The 3DEXPERIENCE SIMULIA Plastic Injection application is a cutting-edge tool that empowers engineers and designers to optimize plastic injection molding processes. This blog will explore its capabilities through the example of a clutch cover design, showcasing how this innovative application streamlines design, manufacturing, and performance.

Challenges in Plastic Injection Molding

Plastic injection molding is a complex process that requires meticulous planning and analysis. Designers often face the following challenges:

1. Material Selection and Behavior: Ensuring the chosen plastic material meets mechanical and thermal requirements.
2. Part Defects: Avoiding common issues such as warpage, sink marks, and weld lines.
3. Cycle Time Optimization: Balancing cost efficiency with high-quality production.
4. Tool Design: Designing molds that support efficient and defect-free manufacturing.

Without advanced simulation tools, these challenges can lead to costly rework and delays.

Importing CAD Models & Role Access

Here’s a detailed walkthrough of using the SIMULIA Plastic Injection application for a clutch cover project:

Step 1: Importing the CAD Model

1. Import the Model: Use the “+” button and select “Import” or simply drag and drop the clutch cover design directly into the workspace.

   

2. Check the Geometry: Use the geometry verification tool to ensure the model is error-free and ready for simulation.

Step 2: Open the Compass

1. Locate the Compass: Access the 3DEXPERIENCE platform interface and click the compass icon at the top-left corner of the screen.

   

    

2. Search for the Plastic Injection App: Navigate to the application using the search bar or within the simulation roles.

   

    

3. Launch the Application: Open the Plastic Injection app, where the interface displays the Assistant Driven feature , an intuitive guided approach for plastic design engineers to perform analysis on components aimed to be manufactured by the injection molding process.

Getting Started with Assistant-Driven Plastic Injection Simulation

The Assistant panel in 3DEXPERIENCE streamlines the simulation process by offering a structured set of selection-based actions to guide users effectively. It organizes tools and guidance into three distinct sections:

A- Toolbar:

The toolbar offers quick access to frequently used commands, such as model checks, simulation status, and other essential functions, enabling users to streamline their workflow.

B- Actions:

Actions are categorized tasks (e.g., process settings, molding conditions) that users need to define and complete in order to set up and run a simulation effectively.

C- Commands:

Commands provide direct access to the necessary tools and guidance for executing specific actions. These options enable users to perform respective tasks while offering detailed descriptions and visual aids to simplify the process and ensure accurate simulation setup.

This structured layout ensures users have everything they need at their fingertips for efficient plastic injection simulation.

Quick Access Through the Toolbar

The toolbar in the Plastic Engineer role offers fast access to commonly used commands, streamlining repetitive tasks and improving efficiency.

1-Simulate: Specifies the parameters for running the simulation and then runs it.

2-Simulation Status: Shows the solve status of the simulation.

3-Feature Manager: Manages the simulation features.

4-Visibility Manager: Controls the visibility of simulation-related representations, connections, and features.

5-Diagnostic Viewer: Displays pertinent status, warning, and error messages after you run a simulation.

6-Update:Update All.

Actions :

Actions are categories of tasks, such as boundary conditions and loads, that you perform to define and run a simulation.

The Assistant presents actions in a logical order; however, you do not always need to perform the actions in the order by which they are listed. In addition, some actions have prerequisite actions while other actions might be entirely optional.

Commands :

The Commands section in the lower half of the Assistant provides easy access to commands and user assistance related to your current action.

When you click any action in the upper half of the Assistant, the Commands section of the panel displays options and information related to that action. For example, when you click the Condition action in the upper half, the lower half displays a set of injection-related commands.

Set Up the Simulation: Assign Domains to Contributing Geometries

Each geometry that plays a role in the simulation must be assigned an appropriate domain. A domain defines the type of component from the injection molding machine involved in the simulation. The following domains should be assigned:

• Plastic: Represents a mold cavity
• Hot Runner
• Cold Runner
• Part Insert
• Coolant
• Mold Insert

Step 3 : Assigning Domains to Contributing Parts

1. In the Assistant dialog box, click on Parts.
2. In the Commands box, select Contributing Parts. (Alternatively, you can choose Contributing Parts from the Setup tab in the Action bar).
3. The Contributing Parts dialog box will appear.
4. Assign the Plastic domain to the Spiegeln part.
5. Right-click on Spiegeln to view the options.
6. From the drop-down menu, select Plastic (as this part represents the mold cavity to be filled with plastic).
7. Click OK to confirm the assignments in the Contributing Parts dialog box.

Step 4: Apply Materials to Components

In this step, you will assign materials to Spiegeln part. Specifically, you will apply ABS ensuring that the chosen material has the necessary injection molding behavior within its simulation domain.

1. Open the Assistant dialog box and select Materials.
2. In the Commands box, click on Material Palette. (Alternatively, you can access the Material Palette from the Setup tab in the Action bar).
3. In the search box, type ABS to filter the material list.
4. Expand the Plastics (ABS) folder.
5. Select Generic Material / Generic ABS | A.1 and review the material’s simulation properties by clicking on the Simulation tab.
6. Return to the Core Material box.
7. Drag and drop Generic Material / Generic ABS | A.1 onto the Spiegeln part to assign the material.
   

