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FALL2005

For eng ineer ing p ro fess iona ls in des ign through manufac tu r ing

Fromart to part:

iMUG 05:Art to Part Pavilion

Features Moldflow Partners

Reducingproject turnaround

Improvingefficiency

Enhancingproduct performance

492 Old Connecticut Path Suite 401 Framingham, MA 01701


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More tools to help you design easier,collaborate easier, and breathe easier.

Image courtesy of National Optical Astronomy Observatory, operated by the Association of Universities for Research in Astronomy, under cooperativeagreement with the National Science Foundation. 2005 SolidWorks Corporation. SolidWorks is a registered trademark of SolidWorks Corporation.SolidWorks Corporation is a Dassault Systemes company. All other product names are trademarks or registered trademarks of their respective owners.

UPGRADE TO SOLIDWORKS OFFICE PREMIUM TODAY. How much better would

work be if you could manage your CAD data, test design concepts, and communicate

it all faster and easier? Now you can. SolidWorks Office Premium offers the most

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and quality, for managing product data, and for collaborating with others. All from

a company thats 100% focused on speeding up your product design process and

helping you breathe a little easier. To learn more, visit solidworks.com

More tools to help you design easier,collaborate easier, and breathe easier.

Image courtesy of National Optical Astronomy Observatory, operated by the Association of Universities for Research in Astronomy, under cooperativeagreement with the National Science Foundation. 2005 SolidWorks Corporation. SolidWorks is a registered trademark of SolidWorks Corporation.SolidWorks Corporation is a Dassault Systemes company. All other product names are trademarks or registered trademarks of their respective owners.

UPGRADE TO SOLIDWORKS OFFICE PREMIUM TODAY. How much better would

work be if you could manage your CAD data, test design concepts, and communicate

it all faster and easier? Now you can. SolidWorks Office Premium offers the most

complete product design solution available. In addition to production-proven

SolidWorks 3D CAD software, you get innovative tools for validating design safety

and quality, for managing product data, and for collaborating with others. All from

a company thats 100% focused on speeding up your product design process and

helping you breathe a little easier. To learn more, visit solidworks.com


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Copyright 2005 Moldflow Corporation. All rights reserved. Flowfront is a quarterly publication of Moldflow Corporation. Moldflow, Moldflow PlasticsAdvisers, MPA, Moldflow Plastics Insight, MPI, Moldflow Plastics Xpert, MPX, Shotscope, Celltrack and Altanium are trademarks or registered trademarks ofMoldflow Corporation and/or its subsidiaries worldwide. All other trademarks are properties of their respective holders.

contents

features

departments

4 from the editor Art to Part

8 whats new Celltrack Goes Wi-Fi:

Improve your Productivity

and Profitability

Moldflow Plastics Xpert:

Tools Every Molder Should

Have

Groundbreaking: CommonHardware for Moldflows

Shop Floor Solutions

33 tips & techniques Avoid Common Molding

Problems with Altanium

Hot Runner Process Con-

trollers

35 the analyst says Whats Your Business IQ38 index Make the most of

Altanium hot runnerprocess controllers. Learn how available

options can help you detect and avoid

common molding problems.

33

Thin-wall molding

-- no problem!

Systematic design

validation with Moldflow solutions helps

one manufacturer deliver higher quality

products with confidence.

27

MPI 6.0 user inter-

face enhancements

eliminate workflow bottlenecks. Now you

can more easily analyze complex parts,

compare more alternatives and ultimately,

complete more projects.

2212 cover story MPI 6.0 Release Highlights Range of 3D Solutions with New Solver and Technology

Enhancements

16 design & molding Rigorous Mold Tryout: A Molders Perspective on Manufacturing Quality Parts

19 manufacturing & process control Shotscope 4.0 Enhances Productivity and Efficiency

22 MPI/Synergy Enhancements Boost User Productivity

27 real world success ITT Industries Optimizes Production

29 Moldflow Communicator Aids Globally Distributed Teams

Cover shot illustrates the stages involved in the design of a GPS device.


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Multi-CAD Data Exchange

Advanced Geometry/Topology Healing

Geometry Simplification for CAE solutions

About Elysium Inc.Founded in 1984, Elysium bridges the gap between

CAD systems and enables PDM and product structure

synchronization with its industry-leading technologies.

Elysiums CADporter, CADdoctor, CADfeature,

and CADportalsoftware products enable the translation

of all geometry from one CAD system to another with the

industrys highest success rate. Other products include

CADpdm, a tool which enables CAD integration within

a PDM environment. Platforms supported include,

ABAQUS/CAE, ACIS, CATIA, Inventor, NX (I-deas and

Unigraphics), JT, ParaSolid, Pro/Engineer, SolidWorks and

Wildfire. Elysium has successful partnerships with severalmajor software companies including ABAQUS, Autodesk,

Moldflow, MSC.Software, PTC, SmarTeam, SolidWorks,

Spatial and UGS. Elysium is a member of the AIAG and an

Official Supplier of Renault F1 Team.

Elysium Inc.

100 Galleria Officentre

Suite 426

Southfield, MI 48034 USATel: +1-248-799-9800

Fax: +1-248-281-0672

www.elysiuminc.com

[email protected]

y

,

y

p

g

trademarksoftheirr

espectivecompanies.

ImagecourtesyofRenaultF1Team

Factories-Enstone,

UKandViryChatillon,

France.

Elysium Co., Ltd.World Headquarters

11-1 Asahimachi

Presstower 10F

Hamamatsu, Shizuoka

430-0927 JAPAN

Tel: +81-53-413-1000

Fax: +81-53-413-1010

Elysiums CADdoctor is a standalone translator and automated healing tool which

performs interactive analysis and quick repair of 3D CAD data. Specifically, Moldflow

CAD Doctor addresses problems encountered when importing solid surface-based

models to the Moldflow design analysis environment.

Why did Moldflow select Elysium to OEM a customized version of our product CADdoctor?


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7

This issue of Flowfront is our show piece, coinciding with theInternational Moldflow User Group Conference (iMUG05), heldthis year in Orlando, Florida, October 25-27. In these pages as

well as at iMUG05, customers, industry experts and Moldflow staffshare success stories, business philosophies and product innovations

that impact plastic products from art to part.Our focus in this issue is on the next release of our flagship product,

Moldflow Plastics Insight (MPI) design analysis software. MPI 6.0delivers a host of technology advancements reduce total projectturnaround, improve efficiency and enhance product performance.Preview of new technologies and key enhancements to analyticalsolvers that dramatically reduce solution time for true 3D analysisapplications, provide new result displays in answer to specific userrequests, and deliver new interface capabilities to popular structuralanalysis applications. Learn about user interface enhancements, whichallow users to more easily analyze complex parts, compare morealternatives and ultimately, complete more projects.

Meet Moldflow Communicator, a utility developed to address the needs

of distributed product teams. With Communicator, the assumptions,quality and applicability of CAE analyses can be better understood andaccounted for, and the knowledge gained from performing analysescan be shared more effectively among all participants in the design-to-manufacturing process. Communicator will be rolled out for otherMoldflow software products in the coming months.

Among our customer contributions in this issue, youll find amolders perspective on the challenges facing manufacturers today asGene Wells, senior process engineer at DJ/Nypro Plastics, discussesrigorous mold tryout. Youll also find out how ITT Industries (Dole,France) successfully uses Moldflow technology to validate part designsfor thin-wall molding applications.

Significant developments to the full line of Moldflow ManufacturingSolutions products are highlighted. Find out whats new in the latestCelltrack, MPX and Shotscope releases, and learn how to useavailable options for Altaniumhot runner process controllers to detectand avoid common molding problems.

Finally, Oren Harari, a highly regarded professor of businessmanagement and iMUG05 keynote speaker, gives us his views on the

Business Intelligence Quotient and why its critical for competitivesuccess in todays economy.

Whatever role you fill in taking plastic products from art to part,you will find information here about technology innovations, productapplications and business practices that benefit every stage of productdevelopment through manufacturing.

I hope we will see you in Orlando and at future iMUGs, and I welcomeyour feedback on Flowfront and Moldflow products throughout the yearto [email protected].

