CAE Analysis

CAE / Computer-Aided Engineering Capability CAE analysis Moldflow analysis Computer-aided engineering (CAE) is the use of computer software to simulate performance in order to improve product designs or assist in the resolution of engineering problems for a wide range of industries. This...

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CAE / Computer-Aided Engineering
Capability
CAE analysis
Moldflow analysis
Computer-aided engineering (CAE) is the use of computer software to simulate performance in order to improve product designs or assist in the resolution of engineering problems for a wide range of industries. This includes simulation, validation, and optimization of products, processes, and manufacturing tools.
A typical CAE process comprises of preprocessing, solving, and postprocessing steps. In the preprocessing phase, engineers model the geometry (or a system representation) and the physical properties of the design, as well as the environment in the form of applied loads or constraints. Next, the model is solved using an appropriate mathematical formulation of the underlying physics. In the post-processing phase, the results are presented to the engineer for review.


Benefits of CAE
The benefits of CAE include reduced product development cost and time, with improved product quality and durability.
First of all, many people think that if you know where to gate the part, you do not need to perform the mold flow analysis. That is a misconception and may not really help you that much in reducing costs and timing as well as may not prevent other problems. Yes you will be able to fill the parts and get the parts but will the parts be the best in very first tryout? That is a question that can be answered by performing the flow analysis.


Design decisions can be made based on their impact on performance.
Designs can be evaluated and refined using computer simulations rather than physical prototype testing, saving money and time.
CAE can provide performance insights earlier in the development process, when design changes are less expensive to make.
CAE helps engineering teams manage risk and understand the performance implications of their designs.
Integrated CAE data and process management extends the ability to effectively leverage performance insights and improve designs to a broader community.
Warranty exposure is reduced by identifying and eliminating potential problems. When properly integrated into product and manufacturing development, CAE can enable earlier problem resolution, which can dramatically reduce the costs associated with the product lifecycle.


Case study
1,Mesh
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2,Material

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3,Injection processing

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4,Melt filling flashMelt front advancement
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Melt front advancement is a position indicator as melt front boundary movement in different time duration in the filling process.
From the melt front advancement one can:
Examine imbalances in the filling pattern of the molding.
Check for incomplete filling of cavity or short shot problem.
Identify the weld line locations.
Identify the air trap locations.
Check the flow contribution of each gate for a balanced runner.
Check if the gate location is correct to balance the flow and eliminate weld line.

5,Moldability
image906.jpgThe Yellow or Red regions show the areas where the melt filled with difficulty, which could result in quality related problems.
6,Air Trap
图片1(001).jpgAir Trap result shows the possible locations where air trap can occur.
7,Weld lines
image910.jpgWeld Line result shows the weld lines that indicate potential spots of weaker structure. The darker the weld line, the weaker the structure.
8,Sink Mark Indicator
image912.jpgSink Mark is an index to evaluate the packing effect.
Positive value—shows insufficient packing. This may cause depression or sink marks on the surface of the molded part.
Negative value—shows over packing
Value close to zero—shows correct packing
9,Pressure
image914.jpgPressure result shows the pressure distribution of the plastic at the end of filling. Use the pressure result to analyze the following:
Check the pressure transmission conditions.
Check for drop in pressure in the runner system.
Check the mold design for a balanced flow.
Check for overpacking and flashing of the melt.
Examine the extent of packing or holding.
10,Center Temperature
image916.jpgCenter temperature is the melt temperature of the middle layer (part line) in the thickness direction at the end of filling. Center temperature is an indicator of the thermal energy supplied to the fresh hot melt. If the center temperature is too low, flow hesitation occurs, which can cause short shot problem.
11,Bulk Temperature
22(001).jpgBulk temperature is a velocity-weighted average temperature of plastic melt across the thickness at the end  of filling. The contribution from frozen layer that is stationary is ignored. The effect of heat convection and viscous heating can be displayed from this data. The bulk temperature distribution reflects the trend of  the flow path.
12,Max. Shear Rate
image920.jpgMaximum shear stress result shows the peak value of shear stress at each element during the filling stage.
13,Frozen Layer Ratio
image922.jpgA frozen layer is formed near the cavity surface because of solidification, which is caused by cooling. The frozen ratio gradually increases with time. An increase in frozen layer ratio reduces the cross-section along the flow path and thus increases the flow resistance and sprue pressure. The frozen layer ratio also affects the residual stress and the flow-induced orientation.
14, Max. Cooling Time
image924.jpgThis result shows the maximum cooling time in the thickness direction at the end of filling. The cooling time is the time from the end of packing to the instant when the molded part cools to the ejection temperature.
15,Volumetric Shrinkage
image926.jpgThis result shows the maximum volume shrinkage across the part thickness at the end of filling. A high positive value represents high volume shrinkage, which may cause sink mark or void
16,Gate Contribution
image928.jpgThis result shows the contribution of each gate. The region in the same color represents that it was filled by the plastic from the same gate. The percentage of each color indicates its percentage of volume compared.
With the cavity. This result help determine whether the model was filled by balanced flow pattern
17,Sprue Pressure
image930.jpgThis result shows the plot of sprue pressure versus filling time.
You can use this result to look for any unusual sprue pressure rise during filling.
If the resulting sprue pressure curve stays at the maximum allowed injection pressure, hesitation or even short shot might occur.
18,Clamping Force
image932.jpgThis result shows a plot of the clamping force versus the filling time.
The value is the required clamping force during the molding process instead of the force that molding machine outputs.
You can use this result to identify the flash problem. If the calculated clamping force is larger than 70 percent of the machine maximum clamping force, there is a chance of plastic melt being squeezed outside the cavity and causing flash


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