• To apply this material to the Spiegeln part, click the Application on Spiegeln Part icon from the pop-up menu.

A green tick appears next to the Materials section in the wizard, indicating that the material requirement has been met.

1. Select Close in the pop-up menu to finalize the application.
2. Close the Material Palette dialog box.

At this point, the material has been successfully applied to the Spiegeln part. You can now view the updated study tree.

Step 5: Define the Process Settings

In this step, you will define the Fill, Pack, and Warp process settings for the two-shot plastic injection molding simulation. These settings are crucial for simulating the injection molding process, ensuring accuracy in how the mold cavity is filled, packed, and cooled.

The Plastic Injection app allows you to adjust the operational settings of the injection molding machine. While the default settings for the Fill, Pack, and Warp analysis cases are suitable for most simulations, you have the option to customize them to meet specific requirements.

The Process Settings dialog box provides control over the plastic injection analysis, enabling you to fine-tune these parameters.

Steps to Define Process Settings:

1. In the Assistant dialog box, click on Process Settings.
2. In the Commands box, select Process Settings. (Alternatively, you can access Process Settings from the Setup tab in the Action bar).
3. The Process Settings dialog box will appear. Here, you can view and modify the default Shared settings.
   • For this simulation, we will set the Melt Temperature to 600 Kelvin and the Ejection Temperature to 380 Kelvin.

     

      

4. Expand the Plastic Flow Simulations column to view additional settings.
5. Adjust the Injection Fill Rate. Fill rate profiles define how the filling rate progresses over time or as a percentage of the cavity’s filled volume.
   • Click the Edit Profile icon to open the Fill Rate Profile dialog box.
   • Enter 1.4 in the second row under Time, and 2.4 in the third row.
6. Click OK to confirm the changes in the Fill Rate Profile dialog box.
7. Click OK in the Process Settings dialog box to apply your settings.

With these settings defined, your simulation will be ready to accurately represent the injection molding process, including the filling, packing, and cooling stages.

Step 6: Define Injection Locations

Defining the injection locations is a critical step in determining where plastic materials will enter the part cavity during the injection molding process. Every part must have at least one injection location to facilitate material flow.

Injection Location Types

1. Surface-Based Injection Locations
   In surface-based injection, the plastic material enters the part through an entire selected surface.

• With a Runner System: If your model includes a runner system, the top of the sprue is typically chosen as the injection location.

2. Point-Based Injection Locations
   In point-based injection, the plastic material enters through a specific point you define.

• Without a Surface Representation: If the model lacks a designated surface for the injection location, you can select any point on a surface to represent the center of a circular injection area.
• Diameter Recommendation: The diameter of the injection location is generally 60-80% of the part’s thickness for optimal material flow.

Note: Omitting the runner system in the simulation disregards its effects on plastic temperature and flow, which could influence accuracy.

Automatic Creation of Injection Locations

If you used the Functional Plastic Parts app to create your part geometry and defined injection locations, these will automatically transfer to the simulation. While you can delete or add new injection locations within the simulation, such changes will not propagate back to the Functional Plastic Parts app.

Simulation Workflow: 

1. Click the Injection Location Icon
   • Open the Injection Location dialog box.            
2. Select the Injection Location
   • Choose Face Support and then select a face on the part.
3. • A cone-shaped glyph will appear, indicating the injection location.

By carefully selecting injection locations, you ensure an efficient and accurate simulation that reflects real-world material flow.

Step 7: Mesh the Part

Meshing is a fundamental step in simulating plastic injection molding. The default plastic part mesh is often sufficient for most simulations, but you can refine the mesh to achieve higher accuracy in critical regions, such as injection locations or along boundaries.

Mesh Adjustments

1. Mesh Size
   Adjust the average size of mesh elements throughout the part. Smaller mesh elements are ideal for areas with intricate features, such as gates or narrow passages, to improve simulation accuracy.
2. Boundary Layers
   Boundary layers consist of thin mesh elements near cavity walls, with larger elements toward the center. This configuration improves accuracy in resolving temperature and solidification variations through the part’s thickness.

• For uniform parts, the default setting generates five elements through the part’s thickness, balancing computational cost and accuracy.
• For higher precision, specify two or more boundary layers.

3. First Layer Thickness
   The thickness of the first boundary layer is typically one-eighth of the average wall thickness. Two layers result in a boundary mesh equal to one-quarter of the wall thickness, ensuring accurate thermal and flow behavior modeling.
4. Geometry Simplification
   You can simplify the mesh by defining the minimum size of topological edges to retain. Smaller features, such as logos, can be removed to streamline the mesh and reduce computational complexity. Adjust the maximum height and size for these features as needed.

Simulation Workflow

Open the Plastic Mesh Part Manager

• • Navigate to the Setup section of the action bar and click Mesh Part Manager.
  • The manager displays the average mesh size for the plastic part, coolant parts, and mold.