Art to Part

Marcia SwanEditor

letter from the editor

published by

Moldflow Corporation

492 Old Connecticut Path, Suite 401

Framingham, MA 01701 USA

Tel: +1 508.358.5848

Fax: +1 508.358.5868Web: www.flowfront.com

E-mail: [email protected]

Editor Marcia Swan

Associate Editor Murali Annareddy

Contributing Writers Catherine Baghdiguian

Michel Bruehwiler

Dave Duarte

Dave Rotondo

Nick Smith

Graphic Design Liz Goncalves

Circulation Assistant Peggy Cicalis

Publisher Peter Rucinski

Advertising Manager David Kagan

Marketing Associate Shelley Waller

Flowfront Editorial Board

Ken Welch EVP/Design

Tim Triplett EVP/Manufacturing

Ian Pendlebury VP/Products

Peter Kennedy VP/Technology

Moldflow Corporation Executive Management

Roland Thomas President & CEO

Christopher Gorgone EVP/Finance

Lori Henderson VP General Counsel

advertising informationTel: +1 508.358.5848 x285


subscriptions & reprints

Tel: +1 508.358.5848 x295

E-mail [email protected]

case studies & press releases

Tel: +1 508.358.5848 x289


for more informationDownload ad rates, subscribe, send press re-

leases and contact us at:

www.flowfront.com

Flowfront reaches 20,000 engineering profes-

sionals around the globe each quarter.

For more information about Moldflow,its com-

munity of over 10,000 users in the design and

manufacturing industries, and its local offices in

your area, please visit:

www.moldflow.com


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whatsnew

Flowfront |Fall 20058

Celltrack Goes Wi-Fi:

Improve Your Productivity

and Profitability

By Nick Smith

Moldflows Celltrack real-timeproduction management system isnow available with Wi-Fi (wirelessfidelity) enabled machine interfaceunits (MIUs). The Celltrack systemtracks and reports production andmachine efficiencies. It can beattached to virtually any piece ofcyclic equipment used for discrete

manufacturing and also providescapabilities for work ordermanagement, job scheduling,mold and machine maintenancetracking, labeling and SPC/SQCfunctions.

Many studies have verified thatwireless Ethernet technology canoffer significant benefits versustraditional networking protocols,and the greatest benefits will likelymaterialize in environments wherecollaboration is a priority and easy

access to information and rapiddecision making are important.

Celltrack customers operatedaily in such environments and cannow utilize Wi-Fi to benefit fromthe increased access, flexibility andlower cost that wireless technologycan bring. Specifically, we havefound the following significantbenefits of Wi-Fi enabled MIUs:

Access production data andconnect to the shop floor fromanywhere in the plantimprove

your productivity throughmultitasking.

Installing a wireless networkis cheaper that installingconnectionsimprove yourprofitability and gain moreflexibility simultaneously.

The latest MIUs use wirelesstechnology for data transmissionto the file serveryou can benefitfrom the latest informationmanagement technologies.

Wireless technology is proven and

low risk to implementCelltrack

customers in Europe are alreadyusing the wireless MIUs.

Existing wired MIUs can be

upgraded to wirelesskeep yourexisting equipment and maximizeyour return on investment.

All network technologies aresupported to offer you the bestchoice for your operationsMIU01 and MIU02 continue tobe available with serial, wiredEthernet or the new Wi-Finetworking options.

A single Celltrack installationwill support a network of MIUsutilizing a mix of all three

communication protocolsyoucan mix existing with newtechnologies and choose the besttime to upgrade your equipmentto wireless.

Celltrack customers can now choose a Wi-Fioption to benefit from the increased access,flexibility and lower cost that wirelesstechnology can bring.

Our experience shows thatimplementing a wireless Ethernetnetwork increases the flexibility andmobility of equipment placementon the factory floor and reducesthe cost of installation significantlywhen compared to a hardwiredEthernet or serial network.

With this new capability,Celltrack delivers yet another toolfor manufacturing managers to

gather the critical necessary tomaximize the efficiency of shopfloor operations.

For more information about MoldflowCelltrack Production Management, visit www.moldflow.com.

Moldflow Plastics Xpert:

Tools Every Molder

Should Have

By David Duarte

In todays increasingly compe-titive global environment, manu-facturers must use every tool attheir disposal to reduce costs,increase efficiencies and improveprocess yields. The MoldflowPlastics Xpert (MPX) systemdelivers a unique set of tools tosupport these important initiativesspecifically for injection moldingmanufacturers.

The patented MPX expert systemprovides a systematic methodologyfor the setup and optimization ofthe injection molding process. Itdelivers significant improvementsin productivity and quality, therebydirectly improving profitability. Itis a process control tool kit thatsystematically fixes molded partdefects through an automatedDOE (design of experiments) whichdetermines a robust good partsprocessing window. Once goodparts are produced, MPX maintains

the optimal processing conditionsto produce the best quality part atthe lowest possible cost.

With the recent release ofMPX 4.0, Moldflow has added twosignificant enhancements to thispowerful set of tools, viscositycontrol and a new velocityoptimization routine.

Viscosity ControlIn injection molding manufac-

turing, a consistent materialresponse is desired to ensure


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www.flowfront.com 9

a repeatable process. However,several factors, such as regrindusage, humidity level, factory

temperature, plastication varia-tions and material batch-to-batch variations, often lead to afluctuation in material viscosity.Such variation can affect therepeatability of the process and, onsome occasions, the quality of theparts produced.

The viscosity control methodimplemented in the MPX ProcessControl module takes advantageof the strong relationship that melttemperature has upon material

viscosity, calculating a viscosityindex that can maintain the materialviscosity at a consistent level.

Depending on the magnitudeof the melt temperature change,the density of the part may changedue to the pvT relationship andany changes in flow dynamics. Ifthis resultant change in density isundesirable, the viscosity controlmethod includes an optiionalmelt density compensationfunction, configured by the user.

Compensation for the change inmelt temperature is achieved by

The viscosity control feature in MPX 4.0detects when the viscosity index is outof control and adjusts temperatures toregain statistical control of the molding

process.

adjustment of the packing pres-sure; the new packing pressure isautomatically downloaded to the

controller, assuring consistent partweights are maintained.

Velocity Optimization

One of the challenges to settingup any new tool is determining theoptimum injection velocity. Thevelocity optimization routine in theMPX Process Setup module directlyaddresses this need. Velocityoptimization is an automatedroutine based on the widelyaccepted method to derive an opti-mum velocity from the relativeviscosity vs. shear rate relationship.

The plastics industry has adoptedthe inverse of fill time (1/fill time)as an indicator of shear rate. Useof this relationship is considered bymost to be an accurate method todetermine a starting velocity.

The MPX velocity optimizationroutine accomplishes this byrunning two series of samples atvarying velocities. The first seriesis run starting from an initialvelocity (starting point), then in-creasing velocity until a molding

defect occurs or the upper machinevelocity limit is reached. Thesecond series is then run starting

from this upper velocity,and decreasing velocity untila molding defect occurs.The relative viscosity isdetermined for each velocityused and a plot is presentedwhich displays relativeviscosity as a function ofthe inverse of fill time. Theroutine then determinesthe most stable region forprocessing based on thisrelationship.

A logical question atthis point is, Where do I

determine the starting velocityfor this routine? One of themost powerful tools available inMPX is the ability to determinean initial velocity for the velocityoptimization routine. This can beaccomplished in one of three ways:1) use the MPX velocity wizard asa guide; 2) download machine

profiles from a machine controller,

if the part has been previouslyrun; or 3) download the velocityand pressure profile results from

MPX Process Setup determines therelationship between relative viscosity andshear rate, and recommends an optimumvelocity.

Moldflows industry-leading DesignAnalysis Solutions, Moldflow PlasticsInsight(MPI) or Moldflow PlasticsAdvisers(MPA) products.

Using result files generated byMPI or MPA plastics flow simulationsin MPX directly links design tomanufacturing, leveraging thevalue of these design analysisproducts on the manufacturing

floor.With these new enhancements,

MPX 4.0 continues to deliver thetools injection molders need to dothe job right the first time.

For more information about Moldflow PlasticsXpert, go to www.moldflow.com.


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whatsnew


FEATURE

YOUR

NEWS

HERE!

Next issue, Flowfront would

like to feature your new

releases.

