MOLD FLOW ANALYSIS
Mold flow analysis (MFA) software simulates the flow of plastic, which allows you to elevate part and mold design to create products of impeccable quality, it helps to reduce manufacturing defects. Like other simulation software, MFA gives you a virtual sneak peek into how your material of choice will fill the mold's cavities and offers a head's up on potential problem spots. The benefit is obvious, right? Simulating the process digitally means you can make changes on desigin stage. This one thing is a big cost savings, not to mention a time saver as well.
When Should Mold Flow Analysis be Used?
In case it wasn't clear, MFA is conducted before tooling production launches. (It wouldn't make much sense to use it afterward!) Using a selected gate location and material properties, the software is able to predict how the part will fill during molding. Different data points can be assessed, including pressure, fill time and melt temperature. Doing so allows for optimization of the process before tool manufacturing ever begins.
Is Analysis Necessary for Every Application?
The short answer: not necessarily. The following factors can help you decide whether MFA should be used for your application:
PRODUCT GEOMETRY
The more complex the product geometry, the more benefit you'll receive from MFA. Why? When the product's design is more intricate, the flow is less predictable. It's easier to predict how a simple mold design would fill, for example.
TOLERANCE REQUIREMENTS
Tight tolerances are an anathema to plastic injection mold designers anyway. Software that can analyse and demonstrate whether a product will meet spec prior to cutting a tool is a godsend.
PROJECT SCOPE
Clearly a project would have to meet certain financial requirements to warrant the investment of resources — time, software and talent — to run the tests.
UNUSUAL MATERIALS
Engineers know the fill patterns of standard materials but others — especially materials that include fillers — benefit from up-front analysis.
Mold flow analysis can provide you following benefits:
Moldflow Filling Analysis
Optimize gating
Optimize runner system
Predict fill pattern
Predict injection pressure
Determine clamp tonnage
Predict temperatures
Visualize shear rate
Visualize shear stress
Determine fiber orientation
Predict volumetric shrinkage
Predict sink
Determine venting
Avoid air traps
Locate weld (knit) lines
Develop optimum ram-speed profile
Moldflow Cooling Analysis
Find hot spots
Calculate time to freeze
Visualize uneven cooling across core and cavity
Determine uneven cooling between core and cavity
Define required coolant flow rates
Measure pressure drop in cooling system
Determine (and reduce) cycle time
Optimize the cooling layout
Moldflow Packing Analysis
Calculate proper packing pressure
Define optimum packing profile
Moldflow Warpage Analysis
Predict warpage
Find cause of warpage
Determine warpage due to orientation
Predict warpage due to differential cooling
Understand warpage due to differential shrinkage
Moldflow Gas-Assist Analysis
Determine optimized gas channel layout
Predict gas penetration
See gas permeation
Predict skin/core ratio Establish required gas pressure
Define optimized gas pressure profile
Refine spillover design
Moldflow Co-Injection Analysis
Compute skin/core ratio
Calculate skin/core distribution
Establish switch over points for skin/core (A-B)
Establish switch over points skin/core/skin (A-B-A)
