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Products - Moldex3D Solid
Mesh : Flow : Pack : Cool : Warp : Fiber : RIM
Moldex3D-Solid is used for thick parts with large thickness variations.
The Shell analysis can provide qualitative results to thin parts only. From the geometrys point of view of the molded parts, sometimes, ambiguity exists in identifying the mid-plane. Moreover, the construction of mid-plane is very time-consuming. In addition, some 3D flow phenomenon (gapwise) will be lost by using shell model to simulate, such as flow passing through expansion and contraction area, small dimension-to thickness ratio area and for materials containing fiber. The results obtained from the shell based CAE are less accurate or even misleading. Therefore, 3D based CAE analysis is required to accurately capture the flow behavior of the polymer in the mold.
Moldex3D/Solid modules support almost all common types of elements, such as TETRA, HEXA, PYRAMID, PRISM etc.
One of the salient features of Moldex3D Solid is the automatic creation of runner system 3D mesh and cooling system 3D mesh. The runner lines and cooling lines are created and the solid mesh is automatically generated in Moldex3D.
Features of Moldex3D/ Solid
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Capability to analyze the fill, pack, cool and Warp stages of injection molding procedure. High Performance Finite Volume Method is adopted. |
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Capability to analyze the filling stage 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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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 - Mesh
Moldex3D-Solid Mesh is the Mesh generator 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 good 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 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 from any surface model. Moldex3D Mesh has many functions to automatically refine the mesh like autofix poor elements, rebuild surface mesh etc. After refining the mesh, Moldex Mesh can be used to generate 3D solid tetrahedral, pyramid, prismatic and voxel mesh. Users can create structured prism and hexahedral mesh using various options available in Moldex Mesh. A very high quality prism mesh for runner and coolant system can be generated automatically in Moldex Mesh. The mold base solid mesh is created automatically to run the cooling analysis.
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 - Solid/ Flow
Moldex3D-Solid Flow predicts the process dynamics of mold filling stage of the injection molding cycle. 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, etc. It can be used to optimize process conditions such as filling time, switch-over point, melt temperature, injection pressure and holding pressure profiles.
Features of Moldex3D/ Solid - Flow
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Capability to analyze the filling stage 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. |
| |
Provides 2D x-y curves of the following items: |
| |
Sprue pressure history curves: indicates the injection pressure variation of the whole mold. |
| |
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. |
>> Click Here to view illustrations
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Moldex3D - Solid/ Pack
Moldex3D-Solid Pack predicts the packing stage of Injection molding. Packing analysis can be utilized to minimize the volumetric shrinkage variation within the cavity, which can contribute to warpage. It can also be used to reduce thermally-induced residual stresses, identify and reduce sink marks etc.
Features of Moldex3D Solid/ Pack
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Capability to analyze the packing stage of injection molding procedure. |
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Capability to analyze the packing stage 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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Provides shaded plots of the following items: |
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Melt front advancement: indicates filling dynamics during fill and pack stages |
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Temperature distribution: indicates hot spot and cold material region |
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Pressure distribution: indicates pressure-consumption and distribution |
| |
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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Provides 2D x-y curves of the following items: |
| |
Sprue pressure history curves: indicates the injection pressure variation of the whole mold |
| |
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.) of 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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Moldex3D-Solid - Cool
Moldex3D-Solid 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.
Features of Moldex3D/ Solid - Cool
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Capability to analyze the cooling stages of injection molding procedure. |
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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 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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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. |
>> Click Here to view illustrations
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Moldex3D-Solid - Warp
Moldex3D-Solid - 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.
Features of Moldex3D/ Solid - Warp
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Capability to analyze the out-of-mold part shrinkage and warpage behavior of injection molding process. |
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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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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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Thermal 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-Solid/ Fiber
Moldex3D-Solid Fiber can simulate the anisotropic conditions that are created by fiber-filled materials. Moldex3D provides a full 3D Flea's Eye View walk through the wall thickness, providing both fiber direction and degree of orientation. The results ultimately offer a significant improvement in part Shrinkage and Warpage predictions.
Features of Moldex3D-Solid/ Fiber
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Capability to analyze the fiber orientation on different layers for models which contain fiber. Users can walk through the model using various visualization tools to see fiber conditions in any area of the part. |
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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-Solid/RIM
Moldex3D-Solid 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.
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