Please send press releases to

[email protected]

Groundbreaking:

Common Hardware for

Moldflows Shop FloorSolutions

By David Rotondo

Many injection molders havemade sizable capital investmentsto become more competitive andimprove quality and efficiency.Despite these investments, moldersoften incur significant cost due todiffering hardware platforms usedin their plants. Simplifying the tasks

of running an injection molding cell,for example, or adding anotherprocess monitoring system, oftenmeant integrating various differenthardware platformsa challengingtask for any organization.

Moldflows new commonhardware solution helps moldersovercome these challenges, saveintegration cost and improvequality and efficiency. The commonhardware is currently available forMoldflow Plastics Xpert (MPX)

and Shotscope systems and theMatrix operator interface forAltanium hot runner processcontrollers. The common hardwarehas been successfully utilized bymany molders since its introductionin July 2005a clear sign of theplatforms proven capabilities.

Simplify the ComplexThese capabilities help to

simplify the tasks of running acomplex injection molding cell,

comprised of the injection moldingmachine, the mold and all ofthe various auxiliary equipmentnecessary to produce high-qualityparts. The auxiliary equipmentoften comes from differentmanufacturers employing theirown unique display to managetheir equipment. A typical injectionmolding cell may have five to 10different displays, all of which anoperator must be able to handle.Quite often, these displays are not

even at the same location, so thatan operator may also have to go to

five or 10 different places to adjustprocess parametersan inefficientand time-consuming task.

Consequently, many moldersattempt to consolidate the numberof interfaces in an injection moldingcell to a more manageable number,ideally to just one. Moldflows new,proven common hardware platformallows molders to reduce thenumber of interfaces significantlyand approach the ideal case of justone interface.

Savings Impact YourBottom Line

Maximizing manufacturingprocess control is importantmeasure to improve quality andreduce cost. With the introductionof the common hardware forMoldflow Manufacturing Solutionsproducts, current AltaniumMatrix users, for example, canadd Shotscope or MPX technology,which will run on the same screenas the Matrix operator interface.Similarly, current Shotscope orMPX users can easily add Altanium

Matrix technology to their toolset, without having to purchaseadditional computers or interfaces.This can result in savings of severalthousand dollars on every system.

Another advantage of Moldflowscommon hardware solutionis increased flexibility for thefuture. For example, if a molderhas future interest in hot runnerprocess control capabilities, butinitially focuses on implementingShotscope or MPX technology, the

hardware can be configured asAltanium Matrix-Ready when it isinitially installed. This configurationenables molders to add hot runnerprocess control capability laterby purchasing only the AltaniumMatrix software, the Altaniummainframe and the number ofrequired control zones. There is noneed to purchase another operatorinterface, which again results insaving of several thousand dollarsper system.

Moldflows new commonhardware solution helps molders

Moldflows common hardware solutionfor Altanium Matrix, MPX and Shotscopesystems helps molders save integrationcost and improve quality and efficiency intheir operations.

reduce cost, improve efficiency anddeliver high-quality parts to theircustomers.


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z


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coverstory


Succeeding in todays global market dependson continuously increasing efficiency andperformance. This is especially true in the

plastics industry, where the past 10 years have seena widespread shift to using 3D CAD systems forintegrated part and tool design and a correspondingshift to relying on CAE analysis technologies that rundirectly on those 3D models. Moldflow has alwaysbeen the technology leader in this area, consistentlydelivering the broadest range of true 3D analysiscapabilities, introducing patented Dual Domaintechnology and focusing development efforts to

support our customers evolving needs for faster,more accurate CAE solutions.

With the release of Moldflow Plastics Insight(MPI) 6.0, Moldflow will deliver several major solverenhancements that support the overarching goal setfor this release: to reduce total project turnaroundtimes by improving user efficiency and productivityand enhancing product performance. MPI/3D users,in particular, will be able to realize substantialperformance improvements as well as benefit fromnew capabilities.

Next-Generation, Coupled 3D Flow

SolverMPI 6.0 introduces a new, coupled 3D Flow solver.

The new solver replaces the current, segregated 3DFlow solver available in MPI 5.1 and earlier releases.The coupled 3D Flow solver combines pressure andthree velocity components into a single matrix, whichis then solved. In contrast, the old, segregated 3DFlow solver solves for pressure first and then solvesfor the three velocity components. This fundamentaldifference in the solution method translates intodramatic speed improvement, although there is apremium on memory required.

The release of the coupled 3D Flow solver is the

culmination of a major research and developmentundertaking which aimed to develop a next-generation solver platform that could be extendedeasily to support multiple mesh domains and multipleinjection molding processes. Although in its initialapplication the new solver will support 3D tetrahedralelements and beams, it can be easily extended toMidplane and Fusion meshes as well as the yet-to-be-commercialized hybrid mesh whichwill combine DualDomain elements in thin sections and tetrahedralelements in thick and solid sections of a single model.

The coupled 3D Flow solver was newly developedto take advantage of the latest numerical simulation

techniques. Several methods to improve speed andaccuracy are featured in this new solver:

Improved algorithms for calculating flow-frontadvancement now allow larger time-steps to beused to achieve greater speed without sacrificingaccuracy.

Improved algorithms that determine the rate ofsolution convergence in each time step contributeto the speed increase.

A more accurate upwinding calculation improves thetemperature solution, especially around corners.(Upwinding is a numerical scheme whereby the

result at a downstream location in the flow pathis calculated based on the conditions at a selectedupstreamor upwindlocation.)

The shear heating calculation is improved toachieve greater accuracy, especially where shearheating changes rapidly along the flow path, suchas near a gate.

Shear heating flow imbalance predicted by the MPI 6.0 coupled 3DFlow solver highlights the effect of rapid changes in shear heatingalong the flow path.

Unlike the segregated 3D solver, which allowedusers to choose between Fast and Navier-Stokesoptions, the new, coupled 3D Flow solver is of justone type. Despite solving the full Navier-Stokesequations, this coupled 3D Flow solver is remarkablyfaster than the segregated solver used in MPI 5.x.On average, the coupled solver speed was found toincrease by a factor of about 134 percent comparedto the speed of the segregated 3D Fast solver option.Compared to the segregated 3D Navier-Stokes solveroption, the new, coupled 3D Flow solver deliversa performance improvement of better than 800

percent.

MPI 6.0 Release Highlights Range of 3D Solutions

with New Solvers and Technology Enhancements

By Murali Annareddy


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coverstory

www.flowfront.com 13

Other new features available with the coupled 3DFlow solver in MPI 6.0 include:

New 3D analysis capabilities to predict air traps andto simulate gas penetration in 1D beam elements.

Unique, first-of-its-kind capability to simulate thephenomenon of jetting. This innovative technologygives MPI users a powerful tool for designing gatesin automotive lenses, where the initial flow of meltthrough the gate can lead to visible defects.

Support for 3D meshes created in previous versionsof MPI.

Can be used with both thermoplastic and thermosetmaterials, including for microchip encapsulationand underfill encapsulation applications.

Supports all capabilities of the segregated 3D solverused in MPI 5.x, including gas-assist, fiber, coreshift, insert overmolding and two-shot overmolding

applications, as well as inertia and gravity effects.

New air traps result overlaid with fill pattern now gives MPI/3Dusers more explicit information to better predict effects of air trapsand determine appropriate venting locations.

New Re-melt Zone Result in 3DOvermolding Analysis

With part insert overmolding and two-shot,sequential overmolding processes, there is a potentialfor re-melting to occur at the interface of the twocomponents. A new result is provided in MPI 6.0 to

New jetting prediction allows users to test gate design changes toeliminate this phenomenon, which is particularly useful in applications

where it is important to avoid visible defects, such as automotive lenses.

highlight areas of the first shot or plastic part insertwhich have been reheated to above the materialstransition temperature. The objective of this result is

to alert the user to the potential for smearing of thefirst material into the second material.

New re-melt zone result alerts users to the potential for smearing tooccur at the material interface in overmolding applications.

3D Warp Solver Speed IncreaseMPI 6.0 features two new methods to increase

the speed of the 3D Warp solver.

