Mold design and mold flow analysis are a complementary work system. There are always friends in industry who suspect each other? Is it that we are not doing well in some places? Next, let's talk about it in detail, how to consider from various environments, so that our design and experimental data can match more accurately, make work more reasonable, more efficient, and more practical.

Material parameter proofreading: In the world of mold design, Moldflow analysis is like a precise detective, which helps us uncover mystery of plastic flow and ensure that our mold design can be accurate. But detective's work is not done overnight, it requires us to provide detailed and accurate clues-that is, those crucial material parameters.
Imagine that you are doing Moldflow analysis for a precision plastic product. You carefully selected key parameters such as thermal expansion coefficient, thermal conductivity and viscosity, just like a detective collecting key evidence for a case. But did you know? Even for same plastic material, there may be subtle differences between different brands or batches. If you accidentally use wrong viscosity parameter, "detective" may mislead you and make your flow analysis results (such as filling time and pressure distribution) very different from actual situation, just like detective misread clues and led case astray.

 

Model simplification rationality: Before Moldflow analysis, we also need to "slim down" 3D model of mold and product - that is, simplify it. But please note that this is not a simple weight loss, but to make model lighter without losing key information. Otherwise, just like you over-diet during weight loss process, which leads to damage to your body function, over-simplification of model will also make analysis results lose authenticity. For example, for products with fine structures, if you directly "cut off" them during simplification process, analysis results may not truly reflect problems in actual molding process, just like detective ignored important clues, resulting in truth of case being covered up
Boundary condition setting: We need to set correct boundary conditions for Moldflow analysis, which is like framework and scope set by detective when investigating case. Parameters such as mold temperature, melt temperature, injection speed, etc. should be as close to actual injection molding process parameters as possible. If boundary conditions are set incorrectly, such as mold temperature is set too high or too low, cooling analysis results will be biased, just like detective deviated from correct direction during investigation, causing case to be deadlocked.

Mutual influence of various factors: During optimization process, we also need to consider mutual influence of various factors, just like detective needs to comprehensively consider relationship between various clues and evidence when investigating case. Mold design is a complex system engineering. When we optimize a factor (such as gate position) based on Moldflow analysis results, we must consider its influence on other factors (such as weld lines, cooling effects, warpage, etc.). Otherwise, it is like a detective who only focuses on one clue during investigation and ignores relevance of other clues, resulting in a one-sided interpretation of truth of case.
Overall performance trade-off: We also need to weigh different performance requirements of product, just like a detective needs to weigh importance and credibility of various evidence when investigating a case. In order to reduce warpage, we may adjust wall thickness or cooling system, but this may have a certain impact on strength or appearance quality of product. Therefore, designers need to comprehensively consider multiple performance indicators such as appearance, dimensional accuracy, and strength of product to find an optimal balance point, just like a detective needs to comprehensively consider relevance and importance of various clues and evidence during investigation to reveal truth of case.

 

Equipment capacity matching: Optimized mold design solution must match capacity of actual injection molding production equipment. For example, according to Moldflow analysis results, a higher injection pressure may be required to achieve a good filling effect, but maximum injection pressure of actual injection molding machine may not meet this requirement. At this time, it is necessary to reconsider optimization plan or replace appropriate injection molding equipment.
Adjustability of process parameters: Optimized mold design should consider adjustability of process parameters in actual production. Although Moldflow analysis can provide theoretically optimal process parameters, in actual production, process parameters may need to be adjusted due to various factors (such as material batch differences, ambient temperature changes, etc.). For example, design of cooling channel should be able to adapt to changes in process parameters such as different cooling water temperatures and flow rates to ensure cooling effect of mold.

Cost control: When optimizing mold design based on Moldflow analysis results, cost factors should be considered. For example, adding a complex cooling system to improve cooling effect, or using multiple gates to optimize filling pattern will increase manufacturing cost of mold. Designers need to evaluate whether benefits of optimization measures (such as improving product quality, reducing scrap rate, etc.) can offset increase in costs.

 

Production efficiency improvement: In addition to considering quality improvement, we should also pay attention to impact of mold design optimization on production efficiency. For example, by optimizing cooling system and shortening cooling time, production efficiency can be improved. However, if optimization process is too complicated, it will lead to an extension of mold manufacturing cycle or an increase in maintenance costs. In this case, it is necessary to comprehensively weigh relationship between improved production efficiency and cost.