhinoceros and allows users to utilize the advantages of both Rhino and Moldex3D. Rhino is a powerful 3D surface modeling program, known as The King of the 3D Surface. Users can easily create a 3D model from scratch, or import and modify an existing CAD model. Rhino can import CAD files in IGES, STEP, etc formats.
Moldex3D-Mesh can generate high quality mesh from any surface model in Rhino. It can also import existing surface or solid mesh from a variety of other programs. With numerous functions to check, modify, and rebuild the mesh, Moldex3D-Mesh is a very powerful and easy to use mesh generator. The high quality Finite Element Mesh created by Moldex3D-Mesh can be used in a variety of CAE analysis programs, including Computational Fluid Dynamics and Stress Analysis.
Moldex3D-Mesh can generate 3D triangular surface mesh for 2.5D shell analysis.
This can be done by extracting the surface from either core side or cavity side of the part.
Moldex3D Mesh has the capability to assign the thickness to the shell mesh automatically. Moldex3D Mesh has many functions to automatically fix the mesh suitable for shell analysis like fill holes, fill an annulation, stitch meshes etc. Runner/ Coolant lines can be created easily in Rhino and the diameters to them are assigned.
Moldex3D-Mesh is the perfect pre-processor for Moldex3D plastic flow analysis software. It supports many toolkits to create and assign object attributes such as runner systems, cooling lines, and mold bases. These functions make Moldex3D flow analysis fast, easy, and accurate.
Using Rhinoceros and Moldex3D-Mesh, users can easily create a model and generate a good mesh. Together, they make the perfect tool for CAE Engineers.
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Moldex3D/ Shell - Flow/ Pack
Moldex3D-Shell Flow/Pack predicts the process dynamics of mold filling/ packing stages of the injection molding cycle to ensure quality parts for today's ever-competing market. It is a powerful tool for part/mold designers, mold makers, and molders. It can be used to determine the part wall thickness distribution, gate and runner system dimensioning and layout in the design phase; it can be used as a trouble-shooting tool to detect possible molding defects such as short shots, undesired weld line locations, air-traps, unbalanced flow, overpacking, underpacking, etc. It can be used to optimize process conditions such as filling time, packing time, switch-over point, melt temperature, injection pressure and holding pressure profiles.
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Features of Moldex3D/ Shell - Flow/ Pack
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Capability to analyze the filling/ packing stages of injection molding procedure. |
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Capability to analyze the filling/ packing stages under non-uniform mold temperature condition. That is, if the mold temperature distribution in the mold is available from the cooling analysis, the software will consider the non-uniform mold temperature distribution as the boundary condition for calculation. If the mold temperature distribution is not available, the calculation is based on a user-specified uniform mold temperature. |
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Capability to analyze situation when a vacuum-pump is used for the mold. |
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Capability to analyze cases with valve-gates in sequential gating of hot runner systems for better filling-pattern control. |
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The analysis speed is fast. For a typical case composed of 17,000 elements on PC (say, Pentium 4 2.4GHz) the analysis time should not exceed 10 minutes. |
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Provides shaded plots of the following items: |
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Melt front advancement: indicates filling dynamics |
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Temperature distribution: indicates hot spot and cold material region |
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Pressure distribution: indicates pressure-consumption and distribution |
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Volumetric shrinkage distribution: indicates the potential of part shrinkage |
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Shear rate/stress distribution: indicates the potential of part breakage |
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Velocity vector: indicate the flow direction |
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Gapwise temperature/ velocity distribution for all nodes: indicate the frozen-layer and heat-conduction phenomena. |
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Provides 2D x-y curves of the following items: |
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Sprue pressure history curves: indicates the injection pressure variation of the whole mold. |
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Sprue flow rate history curves: indicates the compressibility of plastic melt and extent of packing. |
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Clamping force history curves: indicates the clamping force requirement that is a consideration point for injection molding machine size. |
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Time history curves of variables (temperature, flow rate, etc.) at selected nodes (sensor nodes) in the model: helps users to monitor the thermo mechanical history of critical points of the part during the injection molding cycle. |
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Indicates regions with short-shot, air-trap, and welding line potential. |
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Provides data-sampling function for users to extract detail analysis data of selected node/ element. |
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Provides tools to save the Melt front advancement animation result displaying the filling dynamics of the process in .avi or .mpeg formats. |
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Moldex3D - Shell Cool
Moldex3D-Shell Cool predicts the mold cooling stage of the injection molding cycle to minimize cycle time and improve part quality. This becomes a powerful tool for part/mold designers, mold makers, and molders. It can be used to determine the layout and size of the cooling channels in the design phase. It can also be used as a trouble-shooting tool to detect possible molding defects such as unbalanced cooling, hot spots, and prolonged cooling time due to low cooling efficiency. It provides information such as cooling time, mold temperature distribution, heat flux, etc. The fast computation speed of Moldex-Cool helps you to quickly examine your cooling channel layout and make any necessary modifications.