New AMG Matrix Solver

A typical 3D Warp solution involves two steps:assembling a solution matrix followed by the actualiterative solution of that matrix. The latter steprepresents approximately 70 percent of the totalanalysis time, depending on model complexity. MPI6.0 introduces an Algebraic Multigrid (AMG) matrixsolver that delivers a substantial reduction in the timespent in the second step, at the cost of an increased

memory requirement. As shown in the table below,

Model Size(Number ofElements)

MPI 5.1Segregated 3D

Flow, Fast OptionSolution Time

(Seconds)

MPI 5.1 /MPI 6.0Speed

IncreaseFactor

(Seconds)

SolutionSpeed

Improvement(Percent)

23,936 290 238 122%

86,083 806 638 126%

74,279 1,331 938 142%

82,401 1,556 1,220 128%

90,767 696 512 136%

240,846 4,135 2,551 162%

522,656 4,231 3,307 128%

897,293 18,084 13,766 131%

Comparison of Segregated 3D Flow, Fast Option and Coupled 3DFlow Solver Performance.


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coverstory


the overall solution speed increased on average by afactor of about 693 percent (see table below).

Mesh Aggregation

The 3D Warp solver in MPI 6.0 includes anew option to use coarse-through-thickness(aggregated) mesh, which reduces analysistime and memory requirement in most cases. It isimportant to note that the 3D Flow, 3D Cool and3D Fiber solvers continue to use the regular 3Dmesh comprising six or more layers of tetrahedralelements.

The memory and solution time problems withthe 3D Warp solver stem from having to upgrade

first-order (4-node) tetrahedral elements to second-order (10-node) elements to ensure accuracy of thestructural solution in thin geometries. This results in alarger solution matrix, and thereby a longer analysistime. The problem compounds when a model has ahigher number of elements to begin with.

The 3D Flow, 3D Cool and 3D Fiber analysesrequire sufficient layers through the thickness tocapture the changes in temperature, shear rates,viscosity, shear stresses, orientation, etc. However,the 3D Warp analysis may be run on a mesh withfewer layers of elements without compromisingsolution accuracy. Using the aggregated (two-layer)

mesh, the 3D Warp analysis typically runs three toeight times faster and uses only 30 to 50 percentof the memory required to complete the analysison a standard mesh. The mesh aggregation is doneautomatically and requires no user input. At the endof the 3D Warp analysis, the results are mappedback to the original mesh.

Calculate 3D Warp ComponentsA much-requested user enhancement has been

implemented in MPI 6.0 to allow the 3D Warpsolver to isolate the causes of warpage. Throughthis enhancement, deflections due to unbalanced

cooling, non-uniform shrinkage and fiber orientationare calculated in addition to the total deflection. The

insight gained through studying this additional datais important in trying to diagnose and correct partwarpage.

MPI 6.0 delivers a much-requested enhancement to calculatedeflection due to the three components of warpage, as well as thetotal deflection, for 3D Warp analyses.

New Internal Mold TemperatureResult

Users performing cooling analyses on 3D modelswill now be able to view the mold temperaturedistributions through the mold interior. Sectionalcutting planes can be set up to view thesetemperatures. This result can be helpful in optimizingcooling channel placement to achieve effective heat

extraction from the plastic material and efficient heatdissipation through the mold.

New internal mold temperature result allows users to viewtemperature distributions through the mold interior, thus providingbetter data for optimizing cooling channel placement.

continued on page 32

3D Warp Solution Speed Increase Using the AMG Matrix Solver.

Model Size(Number ofElements)

MPI 5.1 3D WarpSolution Time

(Seconds)

MPI 6.03D Warp,

AMG Matrix

SolverSolution

Time(Seconds)

MPI 5.1 / MPI6.0 SpeedIncrease

Factor(Percent)

102,050 12,956 2,227 582%

120,027 17,654 1,593 1108%

301,081 22,615 6,952 334%

305,859 42,259 6,761 625%

237,952 59,713 6,147 971%

244,036 69,635 7,210 966%

569,359 72,219 27,419 263%


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Rigorous Mold Tryout: A Molders Perspective on

Manufacturing Quality Parts

By Gene Wells, Senior Process Engineer, DJ/Nypro Plastics

In todays competitive environment, customersare placing increasingly stringent demands onthird-party molders. Specifically, they require

zero defects in manufactured parts, and low-costmolds and materials. However, its often difficult tomeet these demands because of problems associatedwith the molds design and builda direct result ofcutting corners for cost. My experience has taughtme that when mold designers, mold builders andmolders work together in certain ways they can buildcapable low-cost tools that meet customers demandfor zero rejects.

Collaboration Is KeyThe mold designers and builders are responsible

for building a capable tool that can absorb variationsin the production process. Nonetheless, the molddesigners and builders often dont consider importantvariations in process conditions when proofing atool. As a result, even simple requirementssuch asgetting a part out the first time its ejectedmay notbe met. Further, making changes and performingadditional tests can cost a lot of money and time andcreate unnecessary wear and tear on the mold.

Rigorous mold tryout is about building a mold sothat the molder does not have to break the rules toget the mold up and running. Rigorous mold tryoutcan identify problem molds that have narrow processwindows before full-scale manufacturing begins andbad parts are produced. Ideally, molders would beinvolved in the mold design and building processearly on.

In many organizations, there is one person whomakes the process work. Is there a go-to personin your organization who stands by a machine

processing a mold for flash, shorts, dimension,etc.? What do you do when that go-to person isnot available?

Getting StartedHave you noticed that a particular mold seems to

need attention every time it runs and no one thingseems to work in every situation? Have you everwondered why you can be running merrily along andall of a sudden parts go from good to bad? Are partsfrom certain molds frequently rejected internally andexternally? What is going on?

There are a variety of causes for run degradation.One of the most important reasons, however, is alarge viscosity shift followed by large static and

dynamic pressure losses. Injection molding is more

sensitive to these variations in process conditionsthan most types of molding processes.

Therefore, the mold should be designed towithstand large variations in process conditionsand still produce good parts without breaking therules. Having such a capable tool also means thatany molder can start and run production with it. So,in addition to collaboration in designing and buildingthe mold, rigorous mold tryout is required.

Establish Flow RateFirst, flow rate must be established. How is this

usually done? Is it even studied at all? I havent mettoo many molders who know how important flowrate is, much less try to optimize it. The sad fact isthat its so easy to do.

Think of an injection molding machine as the bestrheometer there is and begin evaluating the process

with at least 90 percent of the machine injectionrate. Then, decrease the fill speed and documentthe viscosity change, noting where viscosity takesa sharp turn upward. This is the shear rate curve,based on shear during fill.

Flow rates should be minimized where the viscositytakes a sharp upward turn, the process becomessupersensitive to fill rate changes caused by variouschanging factors like pressure gradients, molecularalignment, etc. When the viscosity changes and themachine is load-sensitive enough, the process getsextremely sensitive to fill speed changes, which canresult in amplified pressure losses.

Knowing this, what should you do if you have aburn only because you are filling it fast? Rather thanweaken the process by slowing down, fix the burnby venting, or better yet, have venting built into thetool in the first place.

Control Flow RateYou can probably imagine what happens next.

Your most skilled technician does his best finessingonly to find, a viscosity change has yielded shortsor that a flash supposedly fixed suddenly got worse.Then, he thinks hes solved it but a few bad partsmade it to the customer.

design & molding

Rigorous mold tryout is about building a moldso that the molder does not have to break therules to get the mold up and running.


17/40


What if your injection pressure reached maximumlevel when you filled the mold? This is a veryundesirable situation, as you are no longer in controlof the flow rate, the variable that affects viscositythe most. In this situation, determine where themaximum loss is inside the mold or move to a

machine with a higher intensification ratio. Slowingdown may be an option as long as you can decreasethe pressure losses and maintain a high enough fillpressure to compensate for the increased variation.

If the viscosity increases by means other than theflow rate, the machine will require more pressure.In this case, be sure that you are not close to thepressure differential between the flow control valveand the pump.

It would be better to test the mold a little morein the beginning and know its weaknesses. If youaddress these weaknesses early on, they wonttrouble you later.

Offset Pressure LossIts important to have adequate pressure to offset

the effects of static pressure loss during the packingphase. Quantifying pressure loss is crucial to offsetthese effects. It would be negligent not to look insidethe cavity for this type of information. Consequently,the mold should generally be equipped with cavitypressure sensors. In some casesfor example, ifyou are molding bucketsit may not be required toinstall transducers if you are able to pack the moldwell without negative effects. But when producingtight-tolerance and safety-restraint equipment, it

might be foolish not to install transducers.In addition to quantifying pressure loss,

understanding it during sampling is critical, becauseit allows you to define steps to control and monitorthe pressure loss. Heres an example of what youmay see if you packed the part to a small short andmeasured the loss from the injection pressure: if ashort occurs at 1,000 psi, its safe to assume thatthere is a 1,000-psi loss from injection to the end offill. But, if you added another 1,000 psi, it wouldntmean there is 1,000 psi at the end of fill.