1. Modify the Plastic Part Mesh
   • Double-click the row for the plastic part to open the Plastic Mesh Setup dialog box.

1. • Adjust the Mesh Size for overall dimensions and refine it for small or critical regions.
   • Specify the Number of Boundary Layers and their First Layer Thickness for higher accuracy.
2. Simplify Geometry
   • Use the Simplify Geometry field to define the minimum size of edges to retain.
   • To exclude small features like logos, select Remove Logos, and customize the parameters as necessary.
3. Generate and Refine the Mesh
   • Click Mesh to generate the computational mesh.
   • Examine the results and refine the mesh as needed for optimal accuracy.
4. Finalize the Mesh
   • After reviewing and making adjustments, click OK to finalize the mesh.

By refining the mesh in critical areas and simplifying unnecessary features, you ensure a balance between computational efficiency and simulation accuracy, setting the foundation for reliable results.

Step 8: Run the Simulation

Executing the Mold, Fill, Pack, and Warp simulations is the final step in analyzing your design for plastic injection molding. These simulations provide insights into the material flow, packing behavior, and potential warping of the part.

Simulation Setup

1. Configure the Simulation Environment
   By default, simulations run on your local machine using an embedded license. If needed, you can configure the setup to run on a remote machine.
2. Initiate the Simulation

• Navigate to the Simulate section of the Assistant and click Simulate.
• From the Location options, select Local Interactive.
• Click Select All to include all available analysis cases in the simulation.
• Accept the default settings and click OK.

3. CPU Configuration
   You can allocate up to 8 cores per CPU for the simulation to optimize performance and reduce runtime.

Simulation Status Window

The Simulation Status window opens automatically and allows you to:

• Monitor simulation progress in real time.
• Diagnose and address errors if they occur.
• Access the Plots tab to review key result plots, such as flow rate and maximum injection pressure.

Duration

The simulation typically takes around 30 minutes to complete, depending on the complexity of the part and the computational resources available.

Post-Simulation Analysis and Optimization

After the simulation has completed, you can analyze the results in detail, providing valuable insights into the behavior of your plastic injection molded part.

Step 9: Review Simulation Results

Analyzing the simulation results is a critical step in validating and optimizing your design for plastic injection molding. By examining the outputs, you can identify and address potential issues, ensuring manufacturability and part quality.

Fill Simulation Analysis

The fill simulation provides a detailed view of how the plastic material flows into the mold cavity:

• Flow Patterns: Evaluate how material fills the part to ensure uniformity and avoid short shots.
• Air Traps: Identify areas where air is trapped during the injection process. These regions are marked with red circles, helping you pinpoint potential defects that can compromise the integrity of the part. Addressing these areas often involves redesigning vent locations or adjusting process parameters.

Weld Line Analysis

Weld lines occur when separate flow fronts meet during the filling process. These can be visualized in the simulation results:

• Location and Severity: Observe weld line locations and their impact on structural integrity and aesthetics.
• Min-Max Properties: Analyze material strength at these locations to determine whether they meet design requirements.

Advanced Result Plots

You can generate additional plots for a deeper understanding of the simulation results:

• Clamping Forces (X-Y Plots): Analyze the distribution and magnitude of forces required to keep the mold closed during injection.

• Maximum Injection Pressure: Evaluate the pressure required to fill the part, ensuring it remains within machine capabilities.

Sectoring Analysis

Sectoring allows you to divide the part into regions for localized analysis, helping you understand flow behavior, temperature distribution, and other parameters in specific areas of the part.

Step 10: Generating Reports

Once the results have been reviewed, the next step is to document and share your findings:

1. Export Results
   Generate comprehensive reports summarizing the simulation outcomes, including key visuals, plots, and identified issues. Reports can be tailored to highlight critical metrics such as injection pressure, clamping forces, weld lines, and air trap locations.
2. Share Insights
   Utilize the platform’s collaboration tools to distribute results to team members, stakeholders, or clients. Clear documentation ensures that everyone involved has a shared understanding of the simulation findings, fostering informed decision-making.

By thoroughly reviewing results and generating detailed reports, you set the stage for informed design iterations, improved manufacturability, and enhanced product performance.

Conclusion

The 3DEXPERIENCE SIMULIA Plastic Injection application empowers designers to tackle complex challenges in plastic injection molding with confidence. Its robust simulation capabilities, when applied to components like clutch covers, ensure superior quality, efficiency, and innovation. By integrating design, simulation, and collaboration, it transforms the way industries approach manufacturing.

Ready to elevate your plastic injection molding projects? Explore the potential of the 3DEXPERIENCE SIMULIA Plastic Injection application today.

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Hanen Bdioui

CEO at ChampionXperience

As a SOLIDWORKS and 3DEXPERIENCE Champion, I am passionate about driving innovation in design and technology and dedicated to delivering cutting-edge #CAD and #VR solutions tailored for both educational and business success.

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