Mold cooling process of an injection molding cycle is critical from the viewpoint of productivity and quality of molded part. Efficient cooling systems cut down cooling time required and improve molding productivity by shortening the cycle time. On the other hand, undesired defects such as sink marks, differential shrinkage, thermal residual stress built-up, as well as part warpage are attributed to poor cooling system design. These defects can be relieved or even be eliminated through a proper arrangement of cooling channels and the best combination of process conditions. CAE (Computer-Aided Engineering) has been proved to be an efficient engineering tool for part designers and mold engineers to optimize molding cooling system design parameters and verify the design on the computer before mold is build.
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Features of Moldex3D/ Shell - Cool
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Capability to analyze the cooling stages of injection molding procedure. 3D transient-state calculation based on fast finite element method is used. |
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The size of mold base has important effect on the cooling results and is considered in the mathematical model. Mold base size modification is allowable for users to investigate this effect. |
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Capability to analyze gas channel that is hollow in nature. |
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Capability to analyze cooling stage after mold-filling/ packing stages. The results from filling/ packing analysis should be compatible with this software to provide the necessary initial/ boundary conditions for calculation. |
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The thermal property of the material is modeled as a function of temperature. The thermal properties of commonly-used coolants and mold base materials are included in the system-embedded data bank. For user defined materials, the thermal data of the model can be easily defined in the user data base. |
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The analysis speed is very fast. For a typical case composed of 17,000 elements on PC (say, Pentium 4-2.4GHz) the analysis time should not exceed 5 minutes. |
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Provides shaded plots of the following items: |
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Cooling time distribution: indicates the cycle time requirement. |
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Mold temperature distributions: include distribution at the end of cooling and the cycle-averaged values. This indicates the performance of cooling system. |
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Heat flux distributions: indicate the interaction of heat transfer between plastic part and mold/ cooling channel. |
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Cooling channel efficiency distribution: indicates the performance of each cooling channel. |
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Frozen-layer distribution: indicates the solidification (frozen) layer of parts during the cooling state. |
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Provides 2D x-y curves of the following items: |
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Part/ mold temperature history curves: indicate dynamics of cooling stage: |
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Time-Gapwise temperature distribution curves for all nodes: indicate the frozen-layer advancement in the cooling stage. |
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Provides data-sampling function for users to extract detail analysis data of selected node/element |
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Has no theoretical limitation on the numbers of element/node of analysis. |
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Moldex3D/ Shell - Warp
Moldex3D-Shell Warp predicts the shrinkage and warpage behavior of injection-molded parts after they are ejected from the mold cavity. Fully integrated with the Moldex-Flow/Pack/Cool modules, it predicts the displacement distribution and deformed shape of the part after warping. It helps users identify the major causes of warpage and optimize the part dimension quality.
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Features of Moldex3D/ Shell - Warp
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Capability to analyze the out-of-mold part shrinkage and warpage behavior of injection molding process. 3D thermo elastic finite element calculation method is used for analysis. |
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Capability to analyze the part shrinkage and warpage behavior under non-uniform mold temperature (thermal stress effect) and non-uniform volumetric shrinkage distribution (PVT effect). These two mechanisms should be considered in the theoretical model and can be displayed independently. |
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Capability to analyze a gas channel that is hollow in nature. |
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Provides shaded plots of the following items: |
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Displacement distribution : indicates deformation due to thermal stress and PVT effect as a whole in each direction |
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hermal displacement distribution: indicates deformation due to thermal stress in each direction |
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Volumetric shrinkage distribution: indicates extent of part shrinkage due to PVT effect. |
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Sink mark distribution: indicates the potential and extent of sink mark on the part. |
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Deformed shape of the part: indicates the extent of part warpage. The deformed shape can be scaled according a user-specified factor and can be compared with the original shape. |
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In mold constraint effect: the new solver of the warpage considers the actual condition for the cavity in the molding process. It makes the deformation due to the warp more accurate than before. |
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Provides function to indicate the linear shrinkage between two sampling points selected by users. |
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Provides data-sampling function for users to extract detail analysis data of selected node/element |
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Provides tool to save the part warpage animation result in .avi or .mpeg formats. |
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Has no theoretical limitation on the numbers of element/node of analysis. |
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Moldex3D/ Shell - Fiber
Moldex3D-Shell Fiber can simulate the anisotropic conditions that are created by fiber-filled materials. Moldex3D provides a graphical output providing both fiber direction and degree of orientation. The results ultimately offer a significant improvement in part Shrinkage and Warpage predictions.
Features of Moldex3D/ Shell - Fiber
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Capability to analyze the fiber orientation on different layers for models which contain fiber. Users can set the number of layers for this kind of shell model, and obtain the fiber orientation of each layer. |
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Capability to analyze the volume shrinkage of the part due to the fiber orientation. |
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Capability to analyze the warpage of the part due to the fiber orientation. |
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Moldex3D/Shell-RIM
Moldex3D-Shell RIM accurately simulates the curing kinetics of thermoset materials (molding compounds in IC packaging) and provides mold filling and curing analysis results. With Moldex InPack, an advanced meshing program for the IC industry, the software can accurately depict encapsulation on leadframes and similar types of parts.
Mold Filling CAE Analysis of Reactive Molding/IC Encapsulation Process
 
 
Moldex3D/Shell-RIM accurately models the curing kinetics of thermosetting material (molding compound in IC packaging) and provides mold filling and curing analysis results.
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Practical Case Study
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