Why? Because of static pressure loss caused bypoor transmission through long polymer molecules.

There is a certain point in pressure loss wherethings really get critical. Be aware of that anddevelop measures to offset the effects of staticpressure loss. Also, be sure to find out where thehighest loss occurs and, if possible, reduce it.

Reduce Normal VariationsBegin with the material manufacturers minimum

and maximum limits and use the middle as startingpoints for the variables. You start the process fromthere with the goal to change them as little aspossible. If change is required, try to stay withinthe suppliers recommended limits. If you have to

operate outside the recommended range, identifythe limiting factors and attempt to correct them.

You must try not to change the temperature,because changes will affect the cooling rate andcooling time. At this point of the process, thecooling time is set at whatever value required to

make the part rigid enough to be ejected. I havefound that meeting the quoted cycle time couldmean breaking the rules and going outside thesuppliers specifications. In this case, you have toweigh the options carefully. Setting parameters out

of the specifications is a last resort. Unfortunately, itdoes occasionally happen. So, its important to focuson reducing normal variation in all phases of theproduction cycle.

Stay within Material SpecsYou may ask, Does it really matter if I am out

of the suppliers specifications as long as I am

making an acceptable part? Yes and no. If youhave a problem down the line and the customer is

design & molding


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19/40


Moldflows Shotscope system is a criticalquality analysis technology designedspecifically to prevent defective parts from

entering the supply chain. Version 4.0, released inJuly 2005, is loaded with exciting enhancements, bothlarge and small, which help improve manufacturingproductivity and efficiency in injection molding anddie casting operations.

Automatic Shot Diversion afterDowntime Occurrence

One of the most widely used features in theShotscope system has been the ability to divertproduct when a process violation occurs. Shotscope4.0 now adds to this functionality by allowing thesystem to automatically divert product after amachine downtime occurrence.

When a machine has been brought back intoproduction after a period of downtime, there is anadditional amount of time that is required for themachine to stabilize. The parts produced during thistime period are of unknown quality and should bediverted and counted as scrap.

Shotscope 4.0 allows the user to specify the

number of cycles that will be automatically divertedafter a downtime event occurs. The user-specifiedScrap After Downtime Event value is stored in the

job template, which allows this value to be retrievedautomatically each time that job is run.

Labor Tracking ImprovementsShotscope 4.0 has dramatically improved labor

tracking capabilities with the addition of severalkey features, including the ability to log multipleoperators on to one machine, automatic logout atthe end of a shift and support for electronic logon/logoff using swipe cards with bar codes or magnetic

strips.

Two Phases of Independent SampleRate Control

Shotscope 4.0 now enables users to enter two,independent sample rates per cycle. For example,a user can collect data at five milliseconds (0.005second) per point during the filling phase, thenreduce the sample rate to 10 milliseconds (0.010second) per point during the holding and recoveryphases.

By setting independent sample rates for twophases of the molding process, the number of datapoints collected for each shot profile is greatly

reduced. The benefits are significant: critical datacan be stored and retrieved faster, overall networktraffic is reduced and more shot profiles can be

stored before archiving.

Automatic Scrap Input CounterThe Shotscope system has always had the ability

to automatically count defect parts via digital inputs.Shotscope 4.0 adds new features that allow thesystem to count rejects by part or shot.

When counting by part, the system talliesone reject for each time the digital input signal isactivated. When counting by shot, the system rejectsthe entire shot (based on current cavity levels) eachtime the input signal is activated.

This enhancement allows users to collect rejectinformation automatically from downstream, ancillaryequipment that can reject product after the moldingprocess is complete.

Enhanced Job Template EditorShotscope 4.0 introduces a new and improved

job template editor. In the past, it was not possibleto change resources or eliminate job templates;customers reported instances of creating templateswith incorrect resources, sometimes without realizingit until the template had been used on several jobs.

It is now possible to copy data from one template

and create a new template. This procedure allowsusers to start a new, correct template and copy all

Shotscope 4.0 Enhances Productivity and Efficiency

By David Rotondo

manufacturing process & control


20/40


of the contents. The enhanced template editor alsoallows the user to edit all of the template-relatedfields.

Job Suspension at the OperatorInterface

Sometimes the simple enhancements are themost popular. The job suspension feature has alwaysbeen part of the Shotscope system, but it previouslyrequired a higher security status to access it. Nowin Shotscope 4.0, job suspension can be controlledwithin the Operator Interface module. Operators areable to suspend the current job, start a new job,then resume the first job when required resourcesbecome available. This is especially valuable whenmold problems occur and a job must be suspendedin order to repair the mold.

Touchscreen Backlight Screen Saver

Shotscope 4.0 includes a custom screen saverthat works in conjunction with the monitored events,thus assuring that information will be displayed

when attention is required. The Shotscope screensaver disables the display the same way all screensavers work, after a specified duration of inactivity.The difference is in how the display can wake upor reactivate.

Users can configure the display to reactivate after

one or more system events, including: machineshutdown, one or more process parameters are outof specification, all process parameters are withinspecification or the machine goes into an unknowncondition. The user can also manually reactivate thedisplay by touching the touchscreen or the keyboardor mouse.

The Shotscope 4.0 screen saver also includes abacklight saver function which can help to extendthe life of LCD backlight displays.

Like all Moldflow Manufacturing Solutions products,the Shotscope 4.0 release provides new capabilitiesintended to enhance quality, manufacturing

productivity and efficiency for our customers.

For more information about Moldflow Shotscope, visit www.moldflow.com.

manufacturing & process control


21/40

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22/40


Typical CAE analysis projects involve severalphases, from importing geometry, to meshingthe model, setting up the analysis, running

the analysis, reviewing the results and creatingthe project report. Users have found from longexperience that saving time during any phase of theworkflow directly reduces the total time required tocomplete a given project. A primary objective forthe upcoming Moldflow Plastics Insight(MPI) 6.0release was to identify bottlenecks in this workflowand provide solutions to improve user efficiency andproductivity.

Key enhancements have been implemented in theMPI/Synergy user interface to achieve this objective.Synergy is MPIs pre- and post-processor, and userswill find a host of changes in the MPI 6.0 release whichdirectly affect workflow and productivity issues.

Usage scenario of Merge Nodes feature in MPI 5.1 (top) and MPI

6.0 (bottom) is an example of how the new panel-based userinterface improves organization and reduces screen clutter.

Panel-based Modelingand Meshing Tools

Creating, editing and validating geometry andmesh require substantial interaction with the partmodel. Having uninterrupted access to the part modelin the graphics window can greatly improve userefficiency and productivity. This was the motivationbehind a major reorganization of the user interfacein MPI 6.0. At the core of these modifications isthe concept of panel-based modeling and meshingtools.

The modeling and meshing tools, which inprevious releases opened on top of the part model,now have been migrated to the panels on the leftside of the Synergy window. This simple conceptualchange contributes to an improved organization,smoother workflow and reduced screen clutter. Thepart model remains visible in the graphics window,without being obscured by the tools dialog, as it waspreviously.

As part of this user interface reorganization, theProject and Study panels have been consolidatedand made available under a Tasks tab. The modelingand meshing tools are now available under a newlycreated tab, appropriately titled Tools. The Layer

panel continues to exist as an independent entity.While users must switch between the Tasks and Toolstabs in their panel, the Layer panel can be accessedat all times.

Layouts of the Tasks (left) and Tools (right) tabs.

To further improve accessibility, a Toolbox hasbeen implemented on the Tools tab. Through thisToolbox, any of the model creation or mesh editingtools can be accessed easily, without having to pickfrom the Modeling or Mesh menus.

MPI/Synergy Enhancements

Boost User Productivity

By Murali Annareddy


23/40


New Toolbox provides easy and quick access to all modeling andmeshing tools.

Continuing on the theme of improved organizationand reduced screen clutter is the consolidation of alltextual log windows (mesh log, screen output, resultssummary, etc.). The newly consolidated textual log

window is tied to the model graphics window, therebybuilding an association. Through this consolidation,it becomes easier to manipulate the model based oninformation from the log window. The display of thetextual log window can be toggled on or off.

Display of textual log windows in MPI 5.1 contributed to screenclutter

Consolidated textual log window in MPI 6.0 improves access to

information without obscuring the model display.

A single mouse-button click will hide all of thepanels, including the Tasks and Tools tabs and Layerpanel, allowing users to utilize all available screenspace to display the graphics window. This can bequite useful both during model editing and resultsdisplay.

In MPI 6.0, users can hide all panels to enlarge the model area.

Directed DiagnosticsSynergy contains a comprehensive suite of

diagnostic tools that allow users to validate thequality and suitability of various aspects of the meshprior to running an analysis. Once a diagnostic queryis invoked all mesh entities (part elements, beamelements, etc.) that match the query can be isolatedto a diagnostic layer. This allows users to drill down

and take corrective actions, if necessary.


24/40


MPI 6.0 augments this process through theparadigm of directed diagnostics. There are severalcomponents to this feature. At the heart of the newcapability is a navigation tool that allows users tostep through the diagnostic entities.

The diagnostic entities are automatically sorted

by the order of their numerical value or severity, thusallowing users to start with the entity that is highestin value or most severe and progress to the entitythat is lowest in value or least severe. Users canalso jump to the first or last entity on the list. Witheach selection, the model is automatically orientedto give the best visibility of the diagnostic entity.Lastly, for diagnostics that have numerical valuesassociated with them (for example, aspect ratio ofelements), the value is displayed in the status bar.The combination of these tools allows users to veryquickly and efficiently complete the validation ofmesh quality and suitability.

Example of directed diagnostics in MPI 6.0.

Expanded Report Generation OptionsThe use of project reports as a communication

medium is widespread among MPI users, and MPIreleases have included tools to support the reportcreation process for many years. These tools includethe automatic HTML report generator as well as

the ability to export images and animations. Today,however, Microsoft Word and PowerPoint formatsare fast replacing HTML as the preferred format forproject reports. This is mainly due to the greateraccessibility and superior formatting and editingcapabilities of these products.

To support this growing trend as well as tofacilitate concurrent review of analysis results andcreation of report content, several new capabilitieshave been implemented in MPI 6.0.

When users are reviewing analysis results, theycan create report bookmarks. A report bookmark isassociated with a result and remembers the view

orientation of the targeted report image. Multiple

report bookmarks can be created for the sameanalysis result. For example, users may want tocreate two report bookmarks of a pressure result,one showing the entire model and another showingthe close-up of an area of interest (such as the gateregion). Report bookmarks are saved with the project

and can be edited at any time.After all the report bookmarks have been created,

users can specify the format of their report bychoosing from HTML, Word document and PowerPointpresentation formats. Once a report is created, liveconnectivity is maintained between MPI and thereport to allow for the real-time update of both staticand dynamic (report) content.

Analysis results marked for inclusion in the MPI 6.0 project report.

Example MPI 6.0 project report shown in Microsoft Word format.


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Enhanced 3D Mesh DiagnosticsSeveral improvements have been made to the

Mesh Repair Wizard to aid in diagnosing and fixing3D mesh problems:

Before initiating the 3D mesh diagnosis/repair, usersnow can pre-select which checks to perform.

A new option to limit diagnostic checking toelements in visible layers has been implemented.This option is extremely useful when working withlarge 3D meshes, as it improves the speed ofdiagnostic checking.

The effectiveness of automatic mesh fixingfunctions has been improved.

Automatic fixing has been extended to correctcollapsed regions of the 3D mesh.

Additional fixing capability has been implementedthrough the identification of isolated, extremelylarge elements by comparing their volume to theaverage volume.

Local 3D Mesh RefinementIn MPI 6.0, it is now possible to perform local

mesh refinement to increase or decrease the numberof layers of elements in a specific area of interest.Through this option, users can achieve selective meshrefinement without affecting the entire model.

Export Part/Runner/Cooling Model toCAD System

MPI 6.0 now provides the capability to exportrunner system and cooling circuits in IGES format

for further use in a 3D CAD modeling system.Additionally, solid surface part geometry can also beexported. Through this feature, runner and coolingcircuit designs optimized in MPI can now be veryquickly and effectively implemented in the CADsystem prior to cutting the mold.

Enhanced Diagnosis of Analysis Errorsand Warnings

In addition to keeping the user abreast of theanalysis status, the MPI analysis screen output logprovides a list of errors and warnings. While theanalysis errors and warnings can originate from

several sources, those associated with the mesh are

among the most critical. A new capability has beenimplemented in MPI 6.0 to speed up the diagnosis ofsuch mesh-related problems. Through this feature, itis now possible to isolate the problem mesh entitiesto a selection list automatically. Users can review the

entities on the selection list and access the variousmesh editing tools to take corrective actions. Anadded capability of this feature is the flexibility toisolate mesh entities specific to a single warning orerror.

In MPI 6.0, problem elements are isolated automatically to expeditediagnosis and correction.

MPI 6.0 Release Delivers ProductivityImprovements

Key enhancements implemented in MPI 6.0Synergy user interface address workflow bottlenecksidentified in previous releases and provide newsolutions to improve efficiency and productivity.Saving time and effort in common pre- and post-processing tasks such as geometry and meshvalidation, error diagnosis and correction, or projectreport preparation, can allow users to more easilyanalyze complex parts, compare more alternativesand ultimately, complete more projects.

several sources, those associated with the mesh are

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ITT Industries Optimizes Production of Very Thin Parts

By Catherine Baghdiguian and Michel Bruehwiler

ITT Industries, Dole specializes in the designand manufacture of microphone switches andconnectors for the mobile telephony, automotive,

medical and data processing applications industries.Their products are marketed under the Cannonbrand.

Founded in 1928, the Dole site is located in theJura region of France. Part of ITT Industries since1972, the Dole site currently has 450 employees.As operations at this site are tightly integrated, thedesign, manufacture and assembly of products andthe tool shop are all at the same site. Productionis highly automated, with dedicated assembly linesfor each product. The manufacturing shop includes40 injection molding machines with clamping forceranging from 80 to 100 tons. The Dole site producesapproximately 500 million parts per year.

The connectors designed and manufacturedat the Dole site are extremely smallsome nolonger than five to six millimeters. To comply withstringent customer requirements, the manufacturedconnectors must have the longest service life possibleand meet certain standards for lead-free welding ofcomponents on printed circuits. Engineers at this siteuse Pro/ENGINEER (PTC) CAD software to designtheir products. Historically, however, no plastic flowsimulations were carried out. As a result, manyproduct design-related issues were only discoveredafter production had been started.

Specifically, Dole site engineers realized that, insome cases, the injected plastic flowed irregularly

through the very small gates and cavitiesand resulted in a high number of faulty parts.Consequently, the engineers needed to find quickyet permanent solutions to improve the quality, eventhough the products were at a late stage of theirdesign-through-manufacture process. In addition toincurring the cost of the faulty mold, correcting theseprocess problems at this late stage of the productionprocess often meant a delay getting the products tomarketoften with dire economic consequences.

Mr. Wilfrid Elien, a developer engineer of plasticinjection molds at the Dole site, recognized the

potential for improvement and suggested usingMoldflow Plastics Insight (MPI) tools to validate theproduct designs before production. During his timeat schooling, when he used MPI for six months, Mr.Elien recognized the real benefits of doing designand simulation concurrently.

ITT also realized the value of using MPI. In July2004, the Engineering and Design Departmentpurchased MPI/Flow, MPI/Cool, MPI/Warp, MPI/Fiberand MPI/3D modules. With these tools in hand,the engineers were ready to address existingmanufacturing concerns and perform design andsimulation steps simultaneously early in the productdevelopment process.

Elien describes the benefits he gained throughMPI: Using the MPI software enabled us to re-examine the design of the parts that presentedproblems during the filling. Part designs are nowsystematically validated with MPI, and many fewerproblems occur during manufacture.

Moldflow simulations helped ITT Industries, Dole to verify that modifying the sprue geometry from a conical to a spherical design (a) wouldenable these small, thin-wall parts to be molded successfully in a multi-cavity, three-plate mold. Fill time (b) and fkiw front temperature(c) results are shown.

(c)(a) (b)

real world success


28/40


Mr. Elien also says, Thanks to MPI, themanufactured parts are of better quality and theresponse time to orders is reduced. The deliveryschedules are also more reliable, because themajority of the problems occurring downstream arediagnosed and solved quickly.

As expected, using MPI made it possible to solveseveral recurring manufacturing problems at theDole site. Elien remembers a problem with a multi-cavity, three-plate mold used to produce a small

part, which is six millimeters long, three millimeterswide and one millimeter high with a wall thicknessof only 0.1 to 0.5 millimeter. The gate diameter wasalso only approximately 0.3 millimeter. The problem

was that, during the ejection phase, the sprue andrunner remained stuck in the intermediate moldplate, which interrupted manufacturing. An extensivestudy performed by Dole site engineers using MPIresulted in a solution that involved modifying thesprue geometry near the nozzle from a conical to a

spherical design. As a result, the new spherical designminimized the high shear rate domain and enabledthe proper extraction of the sprue and runner.

The lessons learned from solving this particularextraction problem were used to define a new setof new mold design criteria, which apply not onlyto this particular mold, but also to future Dole sitemold designs. Further, ITT believes that increasingthe use of MPI will further improve productivity andpart quality. The company hopes to optimize over-molding parts and extracting parts from molds withthe overall goal of continuously reducing cost andimproving design-through-manufacture processes.

They estimate the cost savings due to MPI will enablethem to recoup the upfront investment in less thana year.

Part designs are now systematically validatedwith MPI, and many fewer problems occurduring manufacture.

real world success


29/40


The past decade has witnessed a widespreadadoption of computer-aided engineering (CAE)software for simulating the injection molding

process. Numerous companies have successfullyused plastics CAE to optimize their design-to-manufacturing operations, saving thousands of dollarsthrough a combination of reduced development andmanufacturing costs, improved part quality andshorter time to market. While the general benefitsof plastics CAE have been well demonstrated andare now widely understood, there is much lessunderstanding of the assumptions, quality andapplicability of specific analyses. Additionally,plastics CAE analysis is still a niche among many ofthe companies that perform it.

The knowledge gained from performing CAEanalyses is rarely shared across the organization.The distributed nature of the industry contributesto this situation, creating a communication barrierthat is compounded by the increasing globalizationof the plastics marketplace. While tooling andmanufacturing outsourcing is already all too common,a growing trend is the outsourcing of analysiswork. Outsourcing brings its own set of challenges,including not knowing whether the analyses wererun using the desired application, model, materialand process conditions.

The introduction of the Moldflow Communicator,a standalone Moldflow results quantification andvisualization system, addresses these communicationand applicability issues and tackles the problem head-on. In its simplest form, the Moldflow Communicatorcan be used to visualize analysis results generatedfrom Moldflow Plastics Insight(MPI) and MoldflowPlastics Advisers(MPA) software. However, its truebenefits lie in the ability to quantify the quality ofanalyses performed. This is achieved through user-specified analysis quality criteria.

Results VisualizationA key function of the Moldflow Communicator is

the visualization of analysis results. This requirementaddresses inadequacies of the current communicationtools, which include project reports created in HTML,Microsoft Word or PowerPoint formats. These reportsmay include a combination of text, static images and2D animations.

Traditional communication tools in Moldflow software, such asthe HTML project report, may not be adequate for sharing criticalinformation among distributed resources.

Says Keith Beattie, Staff Engineer at Fisher-Price, Inc., Often I come across a project reportof an analysis done by either one of our overseasvendors or manufacturing plants worldwide, wherein

I wished the image was created at a slightly differentangle, thus allowing me to get a better perspective.Although I could ask them to provide the analysismodel with results, file sizes are a concern, especiallywhen you only want to review a couple of results.

Through Moldflow Communicator, it will now bepossible to view analysis results dynamically andinteractively on 3D models, without the need toaccess the complete MPI or MPA product. Additionally,Moldflow Communicator features a set of powerfultools to simultaneously compare analysis resultsfrom two or more studies (a study is an analysisiteration), or from one or more studies with a set

of specified analysis quality criteria. It also featuresoptions to synchronize model orientation, result

Moldflow Communicator Aids

Globally Distributed Product Teams

By Murali Annnareddy

While the general benefits of plastics CAEhave been well demonstrated, there is muchless understanding of the assumptions, qualityand applicability of specific analyses. MoldflowCommunicator tackles the problem head-on.


30/40


selection and result plot scale to investigate themodels and results simultaneously.

Moldflow Communicator has extensive modelmanipulation and visualization capabilities, includingthe dynamic and incremental pan/zoom/rotatefunctions, standard view orientations, select saved

view bookmarks, cutting planes and so on. MoldflowCommunicator also features a comprehensiveselection of result displays, including, XY plots;shaded, contour, scalar, vector and tensor plots; iso-surfaces; displacement plots; and animations.

Moldflow Communicator allows anyone to view analysis resultsdynamically and interactively.

Moldflow Results FileThe issue of file size efficiency is addressed

through the creation of a proprietary Moldflow resultsfile. The Moldflow results file (*.mfr) is a single,compressed file that contains model and result datafor one or more studies. Moldflow analysis users havethe flexibility to choose specific results for inclusionin a Moldflow results file. The upcoming MPI 6.0release includes the capability to output Moldflowresults files; a future MPA release will have similarcapability.

Analysis Quantification

When a Moldflow results file is being created,certain analysis quantification information isautomatically captured and saved with the *.mfr file.The quantification information includes:

Creator information, such as user name, companyand date created.

Analysis product information, such as productname, product version and release date.

Model attributes, such as mesh type and meshquality.

Analysis attributes, such as analysis sequencetype, process conditions and material model.

Result attributes, such as projected area, maximuminjection pressure, time at the end of fill, maximumclamp force, maximum shear rate and more.

Moldflow Communicator allows users to compare analysisconfigurations against specified quality criteria.

Analysis Quality CriteriaMoldflow design analysis products will provide

a method for users to specify required analysisattributes, or criteria. Through a comparisonfunction, Moldflow Communicator users can easilyvisualize the differences between what was specifiedand what was obtained. An example of the analysisquality criteria in use is shown above. In the image,the table compares specified analysis criteria withan original analysis configuration and an improvedanalysis configuration.

Examples of analysis attributes for which qualitycriteria can be specified include: Model attributes, such as maximum aspect ratio,

Fusion mesh-match ratio and more.

Process attributes, such as maximum injectionpressure, machine clamp tonnage and more.

Material attributes, such as default shrinkagemodel, material melt and mold temperatures andmore.

The analysis quality criteria editor allows Moldflow users to specifyimportant information to quantify acceptable values or parametersfor analysis attributes.

continued on page 32


31/40

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MPI 6.0 Releasecontinued from page 14

LS-DYNA Interface Provides ServiceLoading Analysis Option

MPI 6.0 includes a new interface to LS-DYNA,which is available for Midplane models. Through this

interface, MPI users can export Midplane meshesand critical, analysis-specific material properties toLS-DYNA to perform more accurate and in-depthstructural (service loading) analyses.

For unfilled materials, the data exported includeselastic modulus, shear modulus, Poissons ratioand coefficient of thermal expansion (CTE) fromthe material database. Additionally, the layer-wiseresidual stresses for each element are exported.

For fiber-filled materials, similar data is exportedwith the exception that the modulus, Poissons ratioand CTE values are calculated by the Flow analysisbased on the flow-induced fiber orientations.

Additionally, for fiber-filled materials, the fiberorientation angle is also exported.

Example of an impact analysis performed in LS-DYNA using inputdata from MPI. Initial condition before impact is shown on the leftand result after impact is shown on the right.

MPI 6.0 Release Cuts Solution Timeand Delivers User-Requested Options

The MPI 6.0 release delivers new technologiesand key enhancements to analytical solvers thatsignificantly reduce solution time, particularly for

MPI/3D users. In addition, new result displaysare provided to answer specific user requests forenhancements. Further, new interface capabilitiesadd options for carrying out service loading analysiswith popular structural analysis applications. Allof these enhancements contribute to the goal ofreducing total project turnaround times by improvinguser efficiency and productivity and enhancingproduct performance.

For more information about Moldflow Plastics Insight products, visitwww.moldflow.com.

vailabilityMoldflow Communicator will be freely accessible

and can be used by both Moldflow customers andon-customers. It will be supported on Windows

C-based hardware systems. The MoldflowCommunicator wi initia y support resu ts exporterom Mo ow P astics Insig t MPI 6.0. Later, it wie extended to support results from other Moldflowroducts, including Moldflow Plastics Advisers (MPA)

software. The product will be distributed with MPI6.0 and made available for download from www.

oldflow.com.

mproved Communication OptimizesBenefits of CAE

Distributed product teams require a product tooth visualize and quantify the quality of plastics

CAE results data. The Moldflow Communicator wascreated specifically to address these needs. Throught e Mo ow Communicator, t e assumptions,qua ity an app ica i ity o t e ana yses can e etternderstood and accounted for, and the knowledge

gained from performing analyses has the potentialto be shared more effectively among all participantsn the design-to-manufacturing process.


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Have you ever had a short shot get stuck inthe cavity and break a core?

Have you ever had an operator injectplastic before the hot runner system is up totemperature and blow a mold seal?

Have you ever used a resin with a tighttemperature window and had it overheat and expeltoxic fumes into the air or harden to the point that itis nearly impossible to remove from the mold?

Any of these scenarios could have been avoidedif your Altaniumhot runner process controller had

been equipped with one of the many optional inputsor outputs that are available.

Options Available for All AltaniumOperator Interfaces

At-Temperature Output Option

The At-Temperature output option sends a signalfrom the Altanium controller to the injection-moldingmachine when all zones in the mold are within theprocessing window. This signal lets the machineknow that it can start making parts.

Abort Error Output Option (PCM)

The Abort Error output option sends a signalfrom the Altanium controller to the injection-molding machine if the mold temperature exceedsthe maximum or drops below the minimum valuesaround the processing window. The machine willimmediately stop injecting and alert theoperator that there is something wrong.

Choosing these options can addvaluable capabilities to your Altanium hotrunner process controller.

Auxiliary Output ConnectorAs a standard feature, the Altanium

Matrix and Delta2 operator interfacesinclude one output option. Any of thenumerous output options offered canbe assigned to the auxiliary outputconnector located on the rear of theoperator interface, labeled AUX OUTPUT(see Figure 1). The mating cable is notincluded with the system; however, it is astandard Conxall four-pin connector thatcan be found at most electronics retailersor purchased from Moldflow.

Add Multiple Options with the

Altanium I/O BoxYou may be saying to yourself, I need both the

At-Temperature and Abort Error output options, butthe auxiliary connector only offers the ability tochoose only one output option.

The addition of any input option ormore than one output option requires theAltanium I/O box (Figure 2). This input/output box connects directly to the Matrixor Delta2 operator interfaces using aneight-pin communications cable.

The input and output options are soldin three packages: two options, fouroptions and ALL. These packages areuser-configurable, allowing the flexibilityto change options to suit your application.For example, if you purchase the four-option package, you can choose to enableup to four input or output options in anycombination. The ALL package allows youto enable every input and output optionavailable.

Avoid Common Molding Problems with Altanium

Hot Runner Process Controllers

By David Rotondo

Altanium hot runner process controllers can support from

one to 384 zones. The self-contained controller units can

be used freestanding, mounted on the mold or mounted

alongside, behind or even inside the injection-molding

machine. Choose among three interchangeable operator

interfaces to best meet particular needs:

The Neo operator interface features a monochrometouchscreen and supports up to 12 zones.

The Delta2 operator interface provides advancedcontrol technology for up to 48 zones through atouchpad interface and a full-color LCD display.

The Matrix operator interface provides intelligenttemperature control capabilities for up to 384 zonesthrough 15-inch to 19-inch LCD touchscreen interfacesfeaturing high-contrast, full-color graphics.

Figure 1. AuxiliaryConnector Detail

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Special Thanksto our iMUG05

Platinum Sponsors

Special ThanksSpecial Thanksto our iMUG05to our iMUG05

Platinum SponsorsPlatinum Sponsors

Input OptionsTo activate any input, all that is required is the

closure of two contacts on the input connector.

Remote Standby Input Option. If the RemoteStandby digital input option is turned on, it willplace all the zones that have a Remote Standby

setpoint into Remote Standby mode once the inputsignal is active.

Remote Boost Input Option. If the Remote Boostdigital input option is turned on, it will place allthe zones that have a Remote Boost setpointinto Remote Boost mode once the input signal isactive.

Remote Start Input Option. If the Remote Startdigital input option is turned on, it will STARTthe system once the input signal is active. Thisstate will remain until the STOP key is touched orRemote Stop is activated.

Remote Stop Input Option. If the Remote Stop

digital input option is turned on, it will STOP thesystem once the input signal is active. This statewill remain until the START key is touched orRemote Start is activated.

Remote Manual Boost Input Option. If the RemoteManual Boost digital input option is turned on, itwill place all the zones that have a Manual Boostsetpoint into Manual Boost mode once the inputsignal is active.

Output OptionsAll outputs are dry contacts. Whatever you put

in, you will get out once the output is active.

Alarm Error Output Option. If the Alarm Error

output option is turned on, it will be activated whenan Alarm or Abort condition occurs. This statewill remain until the Alarm condition is cleared orreset.

Abort Error Output Option (PCM). If the Abort Erroroutput option is turned on, it will be activated whenan Abort condition occurs. This state will remainuntil the Abort condition is cleared or reset.

At-Temperature Output Option. If the At-Temperature output option is turned on, it will beactivated when all zones are within the processingwindow. This state will remain until a zone dropsout of the processing window.

At-Boost Temperature Output Option. If the At-Boost Temperature output option is turned on, itwill be activated ONLY when all zones are within theBOOST processing window. This state will remainuntil a zone drops out of the BOOST processingwindow.

Run Light Output Option. If the Run Light outputoption is turned on, it will be activated wheneverthe green START button is active (system running).This state will remain until the red STOP button isactive (system not running).

CAN Comm Error Output Option. If the CAN CommError output option is turned on, it will be activated

if the operator interface stops communicatingwith the control cards. This state will remain untilcommunications are restored.

Taking advantage of the available add-on optionscan make your investment in Altanium hot runnerprocess control technology even more valuable byenhancing your ability to detect and avoid commonmolding problems.

For more information about Altanium hot runner process controllers,visit www.moldflow.com.

Figure 2. The Altanium I/O box can be connected to Matrix andDelta2 operator interfaces to enable multiple input and outputoptions.

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Whats Your Business IQ?

By Oren Harari, Professor, Graduate School of Management, University of San Francisco

For competitive success in todays knowledgeeconomy, intelligence is power. Im not talkingabout IQ, the notorious Intelligence Quotient.

Im talking about what I call BIQ, or BusinessIntelligence Quotient. Leaders with a high BIQ dotwo things. One, they quickly seize new informationabout new technologies, scientific breakthroughs,changes in customer needs and expectations,shifts in demographics and emergence of newcompetitors with different business models. Two,they do something with that information, includingmobilizing their organizations to create compellingand innovative solutions and products that excite

customers and investors.

A diverse range of exciting and successfulcompanies such as Jet Blue, Zara, Toyota, LouisVuitton and Electronic Arts understand the importanceof BIQ. Their product and service innovations on thefront end and their cost-efficiency and value-chaininnovations on the back end are cutting-edge andunique. Customers and investors recognize it.

Unfortunately, too many managers and executivesdo not get it yet. They often protect existingproducts, services, partners and processes ratherthan break new ground based on new intelligence.Some hoard information that has become outdatedor simply replicated by competitors an especially

un-intelligent move in todays transparenteconomy, which, often, results in improvements ofobsolete products. Continuous improvement can helpcompanies to survive, but alone it will not help themto thrive. Sometimes, leaders wrongly assume thatserial deal-making breaks them out of an earningsrut, even though more than half of high-profile megamergers destroy shareholder value.

Japanese management scholar Ikujiro Nonaka,aptly summarizes todays competitive challenges:

When markets shift, technologies proliferate,competitors multiply and products become obsoletevirtually overnight. Successful companies are thosethat consistently create new knowledge, disseminateit widely throughout the organization, and quicklyembody it in new technologies and products. Thatis the essence of BIQ, and we would be wiser if weheeded Nonakas words and insights.

Think about your customer interaction, valueproposition, technology, organization and back-officeoperation. Are you doing the same-old, same-old?Are you clinging to familiar ground and conventionalhabits? Or, are you aggress

Documents

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